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NRG 1x-60 - Installation & Operating Manual -

819681-00

Specialist terms/Abbreviations

Here, we explain some abbreviations, specialist terms, etc., which are used in this Manual.

IEC 61508

International standard IEC 61508 describes both the type of risk assessment and actions taken to provide
appropriate safety functions.

SIL (safety integrity level)

Safety integrity levels SIL 1 to 4 are used to quantify risk reduction. SIL 4 is the highest level of risk reduc-
tion. 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 sys-
tems. Data can be sent and received.

NRG .. / URS .. / URB .. / SRL .. / etc.

Equipment and type designations of GESTRA AG, see page 9.

SELV

Safety Extra Low Voltage

Содержание NRG 111-60

Страница 1: ...Original Installation Operating Manual E N English Level Electrodes NRG 16 60 NRG 17 60 NRG 19 60 NRG 111 60 819681 00 ...

Страница 2: ... product liability 11 Functional safety safety integrity level SIL 12 Check the safety function regularly 12 Reliability data to EN 61508 13 Function 14 Technical data 16 Name plate Identification 18 Factory settings 19 Overall view 20 NRG 16 60 NRG 17 60 NRG 19 60 20 NRG 111 60 20 Dimensions of the NRG 16 60 NRG 17 60 NRG 19 60 22 Dimensions of the NRG 111 60 23 Preparing for installation 24 Esta...

Страница 3: ...essary 39 Notes on changing communication parameters bd rt Id 41 Changing the baud rate 42 Changing the limiter ID 42 Manually initiating a display test 42 Checking the low water switchpoint by lowering the level 43 Checking the limiter switchpoints by initiating a test function 43 Lockout function 43 Starting operation and testing 44 System malfunctions 47 Causes 47 Indication of system malfuncti...

Страница 4: ...mination to third parties is not permit ted The General Terms Conditions of GESTRA AG apply Scope of delivery Product package 1 x NRG 1x 60 level electrode 1 x sealing ring D 27 x 32 form D DIN 7603 2 4068 bright annealed for NRG 16 60 NRG 17 60 NRG 19 60 D 33 x 39 form D DIN 7603 2 4068 bright annealed for NRG 111 60 1 x electrode extension 1 x measuring surface extension optional 1 x Installatio...

Страница 5: ...nual 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 plea...

Страница 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 ...

Страница 7: ...ty integrity level Safety integrity levels SIL 1 to 4 are used to quantify risk reduction SIL 4 is the highest level of risk reduc tion 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 sys tems Data can be s...

Страница 8: ...9 60 and NRG 111 60 level 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...

Страница 9: ...evel Level electrode for low water Safety control unit as level limiter Operating unit Monitoring unit SIL 3 to EN 61508 NRG 16 60 NRG 17 60 NRG 19 60 NRG 111 60 URS 60 URS 61 URB 60 SPECTOR control SRL 6 60 Fig 1 Key to Fig 1 NRG level electrode URS SPECTORconnect safety control unit URB visual display and operating unit SRL monitoring unit To ensure the proper use of equipment during all types o...

Страница 10: ...cool Perform all installation and maintenance work only on level electrodes that have been allowed to cool There is a risk of electric shock during work on electrical systems Always switch off the 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 NRG 111 60 level electrodes due to the sudden ...

Страница 11: ...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 setup work may only be performed by authorised staff who have undergone specific training Setup work Specialist staff Persons trained by the plant operator to work with pressure and temper...

Страница 12: ...ifications Combining them with accessories produces a type B subsystem The technical and safety characteristics in Fig 4 are based solely on NRG 1x 60 level electrodes Breakdown of safety function failure rates LW burner switch off NRG 1x 60 NRG 1x 60 mechanical NRG 1x 60 electronic CANopen URS 60 URS 61 Burner safety circuit The CANopen interface is a Black Channel type and can be ignored during ...

Страница 13: ...failure fraction SFF 99 0 Test interval T1 1 year Probability of failure on demand PFD 20 10 5 Diagnostic coverage Percentage of dangerous failures detected by a test DC 99 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 MTTR...

Страница 14: ...100mm installation is regarded as internal In this case upstream monitoring of flushing processes is not required In total two NRG 1x 60 level electrodes can be operated in conjunction with a URS 60 URS 61 safety control unit as a water level limiter system An automatic self test cyclically monitors the safety and function of the level electrode and measured value recorder The data are transferred...

