Related Manuals for GESTRA NRG 16-60
Summary of Contents for GESTRA NRG 16-60
- Page 1 Level Electrodes NRG 16-60 NRG 17-60 NRG 19-60 NRG 111-60 Original Installation & Operating Manual 819681-00 E n g l i s h...
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Page 2: Table Of Contents
Establishing the measuring length of the level electrode ................25 Screw the level electrode and electrode extension together ..............26 Installation ..............................27 Sealing surface dimensions for NRG 16-60, NRG 17-60, NRG 19-60 ............28 Sealing surface dimensions for NRG 111-60 .....................28 Example ..............................29 Installing two level electrodes in a flange ....................30... - Page 3 Contents Installation examples with dimensions ......................31 Positioning the terminal box .........................35 s ..........................36 Functional element Connecting the CAN bus system ........................37 Bus line, cable length and cross-section ....................37 Example ..............................37 Important notes on connecting the CAN bus system ..................38 Pin assignment of the CAN bus connector and coupling for non pre-wired control cables ......38 Bringing into service .............................39 Changing the factory settings if necessary ....................39...
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Page 4: Content Of This Manual
■ ■ 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 ◆... -
Page 5: How To Use This Manual
How to use this Manual This Installation & Operating Manual describes how to correctly use NRG 16-60, NRG 17-60, NRG 19-60 and NRG 111-60 level electrodes. It applies to persons who integrate this equipment in control sys- tems, 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
Types of warning DANGER Warning of a dangerous situation 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: Specialist Terms/Abbreviations
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... -
Page 8: Usage For The Intended Purpose
Visualisation and operation take place via the URB 60 or SPECTOR control operating unit. ■ ■ Applicable directives and standards NRG 16-60, NRG 17-60, NRG 19-60 and NRG 111-60 level electrodes have been tested and approved for use in the area governed by the following directives and standards: Directives:... -
Page 9: Admissible System Components, Dependent On The Required Safety Integrity Level
Level Safety control electrode Operating Monitoring unit as level for low unit unit limiter water NRG 16-60 SIL 3 URB 60 NRG 17-60 URS 60 SRL 6-60 SPECTOR NRG 19-60 URS 61 control EN 61508 NRG 111-60 Fig. -
Page 10: Improper Use
When bringing the level electrode into service, check that it is tight. ■ ■ Attempts to repair the equipment will cause the system to become unsafe. NRG 1x-60 level electrodes may only be repaired by the manufacturer, GESTRA AG. ■ ■ Only replace faulty equipment with identical equipment from GESTRA AG. -
Page 11: Required Personnel Qualifications
Required personnel qualifications Activity Personnel Integration in control system Specialist staff Plant designer The unit is an item of equipment with a safety function (EU Pressure Equipment Installation/electrical Specialist staff Directive) and may only be installed, electri- connection/bringing into service cally connected and brought into service by suitable, trained staff. -
Page 12: Functional Safety, Safety Integrity Level (Sil)
Functional safety, safety integrity level (SIL) In combination with the URS 60 / URS 61 safety control unit, NRG 16-60, NRG 17-60, NRG 19-60 and NRG 111-60 level electrodes are suitable for use with safety functions up to SIL 3. -
Page 13: Reliability Data To En 61508
Reliability data to EN 61508 Description Characteristic values Safety integrity level SIL 3 Architecture 1oo1 Type of equipment Type B Hardware error tolerance HFT = 0 λ Overall failure rate for dangerous undetected failures = < 20 * 10 λ Overall failure rate for dangerous detected failures = <... -
Page 14: Function
An NRG 1x-60 level electrode can be installed in a protective tube or level pot together with an NRG 1x-61 level electrode or continuous GESTRA NRG 26-60 level electrode. If a level electrode is installed in a lockable level pot outside the boiler, the connecting pipes must be flushed regularly. - Page 15 Function Behaviour in the event of malfunctions The safety functions of the equipment are monitored in the sensors through periodic self-tests. Fault indications are updated with each self-test. If there are no malfunctions, the message is automatically deleted. Alarm and fault indications are shown by LEDs or an operating unit. They are also saved in the level electrode and transferred to the URS 60 / URS 61 safety control unit using the CANopen protocol.
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Page 16: Technical Data
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 ■... - Page 17 - 40 °C – 80 °C ■ ■ Air humidity: 10 % – 95 %, non-condensing ■ ■ Weight NRG 16-60, NRG 17-60, NRG 19-60 approx. 2.1 kg ■ ■ NRG 111-60 approx. 2.7 kg ■ ■ Admissible installation positions Vertical ■...
