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LRR 1-52, LRR 1-53, URB 55 - USA - Installation & Operating Manual -

850703-00

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Summary of Contents for LRR 1-52

Page 1: ...Original Installation Operating Manual Conductivity Controller LRR Visual Display and Operating Unit URB LRR 1 52 LRR 1 53 URB 55 850703 00 EN USA English ...

Page 2: ...binations of functions and equipment 14 Technical data for the LRR 1 52 LRR 1 53 16 Technical data for the URB 55 18 Factory settings of the LRR 1 52 LRR 1 53 20 LRR 1 52 20 LRR 1 53 20 LRR 1 52 LRR 1 53 20 Factory default settings of the URB 55 21 Rating plate identification of the LRR 1 52 LRR 1 53 22 Rating plate identification of the URB 55 23 Functional elements and dimensions of the LRR 1 52...

Page 3: ...anipulated variable output 4 20 mA 34 Connecting the standby input 24 V DC 34 Connecting the potentiometer 0 1000 W 34 Connecting the data line between the conductivity controller and the URB 55 35 Connecting the SPECTORmodul bus system 35 Changing the equipment settings 36 Status display of the LRR 1 52 LRR 1 53 38 Visual display and operating unit URB 55 39 Switching on the supply voltage 39 Ope...

Page 4: ...factor C 60 Setting the measuring range of the LRR 1 52 61 Setting the measuring range of the LRR 1 53 61 Setting the control parameters 62 Guide to setting control parameters 62 Setting automatic intermittent blowdown 63 System malfunctions of the URB 55 64 Indication of system malfunctions in the alarm and error list using error codes 64 Common faults and issues during use of the URB 55 65 Syste...

Page 5: ...Installation Operating Manuals on our website http www gestra com 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 supply product package LRR 1 5x 1 x Conductivity controller LRR 1 52 or LRR 1 53 URB 55 1 x visual display and operating unit URB 55 4 x retaining clips 1 x p...

Page 6: ...ts Read this Manual 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 acces sible 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 th...

Page 7: ...s situation that results in death or serious injury WARNING Warning of a dangerous situation that may possibly result in death or serious injury CAUTION CAUTION Warning of a situation that may result in minor or moderate injury ATTENTION ATTENTION Warning of a situation that results in damage to property or the environment ...

Page 8: ...owdown interval The actual duration of intermittent blowdown can be set between 1 and 10 seconds For large boilers repeated intermittent blowdown pulses may be required Repetition can be set between 1 and 10 with an interval from 1 10 seconds pulse interval External intermittent blowdown If more than one steam boiler is connected to a single blowdown receiver simultaneous blowdown is not permitted...

Page 9: ...he continuous blowdown valve to move to the CLOSED position The MIN MAX limits and monitoring functions remain active in standby mode When the equipment is back in normal mode the continuous blowdown valve returns to the control position An intermittent blowdown pulse is also triggered if automatic intermittent blowdown is enabled and a blowdown interval and blowdown time have been set Pb proporti...

Page 10: ... information is viewed via the URB 50 or URB 55 visual display and operating unit The URB 55 is designed for installation in a control cabinet door or switch panel It may only be used when correctly installed If you are using a URB 50 please pay attention to the information in Installation Operating Manual LRR1 52 LRR1 53 URB50 Overview of possible equipment combinations Conductivity controller Co...

Page 11: ...place To fully protect a PLC runtime system on a control system that is available on the Internet the use of common security mechanisms firewall VPN access is absolutely essential Restrict access to all components to authorized persons only Change default passwords before bringing into service for the first time Deploy defense in depth mechanisms in your plant security to restrict access and contr...

Page 12: ...rol and Laboratory Use Part 1 General Requirements UL 61010 2 201 and CAN CSA C22 2 No 61010 2 201 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 2 201 Particular Requirements for Control Equipment Improper use There is a danger of death due to explosion if the equipment is used in potentially explosive atmospheres Do not use the equipment in potential...

