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GESTRA NRG 26-61 Original Installation & Operating Manual

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E n g l i s h
Level Electrode
NRG 26-61
Original Installation &
Operating Manual
819874-00

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Summary of Contents for GESTRA NRG 26-61

  • Page 1 Level Electrode NRG 26-61 Original Installation & Operating Manual 819874-00 E n g l i s h...

  • Page 2: Table Of Contents

    Bus line, cable length and cross-section ....................36 Example ..............................36 Important notes on connecting the CAN bus system ................. 37 Pin assignment of the CAN bus connector and coupling for non pre-wired control cables ............................37 NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 3 Checking installation and function ......................56 Taking out of service ............................ 57 Cleaning the level electrode ......................... 58 Cleaning interval ............................58 Disposal ................................ 58 Returning decontaminated equipment ......................58 EU Declaration of Conformity ........................59 NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 4: Content Of This Manual

    BAN 819874-00/08-2019cm © 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 ■ ■...

  • Page 5: How To Use This Manual

    How to use this Manual This Installation & Operating Manual describes the correct use of the NRG 26-61 level electrode. It applies to persons who integrate this equipment in control systems, install, bring into service, operate, maintain and dispose of this equipment. Anyone carrying out the above-mentioned activities must have read this Installation &...

  • Page 6: Types Of 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. NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 7: Specialist Terms/Abbreviations

    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...

  • Page 8: Usage For The Intended Purpose

    Use as a safety high-level (HW) limiter and low-level (LW) limiter The NRG 26-61 level electrode is used in conjunction with the URS 60 / URS 61 safety control unit as a safety high-level limiter and low-level limiter for pressurised steam and hot-water plants.

  • Page 9: Applicable Directives And Standards

    Usage for the intended purpose Applicable directives and standards The NRG 26-61 level electrode has 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 ■ ■...

  • Page 10: Admissible System Components, Dependent On The Required Safety Level

    & Operating Manuals for the system components used. You will find the latest Installation & Operating Manuals for the system components named ■ ■ in Fig. 1 on our website: http://www.gestra.com/documents/brochures.html NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 11: Improper Use

    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. NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 12: Basic Safety Notes

    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 hole.

  • Page 13: Required Personnel Qualifications

    Persons trained by the plant operator to work Retrofit Specialist staff with pressure and temperature. Fig. 2 Notes on product liability We the manufacturer cannot accept any liability for damages resulting from improper use of the equip- ment. NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 14: Functional Safety, Safety Integrity Level (Sil)

    Functional safety, safety integrity level (SIL) In combination with the URS 60 / URS 61 safety control unit, the NRG 26-61 level electrode is suitable for safety functions up to SIL 2. It is an element of a safety circuit up to SIL 2 as per EN 61508 in the SPECTOR connect system, and can transmit alarm notifications.

  • Page 15: Reliability Data To En 61508

    Fraction of undetected dangerous failures that have a beta = 2 % common cause Fraction of detected dangerous failures that have a com- beta d = 1 % mon cause Fig. 4 NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 16: Function

    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.
  • Page 17 Display and signals, see page 47 / 51 * The NRG 26-61 level electrode has a green 4-digit, 7-segment display for showing readings, status infor- mation and fault codes. A red and green LED indicate the operating status.
  • Page 18 Level control functions In addition, the NRG 26-61 level electrode can be used in conjunction with an NRR 2-60 / NRR 2-61 level controller to form a level control system. The controller parameters are set solely on the URB 60 visual display and operating unit.

  • Page 19: Technical Data

    0.1 % ■ ■ Resolution for internal processing: 15 bits with sign (16 bits) ■ ■ Supply voltage 24 V DC +/-20 % ■ ■ Power consumption Max. 7 VA ■ ■ NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 20 ■ ■ Admissible installation positions Vertical ■ ■ Oblique to a maximum inclination of 45°. In this case, the length of the electrode rod is limited ■ ■ to 688 mm maximum. NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 21: Name Plate/Identification

    Manufacturer GESTRA AG Protection class Münchener Str. 77 28215 Bremen Disposal information GERMANY Serial number Fig. 5 The date of production is stamped on the screw-in body of every level electrode. NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 22: Factory Settings

    Factory settings The NRG 26-61 level electrode is delivered ex-works with the following settings: Parameter values Display in Parameter Unit menu NRG 26-61 Limiter ID Id.Lo 0002 - - - Limiter ID Id.Hi 0005 - - - Controller group 0001...

