GESTRA NRG 26-61 Original Installation & Operating Manual Download Page 1

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Original Installation &

Operating Manual

E N

E n g l i s h

Level Electrode

NRG 26-61

819874-00

Summary of Contents for NRG 26-61

Page 1: ...Original Installation Operating Manual E N English Level Electrode NRG 26 61 819874 00 ...

Page 2: ...l safety safety integrity level SIL 14 Check the safety function regularly 14 Reliability data to EN 61508 15 Function 16 Technical data 19 Name plate Identification 21 Factory settings 22 Overall view of the NRG 26 61 23 Dimensions of the NRG 26 61 24 Preparing for installation 25 Installation 26 Sealing surface dimensions for NRG 26 61 27 Example 27 Installing two level electrodes in a flange 28...

Page 3: ... the active measuring range CAL P 43 Calibration to the upper bound of the active measuring range CAL H 100 calibration value 44 Setting the filter constant Filt 44 Manually initiating a display test 45 Activating URB 2 compatibility ConP 45 Checking the level display by raising or reducing the level 46 Checking the limiter switchpoints by initiating a test function 46 Lockout function 46 Starting...

Page 4: ...8 2019cm Copyright All rights reserved Any misuse particularly reproduction and dissemination to third parties is not permit ted The General Terms Conditions of GESTRA AG apply Scope of delivery Product package 1 x level electrode NRG 26 61 1 x sealing ring D 27 x 32 form D DIN 7603 2 4068 bright annealed 1 x Installation Operating Manual ...

Page 5: ...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 also hand over t...

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: ...afety systems CAN Controller Area Network bus Data transmission standard and interface for connecting electronic equipment sensors and control systems Data can be sent and received NRG URS URB SRL etc Equipment and type designations of GESTRA AG see page 10 SELV Safety Extra Low Voltage Operating point of the plant The operating point describes the operating parameters within which a plant or boil...

Page 8: ... in condensate and feedwater tanks In combination with the NRR 2 60 NRR 2 61 level controller the electrode can be used as a level control system with MIN MAX alarm for example The limiter functions can be disabled independently and by an infinitely variable measurement signal Influences of the test fluid The NRG 26 61 level electrode can be used in fluids with different conductivity However a con...

Page 9: ...uipment 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 Water tube boilers requirements for limiting devices EN 60730 1 Automatic electrical controls Part 1 General requirements EN 61508 Functional safety of electronic systems Standards do...

Page 10: ...nit for limiters Control unit as level controller and limit indicator Operating unit SIL 2 to EN 61508 NRG 26 61 URS 60 URS 61 URB 60 SPECTORcontrol Without SIL as per EN 61508 NRG 26 61 NRR 2 60 NRR 2 61 URB 60 SPECTORcontrol Fig 1 Key to Fig 1 NRG level electrode URS SPECTORconnect safety control unit URB visual display and operating unit SRL monitoring unit NRR level controller continuous To en...

Page 11: ... 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 12: ...ming connection work Check that the plant is not carrying live voltage before commencing work Danger to life from a faulty NRG 26 61 level 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 NRG 26 61 level electrode causing pressurised hot steam or hot water to escape through the pressure relief h...

Page 13: ...y be installed electri cally connected and brought into service by suitable trained staff Operation Boiler service technician Staff trained by the plant operator Maintenance work Specialist staff Maintenance and conversions may only be performed by authorised staff who have undergone specific training Retrofit Specialist staff Persons trained by the plant operator to work with pressure and tempera...

Page 14: ...ode Breakdown of safety function failure rates safety shutoff NRG 26 61 NRG 26 61 mechanical NRG 26 61 electronic CANopen URS 60 URS 61 Safety circuit 1 Safety circuit 2 The CANopen interface is a Black Channel type and can be ignored during calculation due to the low failure rate of 1FIT Check the safety function regularly Check the limiter function of the level electrode at least once a year by ...

Page 15: ...failure fraction SFF 99 0 Test interval T1 1 year Probability of failure on demand PFD 100 10 6 Diagnostic coverage Percentage of dangerous failures detected by a test DC 98 0 Mean time to failure MTTFD 30 a Diagnostic interval T2 1 hour Performance level to ISO 13849 PL d Probability of failure per hour PFH 20 10 9 1 h Ambient temperature as a basis for calculation Tu 60 C Mean time to repair MTT...

Page 16: ...S 60 or URS 61 safety control unit initiates a safety shutoff This High Water HW switchpoint can be adjusted solely using the rotary knob on the NRG 26 61 level electrode If the water falls below the set low level point the URS 60 or URS 61 safety control unit initiates a safety shutoff This Low Water LW switchpoint can be adjusted solely using the rotary knob on the NRG 26 61 level electrode The ...