Страница 15: ... are also saved in the level electrode and transferred to the URS 60 URS 61 safety control unit using the CANopen protocol Simulation of the alarm state The triggering of an alarm can be simulated by pressing the rotary knob of the NRG 1x 60 pressing the appropriate button on the URS 60 URS 61 or using the URB 60 The equipment will then behave as if a normal alarm had been triggered The tables on ...

Страница 16: ...Si12 powder coated Sheath 1 4301 X5 CrNi 18 10 Electrode extension 1 4401 X5 CrNiMo 17 12 2 Electrode insulation of NRG 16 60 NRG 17 60 NRG 19 60 Gylon Electrode insulation NRG 111 60 Special ceramics Screw in body NRG 16 60 NRG 17 60 NRG 19 60 1 4571 X6CrNiMoTi17 12 2 NRG 111 60 1 4529 X1NiCrMoCuN25 20 7 pH value NRG 111 60 Maximum admissible 10 Electrode lengths supplied 500 mm 1000 mm 1500 mm 2...

Страница 17: ... 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 humidit...

Страница 18: ...r 77 28215 Bremen GERMANY TÜV XXX XX XXX 70 C 158 F T Pmax Pmax Tmax Tmax PN40 G3 4 1 4571 IP65 32 bar 464psi 238 C 460 F IN OUT CAN Bus V 20 24 7 VA Data interface Safety note Equipment designation Nominal pressure rating connection thread Material of screw in body Equipment function Current approval Manufacturer Serial number IP rating CE marking Appointed authority Supply voltage Protection cla...

Страница 19: ...ir instructions de montage NRG 19 60 0525 GESTRA AG Münchener Str 77 28215 Bremen GERMANY TÜV XXX XX XXX 70 C 158 F T Pmax Pmax Tmax Tmax PN160 G3 4 1 4571 IP65 100 bar 1450psi 311 C 592 F IN OUT CAN Bus V 20 24 7 VA Niveauelektrode Level electrode Électrode de niveau IEC 61508 SIL 3 Betriebsanleitung beachten See installation instructions Voir instructions de montage NRG 111 60 0525 GESTRA AG Mün...

Страница 20: ...20 NRG 1x 60 Installation Operating Manual 819681 00 Overall view Fig 7 NRG 16 60 NRG 17 60 NRG 19 60 NRG 111 60 OK OK A B C D E H L K N G J M O P P I F ...

Страница 21: ...g ring I Sealing ring D 27 x 32 form D DIN 7603 2 4068 bright annealed for NRG 16 60 NRG 17 60 NRG 19 60 Sealing ring D 33 x 39 form D DIN 7603 2 4068 bright annealed for NRG 111 60 J Electrode thread K Tip of electrode L Retaining spring M Electrode extension N Measuring surface extension O Lock washer P Insulator Description of protective sleeve F for the NRG 111 60 level electrode Mistakes duri...

Страница 22: ...ions of the NRG 16 60 NRG 17 60 NRG 19 60 Fig 8 All lengths in mm OK 140 175 338 100 x available electrode extensions 500 mm 1000 mm 1500 mm 2000 mm 2500 mm 3000 mm b 70 G 41 mm A F x 0 Nm 50 70 90 110 120 100 80 60 41 Thermal insulation provided at the site 20 ...

Страница 23: ... Dimensions of the NRG 111 60 Fig 9 All lengths in mm OK 140 175 400 136 x available electrode extensions 500 mm 1000 mm 1500 mm 2000 mm 2500 mm 3000 mm b 70 41 mm A F G 1 30 x 0 Nm 50 70 90 110 120 100 80 60 41 Thermal insulation provided at the site 20 ...

Страница 24: ...elow freezing use a suitable heat source e g control cabinet heater etc Connect all system 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 lightning insects and animals and salty ai...

Страница 25: ...tchpoint 1 Manually screw the electrode extension M into the tip of the electrode K 2 Determine the required measuring length of the level electrode and mark this on the electrode extension M 3 Unscrew the electrode extension M from the electrode tip K 4 Shorten the electrode extension M as far as the mark and deburr the cut edge Fig 10 Required measuring length from seal seat H K M Preparing for ...