Page 13: ...ave as expected it may be faulty Perform failure analysis Only replace faulty equipment with identical equipment from GESTRA AG Required personnel qualifications Activity Personnel Integration in control system Specialist staff Plant designer Installation electrical connection bringing into service Specialist staff Electrician installer Operation Boiler service technician Staff trained by the plan...

Page 14: ...and operating unit enables the following common functions to be performed Conductivity controller LRR 1 52 LRR 1 53 Conductivity measurement with an LRG 1 conductivity electrode and sepa rate Pt 100 resistance thermometer or Conductivity measurement with an LRG 16 9 conductivity electrode with inte grated resistance thermometer l Evaluation of the temperature compensated current signal of a connec...

Page 15: ...ndication of valve position Yw bar chart in l Setting the measuring range l Indication setting of control parameters l Trend log l Indication and listing of errors alarms and warnings l Test of MIN MAX output relays or actuation of intermittent blowdown valve l Manual automatic mode l Password protection l Level and conductivity controllers can be operated simultaneously l Fig 4 ...

Page 16: ... Intermittent blowdown OFF Outputs Continuous blowdown valve CLOSED OPEN 2 x volt free relay contacts changeover relays Maximum switching current 8 A at 250 V AC 30 V DC cos ϕ 1 MIN MAX alarm 2 x volt free relay contacts changeover relays Maximum switching current 8 A at 250 V AC 30 V DC cos ϕ 1 or MAX alarm and MIN relay as intermittent blowdown valve 1 x volt free relay contact changeover relay ...

Page 17: ...erature 14 122 F 10 50 C at power on 32 122 F 0 50 C Storage temperature 4 158 F 20 70 C Transport temperature 4 176 F 20 80 C 100 hours Air humidity Max 95 non condensing Only switch on after a defrosting period of 24 hours Terminal box Terminal box material Lower section of black polycarbonate glass fiber reinforced front of gray polycarbonate 2 x 15 pole terminal strips removable separately Max...

Page 18: ...immable Size field of view 110 mm x 65 mm Protection Front IP66 according to EN 60529 Back IP20 according to EN 60529 Admissible ambient conditions Service temperature 32 140 F 0 60 C Storage temperature 4 158 F 20 70 C Transport temperature 4 158 F 20 70 C Air humidity 5 85 relative humidity non condensing Enclosure Material Front metal glass back metal enclosure for electronics Enclosure attachm...

Page 19: ...data for the URB 55 Weight Approx 2 21 lb 1 kg Internal battery permanently installed non replaceable Type Lithium ion charged automatically If the equipment is out of service for six months or more we recommend connecting it to the supply voltage for one day to recharge the battery ...

Page 20: ...ller software version 311178 13 or later LRR 1 52 LRR 1 53 MAX switchpoint 3000 ppm 6000 µS cm MIN switchpoint 250 ppm 500 µS cm Reset hysteresis MAX limit 3 of set limit factory default Set point 1500 ppm 3000 µS cm Proportional band Pb 20 of set point Reset time Ti 0 seconds Dead band 5 of set point Valve runtime 360 seconds Control mode Automatic MIN relay function MIN alarm 24h flushing On Flu...

Page 21: ...703 00 Factory default settings of the URB 55 The visual display and operating unit is delivered with the following factory default settings PWL 1 111 Conductivity in µS cm VNC Service ON Target IP 192 168 0 84 Subnet 255 255 255 0 Gateway 192 168 0 1 Modbus TCP Off ...

Page 22: ...ermany 4 20mA URB 5 Data OUT Tamb 55 C T131 F Input rating 24VDC 5W Ambient temperature 32 131 F 0 55 C Wiring Use Copper Conductors Only Use 60 75 C Conductors Use No 18 16 AWG Wire Size Only Tightening Torque 0 79Nm or 7lb in Use with accessory LRG 16 4 LRG 16 9 URB 55 OPERATING CONTROL E513189 Output rating Pilot duty B300 R300 LRR1 52 Betriebsanleitung beachten See installation instructions Vo...