  • Page 23: Overall View Of The Nrg 26-61

    M12 CAN bus connector, 5-pole, A-coded Sheath (simplified view) Seal seat for sealing ring Sealing ring D 27 x 32, form D, DIN 7603-2.4068, bright annealed Electrode thread Electrode Electrode rod insulation, PTFE Fig. 7 NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 24: Dimensions Of The Nrg 26-61

    238 °C Ø 15 1004 1110 1000 1214 1100 1319 1200 1423 1300 Fig. 8 All lengths and diameters 1528 1400 in mm 1636 1500 2156 2000 NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 25: Preparing For Installation

    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 page 24: ■ ■ NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 26: Installation

    To prevent current leaks, maintain a minimum distance of 14 mm between the electrode ■ ■ and earth (flange or tank wall). Check the boiler coupling and flange during the preliminary boiler inspection. ■ ■ NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 27: Sealing Surface Dimensions For Nrg 26-61

    I. Sealing ring D 27 x 32 ◆ ■ DIN 7603-2.4068, bright annealed Prohibited seal materials: Hemp, PTFE tape ■ ■ Conductive paste or grease ■ ■ Fig. 10 NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 28: Installing Two Level Electrodes In A Flange

    Screw in the second electrode and tighten the nut in the body to a torque of 25 Nm. Reconnect the electrode wiring to the PCB. Close the rear body panel of the second electrode and screw back on. Installation example with dimensions, see Fig. 13, page 31 NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 29: Installation Examples With Dimensions

    Protective tube (provided at the site) for internal installation. Illustration not to scale. Key, see page 34 G ¾ DN 50 ≥ 14 ≤ 90° Ø 20 Fig. 11 All lengths and diameters in mm NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 30 Protective tube (provided at the site) for internal installation. Illustration not to scale. Key, see page 34 G ¾ DN 50 ≥ 14 ≤ 90° Ø 20 Fig. 12 All lengths and diameters in mm NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 31 Illustration not to scale. Key, see page 34 G ¾ G ¾ DN 100 24.5-26.0 24.5-26.0 ≥ 14 " ≤ 90° Ø 20 Fig. 13 All lengths and diameters in mm NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 32 Level pot (≥ DN 80) for mounting externally. Illustration not to scale. Key, see page 34 G ¾ ≥ DN 20 ≥ 14 § ≥ DN 20 ≥ DN 20 All lengths and diameters in mm Fig. 14 NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 33 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. Tube e.g. 33.7 x 3.2 Fig. 15 All lengths and diameters in mm NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 34: 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 level electrode’s internal wiring. Never rotate the terminal box more than 180 degrees in either direction. ■ ■ NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 35: Functional Elements

    Cover screws M4 x 16 mm Operating panel with 4-digit LED display/alarm and status LEDs and rotary knob, see page 47 M12 CAN bus socket, 5-pole, A-coded M12 CAN bus connector, 5-pole, A-coded NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 36: Connecting The Can Bus System

    - 0 V 120 Ω + 24 V CH = CAN High 24V DC CL = CAN Low Ω S = shield – 100 - 240 V AC Terminating Fig. 17 resistor NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 37: Important Notes On Connecting The Can Bus System

    Fig. 18 diagram. Connector Coupling Fig. 18 Shield (screen) + 24 V Power supply − 0 V Power supply CAN High data line CAN Low data line NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 38: Bringing Into Service

    First, set the “AL.Lo” and “AL.Hi” alarm limits to suitable values for your specific plant,see page 42. Measuring range calibration and the setting of alarm limits are mutually independent. NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 39 Save your set value by pressing the rotary knob for approx. 1 second. The message “donE” is shown and the parameter appears on the display once more. NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 40: Notes On Changing Communication Parameters "Bd.rt, Id.lo; Id.hi Or Grp

    (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 without making any changes.

  • Page 41: Changing The "Id.lo / Id.hi" Limiter Id

    Press and hold the rotary knob until the current limiter ID flashes on the display. Set the desired ID (off/0001 to 0008). off = the NRG 26-61 level electrode has no effect on the URS 60 / URS 61 safety control unit. Save your setting by pressing the rotary knob for approx. 1 second.