Страница 26: ...se an open ended spanner size 13 to firmly hold the electrode during this work If necessary e g for low conductivity of around 0 5 μS cm you can fit the optional measuring surface extension N 7 Push the measuring surface extension N onto the electrode extension M Make sure the electrode extension M protrudes from the underside by at least 2 mm 8 Using an Allen key secure the measuring surface exte...

Страница 27: ... can lead to malfunctions in the system or the level electrode Inspect the sealing surfaces of tank threaded standpipes or flange covers to ensure they are perfectly machined see Fig 12 and Fig 13 Take care not to bend level electrodes during installation The level electrode must not be inclined more than 45 maximum and the electrode rod is limited to 1000 mm maximum see Fig 16 Do not install the ...

Страница 28: ...ead ed standpipe or flange cover Sealing surfaces must be perfectly machined as shown in Fig 12 and Fig 13 Sealing surface dimensions for NRG 16 60 NRG 17 60 NRG 19 60 Ø 33 mm G A ISO 228 1 Ra 3 2 Ra 12 5 0 5 mm Fig 12 Sealing surface dimensions for NRG 111 60 Ø 40 mm G 1 A ISO 228 1 Ra 3 2 Ra 12 5 0 5 mm Fig 13 ...

Страница 29: ... 60 NRG 19 60 120 Nm NRG 111 60 165 Nm Installation example with dimensions see Fig 15 page 31 Example H I Fig 14 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 J Sealing ring D 27 x 32 DIN 7603 2 4068 bright annealed for NRG 16 60 NRG 17 60 NRG 19 60 Sealing ring D 33 x 39 DIN 7603 2 4068 b...

Страница 30: ...de 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 and tighten the nut in the body to a torque of 25 Nm 6 Reconnect the electrode wiring to the PCB 7 Close the rear body panel of the second electrode and screw back on Installation example with dimensions...

Страница 31: ...ples with dimensions Use as an internal water level limiter with protective tube provided on site Illustration not to scale Dimensions marked apply to the NRG 111 60 Key see page 35 Fig 15 G G1 DN 80 Ø 20 20 14 10 90 Ø 20 1 2 8 4 5 6 7 9 3 All lengths and diameters in mm ...

Страница 32: ...1 0 0 0 DN 80 All lengths and diameters in mm 1 2 1 4 6 5 7 8 Oblique installation e g in riser feed tubes of pressurised hot water plants or tanks Illustration not to scale The level electrode must not be at an incline of more than 45 maximum and the length of the electrode rod is limited to 1000 mm maximum Key see page 35 ...

Страница 33: ...ensions Use as an internal water level limiter with protective tube provided on site combined with water level control or high level limiter Illustration not to scale Key see page 35 4 Ø 20 G G DN 100 24 5 26 0 24 5 26 0 20 Ø 20 14 3000 10 90 1 2 4 5 6 7 8 9 3 All lengths and diameters in mm ...

Страница 34: ...allation examples with dimensions Level pot DN 80 as an external water level limiter Illustration not to scale Dimensions marked apply to the NRG 111 60 Key see page 35 Fig 18 All lengths and diameters in mm G G 1 190 20 10 DN 20 DN 20 DN 20 1 4 5 8 0 2 7 14 ...

Страница 35: ...le electrode Protective tube DN 80 Fig 16 oblique installation Protective tube DN 80 Fig 17 two electrodes Protective tube DN 100 7 Electrode spacing 14 mm air gaps and creepage paths 8 Low water LW 9 Fig 15 single electrode Reducer DIN 2616 2 Fig 17 two electrodes Reducer DIN 2616 2 0 Fig 18 Centre distance of connection Positioning the terminal box If necessary you can orientate the display in t...

Страница 36: ...681 00 Functional elements A Terminal box B Cover screws M4 x 16 mm C Operating panel with 4 digit LED display alarm LEDs and rotary knob see page 44 D M12 CAN bus socket 5 pole A coded E M12 CAN bus connector 5 pole A coded Fig 19 OK OK A B C D E ...

Страница 37: ... of the measuring sensors 0 2 A at 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 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 S...

Страница 38: ...network 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 ...

Страница 39: ...equipment is correctly connected Is the polarity of the CAN bus control line correct throughout Is a 120 Ω terminating resistor connected to the terminal devices of the CAN bus line Next switch on the supply voltage Changing the factory settings if necessary You will need the following tools Slotted screwdriver size 2 5 ...