Page 23: ... Use on a Flat Surface of a Type 12 4X Enclosure GESTRA AG Münchener Straße 77 28215 Bremen www gestra com URB 55 Mat Nr 393347 Mat Nr 393347 ANW Nr 307625 Type designation Mains voltage Power consumption Serial number Date of production DD WW Safety information Stock code Protection Disposal information UL listing Admissible ambient temperature Manufacturer Fig 7 ...

Page 24: ...t membrane with status LED see page 24 F Terminal box G Support rail TH 35 Functional elements and dimensions of the LRR 1 52 LRR 1 53 The code switch can be accessed by disconnecting and removing the lower terminal strip Equipment settings see page 24 Fig 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 MAX 1 27 16 17 18 19 20 21 22 23 24 25 26 28 29 30 A B C F G D E 3 94 in 100 mm 2 87 in 73 mm 4 6 5 i...

Page 25: ... DANGER There is a risk of electric shock during work on electrical systems Switch off the voltage to the plant before you install the equipment Check that the plant is not carrying live voltage before commencing work 1 Switch off the voltage to the plant and secure any surrounding equipment in the control cabinet that is live so it cannot be touched 2 Carefully press the unit onto the support rai...

Page 26: ...stallation Operating Manual 850703 00 Dimensions of the URB 55 Fig 9 Fig 10 Required installation aperture in the control cabinet door or switch panel 5 79 in 147 mm 5 35 in 136 mm 2 05 in 52 mm 4 21 in 107 mm 3 78 in 96 mm 0 32 in 8 mm ...

Page 27: ...n aperture 5 35 in 136 mm x 3 78 in 96 mm e g in a control cabinet door B 4 x fastening elements supplied C 4 x mounting holes in the unit 1 Cut an aperture see Fig 11 in the control cabinet door or switch panel 2 Stick the supplied gasket to the back of the display frame 3 Carefully push the URB 55 visual display and operating unit through the aperture making sure the gasket is correctly seated 4...

Page 28: ...D 1 x slot for SD card with FAT32 file format for service purposes SDHC memory cards are not supported L L Connection for 24 V DC supply voltage pin assignment Connector Socket Fig 14 Use a SELV Safety Extra Low Voltage power supply unit for connecting the supply vol tage To connect the supply voltage to the supplied 3 pole connector use a cable with a max wire size of AWG14 2 5 mm2 Pin assignment...

Page 29: ...ection DANGER DANGER Incorrectly connecting the conductivity controller or any associated components is a danger to plant safety Connect the conductivity controller and all associated components as shown in wiring diagrams Fig 16 to Fig 18 in this Manual Do not use unused terminals as jumpers or support terminals ...

Page 30: ...electrodes Fig 16 Relay output for MIN alarm or Actuation of an intermittent blow down valve MIN Relay output for MAX alarm OPEN Supply voltage fuse provided by customer M0 5A medium time lag Data line for URB 55 shield MAX Actual value manipulated variable output switch selectable CLOSED Indication of valve position potentiometer 0 1000 W Standby input for an external command Control OFF Valve CL...

Page 31: ...ut for MIN alarm or Actuation of an intermittent blowdown valve MIN Actuation of a continuous blowdown valve CLOSED Relay output for MAX alarm MAX OPEN Supply voltage fuse provided by customer M0 5A medium time lag Actual value manipulated variable output switch selectable Indication of valve position potentiometer 0 1000 W M Data line for URB 55 shield LRG 16 9 Conductivity electrode with integra...

Page 32: ...D OPEN Relay output for MAX alarm MAX Supply voltage fuse provided by customer M0 5A medium time lag Actual value manipulated variable output switch selectable Indication of valve position potentiometer 0 1000 W Data line for URB 55 M S shield LRGT 1x x Conductivity transmitter 4 20 mA Fig 18 24 V DC 27 16 17 18 19 20 21 22 23 24 25 26 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 24 V DC 4 20 mA M...

Page 33: ...ve loads such as contactors and actuators must have interference suppression using RC combinations as specified by the manufacturer Connecting an LRG 16 4 conductivity electrode Use a shielded multi core TC ER control cable with minimum wire size AWG18 e g OELFLEX CONTROL TM CY 3G1 Connect the conductivity electrode as shown in wiring diagrams Fig 16 to Fig 17 Route connecting cables separately fr...