Page 17: ... you will therefore be asked to change the alarm limits to suitable values for your specific plant To set the AL Lo and AL Hi alarm limits see page 42 Behaviour in normal operation no alarm no faults The display shows the scaled level reading 3 digits 1 decimal place e g 050 3 The scale of the 0 100 measuring range is factory set at a maximum for the electrode length used This way meaningful measu...

Page 18: ...ety contacts Electrode alarms and faults cannot be acknowledged When the alarm or fault is cancelled the display also goes blank and the URS 60 URS 61 safety control unit closes the safety contacts once more Simulating the alarm state The triggering of an alarm can be simulated by pressing the rotary knob of the NRG 26 61 pressing the appropriate button on the URS 60 URS 61 or using the URB 60 The...

Page 19: ...ngth 373 477 583 688 794 899 1004 Measuring range 300 400 500 600 700 800 900 Max electrode length 1110 1214 1319 1423 1528 1636 2156 Measuring range 1000 1100 1200 1300 1400 1500 2000 Do not shorten the electrode rod Measurement quality The information below applies to a compensated fluid conductivity range from 100 10000 µS cm based on 25 C Reading error 1 from the set measuring range at the ope...

Page 20: ...git 7 segment display for showing status information 1 x red LED for indicating an alarm 1 x green LED for indicating OK 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 humi...

Page 21: ...ctrode Électrode de niveau 70 C 158 F T Pmax Pmax Tmax Tmax PN40 G3 4 1 4571 IP65 32 bar 464psi 238 C 460 F 7 VA H mm IN OUT CAN Bus V 20 24 Power consumption Safety note Equipment designation Nominal pressure rating connection thread material of screw in body Equipment function Admissible service pressure admissible temperature Admissible ambient temperature Current approval Manufacturer Serial n...

Page 22: ...D Id Lo 0002 Limiter ID Id Hi 0005 Controller group GrP 0001 Baud rate bd rt 0050 KBit s Alarm limit AL Lo 100 Alarm limit AL Hi 0 Lower bound calibration CAL L variable 0 Raw value hex approx 50 mV on ADC Measuring range section calibration CAL P variable 25 Raw value hex Upper bound calibration CAL H variable 100 Raw value hex approx 2 0 V on ADC Filter constant FiLt 0005 seconds Compatibility m...

Page 23: ...git LED display alarm LEDs and rotary knob see page 47 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 G Seal seat for sealing ring J Electrode H Sealing ring D 27 x 32 form D DIN 7603 2 4068 bright annealed F Sheath simplified view I Electrode thread K Electrode rod insulation PTFE ...

Page 24: ... 238 C Measuring range 373 300 477 400 583 500 688 600 794 700 899 800 1004 900 1110 1000 1214 1100 1319 1200 1423 1300 1528 1400 1636 1500 2156 2000 OK 140 G Fig 8 Size 41 All lengths and diameters in mm 0 Nm 50 70 90 110 120 100 80 60 41 175 b 70 26 2 37 1 338 20 Thermal insulation provided at the site Ø 15 ...

Page 25: ...rature is below freezing At temperatures below freezing use a suitable heat source e g control cabinet heater etc Connect all plant parts to a central earthing point to prevent equalisation currents Use a cover to protect the equipment from direct sunlight condensation and heavy rain Use UV resistant cable ducts for routing the connecting cable Take further measures to protect the equipment from l...

Page 26: ...ns in the plant or the level electrode Inspect the sealing surfaces of the tank threaded standpipe or flange cover to ensure they are perfectly machined see Fig 9 Take care not to bend the level electrode during installation Do not subject the electrode rod to hard impacts The level electrode may be inclined at 45 only when being used in a two hole flange with the length of the electrode rod limit...

Page 27: ... surface dimensions for NRG 26 61 Fig 9 2 Push the supplied sealing ring H onto the seal seat G of the electrode or lay it on the sealing surface of the flange 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 27 x 32 DIN 7603 2 4068 bright annealed Prohibited seal materials He...

Page 28: ...allation example with dimensions see Fig 11 page 29 Installing two level electrodes in a flange 1 Fit the first electrode as described above 2 Slacken and remove the rear body panel of the second electrode opposite the operating unit 3 Unfasten the electrode wiring from the PCB 4 Slacken the nut in the body of the second electrode using a size 19 open ended spanner 5 Screw in the second electrode ...

Page 29: ...l 819874 00 Installation examples with dimensions Protective tube provided at the site for internal installation Illustration not to scale Key see page 34 Fig 11 G DN 50 Ø 20 20 90 Ø 20 1 2 0 4 5 6 8 3 All lengths and diameters in mm 26 9 x 14 ...