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Page 18: Name Plate/Identification
IEC 61508 SIL 3 CE marking Current TÜV. XXX . XX-XXX approval Appointed authority 0525 Protection class GESTRA AG Münchener Str. 77 Manufacturer 28215 Bremen Disposal information GERMANY Serial number Fig. 5 The date of production is stamped on the screw-in body of every level electrode. -
Page 19: Factory Settings
IEC 61508 SIL 3 IEC 61508 SIL 3 TÜV. XXX . XX-XXX TÜV. XXX . XX-XXX TÜV. XXX . XX-XXX 0525 0525 0525 GESTRA AG GESTRA AG GESTRA AG Münchener Str. 77 Münchener Str. 77 Münchener Str. 77 28215 Bremen 28215 Bremen... -
Page 20: Overall View
Overall view NRG 16-60, NRG 17-60, NRG 19-60 NRG 111-60 Fig. 7 NRG 1x-60 - Installation & Operating Manual - 819681-00... - Page 21 For NRG 16-60, NRG 17-60; with a simplified view of the different designs for the NRG 19-60. Seal seat for sealing ring 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...
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Page 22: Dimensions Of The Nrg 16-60, Nrg 17-60, Nrg 19-60
Dimensions of the NRG 16-60, NRG 17-60, NRG 19-60 b = 70 41 mm A.F. Thermal insulation provided at the site G ¾ x = available electrode extensions: 500 mm ■ ■ 1000 mm ■ ■ 1500 mm ■ ■... -
Page 23: Dimensions Of The Nrg 111-60
Dimensions of the NRG 111-60 b = 70 41 mm A.F. Thermal insulation provided at the site x = available electrode extensions: 500 mm ■ ■ 1000 mm ■ ■ 1500 mm ■ ■ 2000 mm ■ ■ 2500 mm ■... -
Page 24: Preparing For Installation
Preparing for installation If the equipment is to be installed outdoors, outside the protection of a building, environ- mental influences may adversely affect function. Pay attention to the admissible ambient conditions in the technical data, ■ ■ see page 17. Do not operate the equipment if the temperature is below freezing. -
Page 25: Establishing The Measuring Length Of The Level Electrode
Incorrectly shortened electrodes will not be able to detect low water. Electrodes must not be longer than the permitted low water switchpoint. NRG 16-60, NRG 17-60, NRG 19-60, NRG 111-60 Manually screw the electrode extension M into the tip of the electrode K. -
Page 26: Screw The Level Electrode And Electrode Extension Together
Preparing for installation Screw the level electrode and electrode extension together NRG 16-60, NRG 17-60, NRG 19-60, NRG 111-60 Following a visual inspection, firmly screw the 13 mm A.F. electrode extension into the electrode tip K. While doing this, push the retaining spring L onto the electrode extension Muntil it is securely held in the hole provided. -
Page 27: Installation
Installation DANGER Danger to life from scalding caused by escaping hot steam. Hot steam or water can escape suddenly if level electrodes are unscrewed under pressure. Reduce the boiler pressure to 0 bar and check the pressure before unscrewing level elec- ■... -
Page 28: Sealing Surface Dimensions For Nrg 16-60, Nrg 17-60, Nrg 19-60
Installation Sealing surface dimensions for Inspect the sealing surfaces of the tank thread- NRG 16-60, NRG 17-60, NRG 19-60 ed standpipe or flange cover. Sealing surfaces must be perfectly machined as shown in Fig. 12 and Fig. 13. Ø 33 mm G ¾... -
Page 29: Example
Screw the level electrode into the threaded standpipe of the tank or flange cover, and tighten securely using a torque wrench (with size 41 open-ended spanner attachment). Tighten to the torques stated below. Tightening torque when cold: NRG 16-60, NRG 17-60, NRG 19-60 = 120 Nm ■ ■ NRG 111-60 = 165 Nm ■ ■... -
Page 30: Installing Two Level Electrodes In A Flange
Installation Installing two level electrodes in a flange Fit the first electrode as described above. Slacken and remove the rear body panel of the second electrode opposite the operating unit. Unfasten the electrode wiring from the PCB. Slacken the nut in the body of the second electrode using a size 19 open-ended spanner. Screw in the second electrode and tighten the nut in the body to a torque of 25 Nm. -
Page 31: Installation Examples With Dimensions
Installation examples 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 G ¾ (G1 *) DN 80 ≥14 ≤... - Page 32 Installation examples with dimensions 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.
- Page 33 Installation examples with dimensions 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 G ¾ G ¾ DN 100 24.5-26.0 24.5-26.0 ≥14 ≤...
- Page 34 Installation 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 G ¾ (G 1*) ≥14 ≥ DN 20 Fig. 18 All lengths and diameters in mm NRG 1x-60 - Installation &...