Page 34: ...d supply voltage Connecting the actual value manipulated variable output 4 20 mA Please note the load resistance of max 500 W Use a shielded multi core TC ER control cable with minimum wire size AWG18 e g OELFLEX CONTROL TM CY 3G1 Maximum cable length 328 ft 100 m Route connecting cables separately from power cables Connecting the standby input 24 V DC 24 V DC input for external command Control OF...

Page 35: ...rams Fig 16 to Fig 18 Wire the 9 pole D Sub connector as shown in Fig 15 Connect the grounding point of the enclosure URB 55 to the central grounding point in the control cabinet Connect the shield just once to the central grounding point in the control cabinet Route connecting cables separately from power cables Connecting the SPECTORmodul bus system Using the supplied data cable 16 ft 5 m connec...

Page 36: ...ange the input and function of the LRR 1 52 LRR 1 53 conductivity controller at any time if necessary using code switch D see Fig 19 Make changes before installing the conductivity controller when access is easier You will need the following tools Flat blade screwdriver size 3 32 in 2 4 mm Pozidriv screwdriver size PZ1 Proceed as follows 1 Switch off the supply voltage to the equipment or plant 2 ...

Page 37: ...IN alarm factory setting ON MIN relay output for actuating an intermittent blowdown valve OFF Node ID 72 ON Node ID 69 compatibility with older equipment factory setting OFF Terminal 3 4 Out 2 as actual value output X factory setting ON Terminal 3 4 Out 2 as manipulated variable output Yw OFF Electrical conductivity measured in µS cm factory setting ON Electrical conductivity measured in ppm Contr...

Page 38: ...LRR 1 52 LRR 1 53 URB 55 USA Installation Operating Manual 850703 00 Status display of the LRR 1 52 LRR 1 53 Fig 20 Multicolor LED amber green red amber power up green in operation red malfunction LRR 1 52 ...

Page 39: ...For the controller s the LED first lights up amber then green The home screen of the URB 55 visual display and operating unit appears If two controllers are connected to the visual display and operating unit both controllers will be shown see example If you tap one of the controller overview screens a full screen for that controller will open on the display see screenshot below If just one control...

Page 40: ...hows operating states and actual values The various parameter screens are opened via the icons These icons change dynamically and are either shown or hidden depending on the current page and configuration All entries and actions e g opening setup menus and parameter screens are initiated by tapping the buttons and input fields The active screen has a gray background see above You can close smaller...

Page 41: ...ing on the display for one hour the program automatically returns to the home screen If communication to the controller is disrupted the message Offline appears in the general display area Entering parameters using the virtual keypad Tapping an input field opens a numeric virtual keypad The keypad shows the old value Old and the limits Min Max Your entries must remain within these limits Function ...

Page 42: ...nutes you will be logged off again Default password Password 111 Recommendation for initial setup Log on using the default password then safeguard your system by creating your own password Scroll bar for long lists and menus You can use the scroll bar to navigate up and down long lists and menus in order to select the desired parameters Scroll bar Disabling parameter entry after successful login P...

Page 43: ...p or valve mode is possible Setup settings Valve mode Only pump or valve mode is possible Home screen Controller parameters Level controller 3E controller parameters Conductivity controller Open valve Close valve Logged in with password Log off Alarm history Info Reset alarm Time Alarm number Password Alarm coming Network Alarm going Modbus TCP overview optional Reset alarm ...

Page 44: ...lowrate Apply entry Confirm entry Steam flowrate Switch on Fill control Switch off Drain control Datalog Trend Pump OFF threshold Electrode calibration Pump ON threshold Set point Stop pump in manual mode Manual mode Start pump in manual mode Max alarm switchpoint Off On Automatic Min alarm switchpoint Off On Relay test Max switchpoint Proportional band Min switchpoint Reset time Set point Valve r...

Page 45: ... 100 valve electrode raw value Damping Correction factor Temperature compensation On Off Temperature coefficient Measuring range setup Automatic intermittent blowdown Intermittent blowdown pulses Intermittent blowdown time Intermittent blowdown active Pulse interval 24h flushing active Controller on standby Continuous blowdown valve in operating position Controller in manual mode Fig 22 ...