Page 30: ...9874 00 Installation examples with dimensions Protective tube provided at the site for internal installation Illustration not to scale Key see page 34 Fig 12 2 G DN 50 Ø 20 20 26 Ø 20 90 1500 1 2 3 4 5 6 0 All lengths and diameters in mm x 9 14 8 ...

Page 31: ... dimensions Protective tube provided at the site for internal installation combined with other equipment from GESTRA AG Illustration not to scale Key see page 34 4 G G DN 100 24 5 26 0 20 Ø 20 14 3000 26 90 Ø 20 1 2 3 4 5 7 8 0 All lengths and diameters in mm 24 5 26 0 9 Fig 13 x ...

Page 32: ...g Manual 819874 00 2 Installation examples with dimensions Level pot DN 80 for mounting externally Illustration not to scale Key see page 34 G DN 20 HW DN 2 LW DN 2 DN 20 1 4 0 All lengths and diameters in mm Fig 14 DN 20 26 x 9 14 5 8 ...

Page 33: ...allation examples with dimensions Oblique installation e g in pressurised steam plants The level electrode must not be at an incline of more than 45 and the length of the electrode rod is limited to 688 mm maximum Illustration not to scale All lengths and diameters in mm Tube e g 33 7 x 3 2 1 3 3 ...

Page 34: ...e tube DN 80 in France as per AFAQ DN 100 7 Protective tube DN 100 8 Distance between electrode rod and protective tube 14 mm 9 Minimum dimension x 10 mm below the electrode length electrode length see page 19 0 Lowest possible LW mark upper bound Reducer DIN 2616 2 K 88 9 x 3 2 42 4 x 2 6 W Reducer DIN 2616 2 K 114 3 x 3 6 48 3 x 2 9 W Level pot DN 80 Centre distance of standpipe Additional elect...

Page 35: ...00 Functional elements Fig 16 A Terminal box B Cover screws M4 x 16 mm C Operating panel with 4 digit LED display alarm and status LEDs and rotary knob see page 47 D M12 CAN bus socket 5 pole A coded E M12 CAN bus connector 5 pole A coded OK A B C D E ...

Page 36: ...uring sensors 0 2 A at 24 V is required per sensor With five 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 five or more sensors 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 Example 5...

Page 37: ...rk a 120 Ω terminating resistor must be connected to the first and last units between terminals CL CH Use the CAN bus connector with terminating resistor if you are using the level electrode as the first or last unit 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 is triggered Pin a...

Page 38: ...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 AL Lo and AL Hi alarm limits are set to Max Min values which is why the warning messages LO LE and HI LE are shown alternately on the display First set the AL Lo and AL Hi alarm limi...

Page 39: ... desired parameter appears on the display The set value is displayed after approx 3 seconds The display alternates between the set parameter and its actual value e g bd rt value bd rt The following parameters are shown one after the other when you turn the knob clockwise Actual value Id Lo Id Hi GrP bd rt C in AL Lo AL Hi CAL L CAL P CAL H Filt diSP ConP Actual value Key to parameters see page 40 ...

Page 40: ...H CAL H upper bound calibration to 100 Filt filter constant diSP initiate a display test ConP activation of compatibility mode for operation with SPECTORconnect do not change setting ConP oFF Notes on changing communication parameters bd rt Id Lo Id Hi or GrP All CAN bus equipment from GESTRA AG has default ex works parameter settings which enable a standard system to be brought into operation wit...

Page 41: ... knob for approx 1 second Changing the controller group GrP For setting the controller group please also pay attention to the information in the Installation Operating Manual of the NRR 2 60 or NRR 2 61 level controller Pay attention to the setting instructions on page 39 and proceed as follows 1 Select the parameter GrP 2 Press and hold the rotary knob until the current controller group ID flashe...

Page 42: ...b for approx 1 second Checking the set AL Lo limit or switchpoint Check the switchpoint by allowing the level to drop below the set AL Lo limit In this case the equipment must behave as if there were an alarm Always check the switchpoint when bringing into service after changing a limit and each time the NRG 26 61 level electrode is changed and do this at the plant s operating point Setting the AL...

Page 43: ...imal display 3 Press and hold the rotary knob until the new value is displayed 4 Save your setting by pressing the rotary knob for approx 1 second 5 Continue with calibration CAL P or CAL H Independent rapid calibration at a water level of 25 of the active measuring range CAL P This parameter enables partial filling of the boiler as an alternative to complete filling The value set for partial fill...

Page 44: ... a hexadecimal display 3 Press and hold the rotary knob until the new value is displayed 4 Save your setting by pressing the rotary knob for approx 1 second Setting the filter constant Filt Here you can set a time constant to smooth the output signal for the level controller and the display The filter constant only affects the display and control and is set at a fixed value for the limiter Pay att...