Страница 40: ...ot enter anything for 30 seconds the display automatically returns to o P E r 2 Once you have selected a parameter press and hold the rotary knob until the current value of this parameter flashes on the display 3 Set the desired value Reducing increasing the value Each parameter has an individual admissible value range By pressing the knob briefly you can jump to the next digit This is a more conv...

Страница 41: ...s equipment from GESTRA AG has default ex works parameter settings which enable a standard system to be brought into operation without making any changes Please follow the steps below if you need to make changes to communication parameters Set the same baud rate for all bus participants To apply changed communication parameters perform the steps below on the URB 60 visual display and operating uni...

Страница 42: ...e parameter Id 2 Press and hold the rotary knob until the current limiter ID flashes on the display 3 Set the desired ID 0001 to 0008 4 Save your set value by pressing the rotary knob for approx 1 second 5 After you have successfully changed the limiter ID restart the entire system Manually initiating a display test Pay attention to the setting instructions on page 39 ff and proceed as follows 1 S...

Страница 43: ...ecking that low water switchpoints are correct NRG 1x 60 level electrodes may only be repaired by the manufacturer GESTRA AG Only replace faulty equipment with identical equipment from GESTRA AG Checking the limiter switchpoints by initiating a test function Check the low water LW switchpoint by letting the water drop below the defined limit In this case the equipment must behave as if there were ...

Страница 44: ...gs OK 1 2 3 4 Notes on the priority of the various indications Fault indications and alarms are displayed based on their priority Indications with higher prio rity 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 48 ff Priority 2 low level alarm Prior...

Страница 45: ... Alarm Behaviour in the event of a malfunction fault code display On the occurrence of a fault Display e g E 008 LED 1 Alarm LED lights up red A fault code is permanently displayed fault codes see page 48 There is an active malfunction LED 2 Operating LED is OFF A fault is present The malfunction or error state is transferred to the URS 60 URS 61 safety control unit via CAN data telegram The malfu...

Страница 46: ...es a level electrode that is no longer immersed LED 1 Alarm LED lights up red Low level alarm LED 2 Operating LED is OFF Alarm The switch off delay is running the signal output closes with without a delay The time delay has elapsed the output contacts open the signal outputs close The test ends Faulty equipment jeopardises system safety If the level electrode does not behave as described above it ...

Страница 47: ...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 level electrodes Are the level electrodes 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 identical f...

Страница 48: ...ectrode E 012 CH1RM RKErr Contamination or loss of insulation Remove check and clean the level electrode E 013 CH1RM RKErr EMC or measuring voltage error In pressurised hot water plants reduce the conductivity E 014 Ch1RangeErr Ch1 Out of Range Check the wiring Replace the level electrode E 015 DutyErr EMC error or measuring frequency faulty Check the installation location Replace the level electr...

Страница 49: ...ce the level electrode E 024 CANErr Wrong baud rate or wiring error Check the baud rate wiring and terminating resistors E 025 ESMG1Err EMC error or internal process error Check the installation location Replace the level electrode E 026 BISTErr EMC or internal error Check the installation location Replace the level electrode E 027 OvertempErr Ambient temperature 75 C Check the installation locati...

Страница 50: ...insulating material wound around it e g hemp or PTFE tape The inner seal of electrode rod is damaged Replace the level electrode The ambient temperature may be too high 75 C Check installation location Lower the ambient temperature of the terminal box Non immersion of the level electrode is not detected LO LE is not displayed Possible causes if no fault indications are present Remedy The vent hole...

Страница 51: ...annot be remedied with the aid of this Installation Operating Manual please contact our service centre or authorised agent in your country Emergency mode for water level limiter systems If the system works with two NRG 1x 60 level electrodes water level limiter system if one electrode fails the equipment can continue working with one level electrode in emergency mode under constant supervision in ...

Страница 52: ...bar WARNING Hot level electrodes can cause severe burns Level electrodes are extremely hot during operation Perform installation and maintenance work only on level electrodes that have been allowed to cool Only remove level electrodes that have 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 voltag...

Страница 53: ...ccept returned goods 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 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 AG know ...

Страница 54: ...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 II 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 online at www gestra de or can be requested from us ...

Страница 55: ...55 NRG 1x 60 Installation Operating Manual 819681 00 ...

Страница 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 819681 00 08 2019cm 808947 00 GESTRA AG Bremen Printed in Germany ...

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