Page 46: ...status of the connected electrode Opening the parameter screens Use the following buttons to open the control ler parameter screens Switchpoints see page 46 Trend see page 46 Test Controller information see page 46 Valve control see page 46 Calibration of conductivity elec trode see page 46 Set controller parameters see page 46 Set automatic intermittent blow down see page 46 Further icons appear ...

Page 47: ...ion of the alarm and error list Alarms and fault indications are entered in the columns Coming Going Reset with a time stamp The most recent alarm is always shown at the top of the list Description of display The alarms are stored in the list with a code A alarm E error Coming Time at which the event occurred Going Time when the event ended Reset Date and time the event was reset Options Reset ala...

Page 48: ... Operating Manual 850703 00 Alarm and fault indications Opening the alarm history All alarms are stored in the alarm history The memory can hold 300 alarms Alarms are stored cyclically and are restored after a power failure Open the alarm history ...

Page 49: ...line containing the URB 55 for 2 s to see the runtime and OS of the URB 55 Opening further menus System information Setting the date time Password Network settings Open Modbus TCP list optional System information Open the System Information menu and select the desired action Description of display The connected controller s are shown with their software version Press the button to update a system ...

Page 50: ... settings Description of display settings Time Date Tap the appropriate field and set the date and time Confirm these changes to apply them Password Open the Password menu Factory default setting 111 Changing your password 1 Tap the input field 2 Enter the new password in the top line and confirm it by entering it again in the second line ...

Page 51: ...CP No Static IP address Yes The IP address is obtained via DHCP IP Address The IP address of the URB 55 Subnet mask The current subnet mask Gateway The IP address of the gateway The URB 55 visual display and operating unit has a Modbus TCP server This enables all values to be forwarded to a higher level control system or control center For Modbus communication switch on the connection using the TC...

Page 52: ...puter To access the URB 55 use the previously set network parameters You also need to switch on the service Data exchange via Modbus TCP If Modbus communication has been switched on you can open the dynamic datapoint list The raw data from the register is shown on this screen There is a scroll bar at the side for scrolling through the data You can find the latest datapoint list on our website at h...

Page 53: ...int Set point MIN alarm switchpoint For each switchpoint press the relevant button and enter the required value using the virtual keypad The icons in the buttons change color to indicate switchpoints alarm points that are too high or too low Description of bar charts X Actual value W Set point The set point is shown with a small arrow in the actual value bar chart Yw Manipulated variable Change of...

Page 54: ... the home screen This is also the case for all further 24h flushing operations Display of remaining valve runtime Ti if 24h flushing is switched on Automatic manual mode The controller is normally in auto matic mode Press the button to switch the controller to manual mode Entering the manipulated variable Here you can enter the valve posi tion or manipulated variable in the input field that opens ...

Page 55: ...eristic curve of the actual value X set point W manipulated variable Yw and alarm limits over a 7 day period The sampling rate is 5 seconds Options Open the associated key Open a menu bar with further functions Navigation Navigate forwards and backwards on the time axis using these but tons or by swiping horizontally Zoom in out using these buttons or two fingers pinch gesture Close the window ...

Page 56: ...in the controller The relevant icons are shown in the top part of the screen depending on the configuration example The relay in the controller remains active as long as you are pressing the button Actual value output 4 20 mA display of current actual value X or Manipulated variable output 4 20 mA display of current manipu lated variable Yw Controller software version 311178 13 or later View if co...

Page 57: ...y Flushing interval Flushing time Activate 24h flushing Press the button to activate 24h flushing Setting the flushing interval and flushing time You can enter the desired times within their limits in the input fields When the set interval has elapsed the flushing interval is activated and moves the valve to Open for the set time When the set flushing interval has elapsed the valve returns to the ...

Page 58: ...N 0 CLOSED Calibrated valve positions The calibrated raw data is shown in both fields Raw data Indicates the current digital valve position Performing calibration 2 Press the Automatic button and switch to manual mode 3 Enter 0 as the manipulated variable Yw 4 When the valve is in the CLOSED end position confirm this position 5 The raw data from the central field is automatically entered in the 0 ...