Page 45: ...display test ends with donE Replacing faulty equipment Faulty equipment jeopardises plant safety If numbers or decimal points are displayed incorrectly or not at all you must replace the level electrode with an identical one from GESTRA AG Activating URB 2 compatibility ConP For operation with SPECTORconnect do not change setting ConP oFF 1 Select the parameter ConP 2 Press and hold the rotary kno...

Page 46: ...art up any plant without first checking that switchpoints are correct The NRG 26 61 level electrode may only be repaired by the manufacturer GESTRA AG Only replace a faulty device with an identical device from GESTRA AG Checking the limiter switchpoints by initiating a test function Check the AL Lo and AL Hi alarm limits of the limiter function by initiating the test function with the rotary knob ...

Page 47: ...ity of the various indications Fault indications and alarms 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 1 fault indications as per fault code table see page 52 ff Priority 2 low level LW alarm Priority 3 high level HW alarm Prio...

Page 48: ...tch on supply voltage Display LO LE HI LE alternating LED 1 Alarm LED lights up red LED 2 Operating LED is off Low and high level alarm LW and HW based on factory set alarm limits AL Lo and AL Hi First set the alarm limits to suitable values for your specific plant see page 42 Normal operation The level electrode is immersed within the set measuring range Display e g 047 3 LED 2 Operating LED ligh...

Page 49: ...t via CAN data telegram There once the time delay has elapsed the alarm message triggers the safety shutoff The affected signal output is activated The URS 60 URS 61 safety control unit does not automatically lock the safety contacts Behaviour in the event of a malfunction fault code display On the occurrence of a fault Display e g E 005 LED 1 Alarm LED lights up red A fault code is permanently di...

Page 50: ... LW mark or rising above the HW mark The respective alarm message and the current reading are shown alternately on the display e g HI LE and 100 0 alternating LED 1 Alarm LED lights up red MIN or MAX alarm LED 2 Operating LED is OFF Alarm The safety control unit URS 60 URS 61 or equipment behaves as if there were a real alarm Once the delay time has elapsed the output contacts of the URS 60 URS 61...

Page 51: ...es the wiring conform to the wiring diagrams Is the bus line polarity correct throughout Is a 120 Ω terminating resistor connected to the terminal devices of the CAN bus line Configuration of the level electrode Is the level 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 r...

Page 52: ...el electrode E 004 Ch1Ch2DiffErr Difference between channels 1 and 2 exceeds 10 error toler ance internal short circuit Replace the level electrode E 005 MaxCh1Err Channel 1 reading above maximum possible internal open circuit Replace the level electrode E 006 MinTSTCh1Err Channel 1 reading internal capacitance 47pF Replace the level electrode E 007 MaxTSTCh1Err Channel 1 reading reference capacit...

Page 53: ... V outside tolerance Replace the level electrode E 022 V1Err System voltage 1 V outside tolerance Replace the level electrode E 023 V12Err System voltage 12 V outside tolerance Replace the level electrode E 024 CANErr Communication failure Check the baud rate wiring and terminating resistors E 025 ESMG1Err µC error Replace the level electrode E 026 BISTErr µC periphery self test error Replace the ...

Page 54: ... Remedy The pressure relief hole is clogged or flooded or may even be missing completely Check the protective tube If necessary add a pressure relief hole The shut off valves of an externally mounted measur ing cylinder option are closed Inspect the shut off valves open if necessary A correctly set electrode that has been in operation for a long period delivers increasingly imprecise readings Poss...

Page 55: ...supply voltage Check all electrical connections The equipment fails to work The display is on and the LEDs light up Possible causes if no error messages appear Remedy The earth connection to the tank is interrupted Clean the sealing surfaces and screw in the level electrode with a metal sealing ring see page 27 Flashing values from t 71 to t 75 appear on the display Possible causes Remedy The ambi...

Page 56: ...Check the switchpoint when bringing into service and every time the NRG 26 61 level electrode is replaced System malfunctions in the NRG 26 61 level electrode also trigger a system malfunction 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 code In the event of...

Page 57: ... 0 bar WARNING The hot level electrode can cause severe burns The level electrode is very hot during operation Always let the level electrode cool down before performing installation and maintenance work Only remove the level electrode after it has cooled down Proceed as follows 1 Reduce the boiler pressure to 0 bar 2 Allow the level electrode to cool to room temperature 3 Switch off the supply vo...

Page 58: ... being returned to GESTRA AG The term media can refer to solid liquid or gaseous substances or mixtures as well as radiation GESTRA AG can accept returned products only if accompanied by a completed and signed return 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...

Page 59: ...irective 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 60: ...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 819874 00 08 2019cm 808994 00 GESTRA AG Bremen Printed in Germany ...

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