  • Page 42: Setting The "Al.lo" (Low-Level Alarm = Lw) Limit

    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.Hi” (high-level alarm = HW) limit Pay attention to the setting instructions on page 39 and proceed as follows: Select the parameter “AL.Hi”.

  • Page 43: Calibration To The Lower Bound Of The Active Measuring Range "Cal.l" (0 % Calibration Value)

    Press and hold the rotary knob until the value (e.g. 0025) appears. The last digit flashes. Set the desired reading > 25 % to match the set level. Save your setting by pressing the rotary knob for approx. 1 second. NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 44: Calibration To The Upper Bound Of The Active Measuring Range "Cal.h" (100 % Calibration Value)

    Press and hold the rotary knob until the current time constant flashes on the display. Set the desired time constant (1 to 30 seconds). Save your setting by pressing the rotary knob for approx. 1 second. NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 45: Manually Initiating A Display Test

    Press and hold the rotary knob until the current status flashes on the display. Set the required status (off / on). ConP = on: This enables the higher-resolution NRG 26-61 readings to be displayed on the URB 2 operating terminal. (by converting from 16 bit to 10 bit) ConP = oFF: 16-bit resolution of the NRG 26-61 readings.

  • Page 46: Checking The Level Display By Raising Or Reducing The Level

    Never start 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.

  • Page 47: Starting, Operation And Testing

    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 Priority of fault code display Higher priority fault codes overwrite lower ones on the display! NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 48 Displays the current level as % of the calibrated The level electrode measuring range. is immersed within the set LED 2: measuring range Operating LED lights up green See the following pages for more information and tables. NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 49 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 and deactivates the relevant signal outputs once more. NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 50 If the level electrode does not behave as described above, it may be faulty. ■ ■ Perform failure analysis. ■ ■ The NRG 26-61 level electrode may only be repaired by the manufacturer, GESTRA AG. ■ ■ Only replace faulty equipment with identical equipment from GESTRA AG. ■ ■...

  • Page 51: System Malfunctions

    Switch off the voltage to the plant and secure so that it cannot be switched back on. ■ ■ Check that the plant is not carrying live voltage before commencing work. ■ ■ NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 52: Indication Of System Malfunctions Using Fault Codes

    Replace the level electrode capacitance (1nF || 47pF) Channel 1 reading with disabled E.010 PWMTSTCh1Err Replace the level electrode measurement signal Channel 2 reading with disabled E.011 PWMTSTCh2Err Replace the level electrode measurement signal NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 53 Virtually all of the aforementioned fault codes can be caused by EMC interference. This is less likely to be the case in the event of permanent faults, but should be considered for sporadic fault messages. NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 54: Common Application And Usage Errors

    The measuring range is incorrectly set. ■ ■ Inspect the electrode and protective tube for soiling and ■ ■ The electrode or protective tube is soiled. ■ ■ clean if necessary. NRG 26-61 - Installation & Operating Manual - 819874-00...
  • Page 55 Reduce the ambient temperature around the terminal ■ ■ If the temperature rises above 75 °, the fault box, e.g. by cooling. code E.027 (Overtemp Err) appears and a plant shutoff occurs. NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 56: Checking Installation And Function

    Check the limiter functions by bringing the level below the set low water (LW) and above the set high ■ ■ water (HW) limits. In this case, the equipment must behave as if there were an alarm. Check the switchpoint when bringing into service and every time the NRG 26-61 level electrode ■ ■ is replaced.

  • Page 57: Taking Out Of Service

    Unplug the connections of the CAN bus control lines and plug them into one another. Next, remove the level electrode. An alarm is triggered when the CAN bus line is interrupted. NRG 26-61 - Installation & Operating Manual - 819874-00...

  • Page 58: Cleaning The Level Electrode

    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.

  • Page 59: Eu Declaration Of Conformity

    EU Declaration of Conformity We hereby declare that the NRG 26-61 level electrode conforms to the following European Directives: Directive 2014/68/EU EU Pressure Equipment Directive ■ ■ Directive 2014/35/EU Low Voltage Directive ■ ■ Directive 2014/30/EU EMC Directive ■ ■...
  • Page 60 You can find our authorised agents around the world at: www.gestra.com GESTRA AG Münchener Strasse 77 28215 Bremen Germany Phone +49 421 3503-0 +49 421 3503-393 e-mail info@de.gestra.com www.gestra.com 819874-00/08-2019cm (808994-00) · GESTRA AG · Bremen · Printed in Germany...

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