Page 59: ...ction factor C see page 59 During operation the indicated conductivity may differ from the reference reading obtained from a reference measurement e g due to dirt deposits When the correction factor is en tered the display is adapted to the current conductivity reading Measuring range dependent on controller see page 59 Enter the measuring range for your particular conductivity controller Temperat...

Page 60: ...e in the correction factor C or Enter the reference reading XRef you previously measured Display after entering reference reading XRef Confirm the calculated correction factor C Reject the calculated correction factor C Display when limit is exceeded If correction factor C exceeds the limit 5 1 cm a warning appears In this case you have no choice but to reject the calculated correction factor C A ...

Page 61: ...nput field and set the desired 100 measuring range Setting the measuring range of the LRR 1 53 1 First bring the conductivity transmitter into service To do this read the relevant Instal lation Operating Manual 2 Tap the input field You will see the screen containing the default measuring ranges 3 Tap the measuring range that is set on the conductivity transmitter ...

Page 62: ...oportional band is then 300 ppm 600 µS cm or in the range from 1200 ppm 2400 µS cm to 1800 ppm 3600 µS cm Reset time Ti larger Slow correction of deviations Reacts quickly smaller Fast correction of deviations the control loop may tend to overshoot Reacts slowly Dead band larger Correction of deviations starts with a delay In this range the manipulated variable does not change Only reacts when the...

Page 63: ...to Manual Switch between automatic intermittent blowdown and manual mode Description of parameters Initiate intermittent blowdown manually The display lights up amber when intermittent blowdown is active or has been initiated manually Intermittent blowdown interval in hours Intermittent blowdown time in seconds The intermittent blowdown valve is switched on regularly at set intervals and opens for...

Page 64: ...necessary Check electrical connection or Switch off temperature compensation E 005 Faulty conductivity electrode measuring voltage 0 5 V DC Check conductivity electrode and replace if necessary Check electrical connection Faulty conductivity transmitter measuring current 4 mA Check conductivity transmitter and replace if necessary Check electrical connection E 006 Faulty conductivity electrode mea...

Page 65: ...the URB 55 with the USB stick inserted and perform the desired action again The USB stick must have the file format FAT32 The USB stick may not be suitable for the data transfer The home screen remains blank Remedy The URB 55 is not correctly connected to the data interface The conductivity controller is not switched over when two units are connected Incorrect parameter display Remedy Reboot the U...

Page 66: ...vibration interference sources etc Wiring Does the wiring conform to the wiring diagrams Do the signal lines have the correct polarity Configuration on the conductivity controller Are the inputs and functions correctly set on code switch D Electrode configuration Are the electrodes correctly set and has the measuring range been calibrated DANGER DANGER There is a risk of electric shock during work...

Page 67: ...RR 1 53 out of service 1 Switch off the supply voltage and switch off the voltage to the equipment 2 Check that the equipment is not carrying voltage 3 Unscrew and pull off the upper and lower terminal strips see Fig 8 A B 4 Release the slider holder on the base of the equipment and detach the conductivity controller from the support rail Taking out of service URB 55 1 Switch off the supply voltag...

Page 68: ...turn note and also a completed and signed declaration of decontamination The return confirmation and declaration of decontamination must be attached to the outside of the return package as 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...

Page 69: ...69 LRR 1 52 LRR 1 53 URB 55 USA Installation Operating Manual 850703 00 For your notes ...

Page 70: ...70 LRR 1 52 LRR 1 53 URB 55 USA Installation Operating Manual 850703 00 For your notes ...

Page 71: ...71 LRR 1 52 LRR 1 53 URB 55 USA Installation Operating Manual 850703 00 For your notes ...

Page 72: ...e 77 28215 Bremen Germany Tel 49 421 3503 0 Fax 49 421 3503 393 e mail info de gestra com Web www gestra com 850703 000 09 2021cm 809156 00 GESTRA AG Bremen You can find our authorized agents around the world at www gestra com ...

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