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Page 35: Positioning The Terminal Box
Installation examples with dimensions Key Fig. 15 to Fig. 18 Fig. 15: Flange (PN 40, 63, 160, 320) DIN EN1029-01 Fig. 16: Flange (PN 40, 63, 160, 320) DIN EN1029-01 Fig. 17: Flange (PN 40, 63, 160) DIN EN1029-01 Fig. 18: Flange (PN 40, 63, 60, 320) DIN EN1029-01 Connection Vent hole (locate as close to boiler wall as possible!) -
Page 36: Functional Element S
Functional element Fig. 19 Terminal box Cover screws M4 x 16 mm Operating panel with 4-digit LED display/alarm LEDs and rotary knob, see page 44 M12 CAN bus socket, 5-pole, A-coded M12 CAN bus connector, 5-pole, A-coded NRG 1x-60 - Installation & Operating Manual - 819681-00... -
Page 37: Connecting The Can Bus System
Connecting the CAN bus system Bus line, cable length and cross-section A shielded, multi-core, twisted-pair control cable, e.g. UNITRONIC ® BUS CAN 2 x 2 x .. mm or RE- ■ ■ 2YCYV-fl 2 x 2 x .. mm must be used as the bus line. Pre-wired control cables (with plug and coupling) are available as accessories in various lengths. -
Page 38: Important Notes On Connecting The Can Bus System
Connecting the CAN bus system Important notes on connecting the CAN bus system A dedicated 24 V DC SELV power supply unit that is isolated from connected loads must be used to ■ ■ supply the SPECTOR connect system. Make sure wiring is in line, not in a star! ■... -
Page 39: Bringing Into Service
Bringing into service Before bringing into service, check that all 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? ■... - Page 40 Bringing into service Selecting and setting a parameter: Using the screwdriver, turn the rotary knob clockwise or anti-clockwise until the 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.
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Page 41: Notes On Changing Communication Parameters "Bd.rt, Id
= initiate a display test ■ ■ Notes on changing communication parameters “bd.rt, Id” 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 42: Changing The Baud Rate
Faulty equipment jeopardises system 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. NRG 1x-60 - Installation & Operating Manual - 819681-00... -
Page 43: Checking The Low Water Switchpoint By Lowering The Level
Never start up any system without first checking 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. -
Page 44: Starting, Operation And Testing
Starting, operation and testing Fig. 22 The operating panel: Display of actual value/fault code/limit value, green, 4 digits LED 1, alarm/fault, red LED 2, function OK, green/flashing during self-test Rotary knob/push-button for operation and settings Notes on the priority of the various indications Fault indications and alarms are displayed based on their priority. - Page 45 Starting, operation and testing Relationship between equipment status, display and alarm LEDs: Start LED test, all LEDs light up Display: Switch on The system is started and tested. S-xx = software version supply voltage The LEDs and display are tested. t-01 = equipment type NRG 1x-60 Operation...
- Page 46 If the level electrode does not behave as described above, it may be faulty. ■ ■ Perform failure analysis. ■ ■ NRG 1x-60 level electrodes may only be repaired by the manufacturer, GESTRA AG. ■ ■ Only replace faulty equipment with identical equipment from GESTRA AG. ■ ■...
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Page 47: System Malfunctions
System malfunctions Causes System malfunctions occur if CAN bus components have been incorrectly installed or configured, if the equipment has overheated, if there is interference in the supply network or if electronic components are faulty. Check the installation and configuration before systematic troubleshooting Installation: Check that the installation location complies with the admissible ambient conditions in terms of ■... -
Page 48: Indication Of System Malfunctions Using Fault Codes
System malfunctions Indication of system malfunctions using fault codes Fig. 23 Display of actual value/fault code/limit value, green, 4 digits Fault code display Internal Fault code Possible faults Remedy designation EMC or Check the installation location E.008 Ch1Ch2DiffErr internal error Replace the level electrode Contamination or loss of E.009... - Page 49 System malfunctions Fault code display Internal Fault code Possible faults Remedy designation EMC or Check the installation location E.019 V6Err voltage error 6.0 V Replace the level electrode EMC or Check the installation location E.020 V5Err voltage error 5.0 V Replace the level electrode EMC or Check the installation location...
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Page 50: Common Faults During Use
System malfunctions Common faults during use Immersion of the level electrode is not detected (“o.P.E.r.” is not displayed) Possible causes if no fault indications are present Remedy Switch on the supply voltage. ■ ■ There may be no supply voltage. Check that the wiring conforms to the ■... -
Page 51: Checking Installation And Function
System malfunctions Checking installation and function When you have remedied system malfunctions, perform a function test as follows. 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 an alarm. Check the switchpoint when bringing into service and every time the NRG 1x-60 level electrode is ■... -
Page 52: Taking Out Of Service
Taking out of service DANGER Danger to life from scalding caused by escaping hot steam. Hot steam or water can escape suddenly if level electrodes are unscrewed under pressure. Reduce the boiler pressure to 0 bar and check the pressure before unscrewing level elec- ■... -
Page 53: Disposal
GESTRA AG! Such media include solid, liquid or gaseous substances, mixtures of these, or radiation. GESTRA AG can accept returned goods only if accompanied by a completed and signed return note and also a completed and signed declaration of decontamination. -
Page 54: Eu Declaration Of Conformity
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. NRG 1x-60 - Installation & Operating Manual - 819681-00... - Page 55 NRG 1x-60 - Installation & Operating Manual - 819681-00...
- Page 56 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 819681-00/08-2019cm (808947-00) · GESTRA AG · Bremen · Printed in Germany...
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