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GESTRA LRG 16-60 Installation & Operating Manual

Conductivity electrodes
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E n g l i s h
Conductivity Electrodes
LRG 16-60
LRG 16-61
LRG 17-60
Installation & Operating Manual
819878-01

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Summary of Contents for GESTRA LRG 16-60

  • Page 1 Conductivity Electrodes LRG 16-60 LRG 16-61 LRG 17-60 Installation & Operating Manual 819878-01 E n g l i s h...

  • Page 2: Table Of Contents

    Overall view ..............................23 LRG 16-60 ............................... 23 LRG 16 -61 .............................. 23 LRG 17-60 ............................... 23 Dimensions of the LRG 16-60........................25 Dimensions of the LRG 17-60........................26 Dimensions of the LRG 16-61........................27 Installation ..............................28 Additional notes for installation ........................ 29 Example LRG 1x-60 ..........................
  • Page 3 Contents s ..........................38 Functional element Connecting the CAN bus system ........................39 Bus line, cable length and cross-section ....................39 Example ..............................39 Important notes on connecting the CAN bus system ................. 40 Bringing into service ............................ 41 Changing the factory settings if necessary ....................41 Changing parameters with password protection enabled .................

  • Page 4: Content Of This Manual

    First edition: BAN 819878-00/08-2019cm © 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 delivery/Product package 1 x conductivity electrode LRG 1x-6x ■...

  • Page 5: How To Use This Manual

    How to use this Manual This Installation & Operating Manual describes the correct use of LRG 16-60/LRG 16-61/LRG 17-60 conductivity electrodes. It applies to all persons who integrate this equipment into control systems, install, bring into service, operate, maintain and dispose of this equipment. Anyone carrying out the above-men- tioned activities must have read this Installation &...

  • Page 6: Types Of Warning

    Types of warning DANGER Warning of a dangerous situation that will result 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 will result in damage to property or the environment.

  • Page 7: Specialist Terms/Abbreviations

    Data transmission standard and interface for connecting electronic equipment, sensors and control systems. Data can be sent and received. LRG .. / URS .. / URB .. / SRL .. / NRG .. / etc. Equipment and type designations of GESTRA AG, see page 9. SELV Safety Extra Low Voltage...

  • Page 8: Usage For The Intended Purpose

    Usage for the intended purpose LRG 16-60/LRG 16-61/LRG 17-60 conductivity electrodes may only be used for measuring electrical conductivity in liquids. LRG 1x-6x conductivity electrodes are used in combination with the URS 60/URS 61 safety control unit as conductivity limiters and in combination with an LRR 1-60 conductivity controller as continuous blowdown controllers and limit indicators in steam boiler and hot water installations.

  • Page 9: Admissible System Components, Dependent On The Required Safety Integrity Level

    To ensure the proper use of equipment during all types of use, please also read the Installation & 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: www.gestra.com LRG 1x-6x - Installation & Operating Manual - 819878-01...

  • Page 10: Improper Use

    Improper use There is a danger of death 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 11: Basic Safety Notes

    When bringing it into service, check that it is leak-tight. ■ Attempts to repair the equipment will cause the plant to become unsafe. LRG 1x-6x conductivity electrodes may only be repaired by the manufacturer, GESTRA AG. ■ Only replace faulty equipment with identical equipment from GESTRA AG.

  • Page 12: Required Personnel Qualifications

    Basic safety notes A lack of proper maintenance and cleaning can result in damage to the conductivity electrodes and/or false measurement results and false alarms. Once a year, perform a check on the conductivity electrodes using comparative measure- ■ ments. Adhere to the maintenance and cleaning intervals, see page 66.

  • Page 13: Functional Safety, Safety Integrity Level (Sil)

    Functional safety, safety integrity level (SIL) In combination with the URS 60/URS 61 safety control unit, LRG 16-60/LRG 16-61/LRG 17-60 conductivity electrodes are suitable for use with safety functions up to SIL 2. They are elements of a safety circuit up to SIL 2 as per IEC 61508 in the SPECTOR connect system, and can transmit alarm notifications.

  • Page 14: Reliability Data To Iec 61508

    Reliability data to IEC 61508 Description Characteristic values Type of electrode LRG 1x-60 LRG 16-61 Safety integrity level SIL 2 SIL 2 Architecture 1oo1 1oo1 Type of equipment Type B Type B Hardware fault tolerance HFT = 0 HFT = 0 Overall failure rate for dangerous undetected λ...

  • Page 15: Function

    The equipment measures the electrically conductivity of conductive fluids. Measuring process of the LRG 16-60 and LRG 17-60 LRG 16-60 and LRG 17-60 conductivity electrodes use the conductometric two-electrode measuring process. A measuring current with a suitable frequency for the measuring range is introduced into the fluid.
  • Page 16 Function These data telegrams contain the following information: Conductivity reading, temperature-compensated ■ Fluid temperature ■ Limiter MAX setting ■ Temperature coefficient (tC) and cell constant (CF) ■ Limiter test command ■ Status or error information ■ Conductivity electrode alarms if the limits are exceeded ◆...
  • Page 17 Function Simulating the alarm state * The triggering of an alarm can be simulated by pressing the rotary knob of the LRG 1x-6x, by 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.

  • Page 18: Technical Data

    Technical data Model and mechanical connection LRG 16-60, LRG 16-61, LRG 17-60 Thread G1 A, EN ISO 228-1, see Fig. 8, 10, 11 ■ Nominal pressure rating, admissible service pressure and temperature LRG 16-60 PN 40 32 bar (abs) at 238 °C ■...
  • Page 19 * Resolution for internal processing based on 15 bits with plus or minus sign (16 bits). The above figures refer to the uncompensated conductivity. Time constant “T” (measured using the two-bath process) Temperature Conductivity LRG 16-60, LRG 17-60 9 seconds 14 seconds ■ LRG 16-61...
  • Page 20 - 40 °C – 80 °C ■ Transport temperature: - 40 °C – 80 °C ■ Air humidity: 10% – 95%, non-condensing ■ Weight LRG 16-60/LRG 16-61/LRG 17-60 approx 2.1 kg ■ LRG 1x-6x - Installation & Operating Manual - 819878-01...

  • Page 21: Example Name Plate/Identification Of The Lrg 1X-60

    & Disposal information Manufacturer § Protection class Material number-serial number & GESTRA AG Münchener Str.77 28215 Bremen Made in Germany Fig. 5 The date of production (quarter and year) is stamped on the screw-in body of each conductivity electrode. LRG 1x-6x - Installation & Operating Manual - 819878-01...

  • Page 22: Factory Settings

    Factory settings LRG 1x-6x conductivity electrodes are delivered ex-works with the following settings. Parameter values Parameter Display in menu Unit LRG 16-60 LRG 16-61 LRG 17-60 Limiter ID Id.Hi Controller group 0001 Baud rate bd.rt kbit/s 0050 Alarm limit AL.Hi µS/cm...

  • Page 23: Overall View

    Overall view LRG 16-60 LRG 16 -61 LRG 17-60 Fig. 7 LRG 1x-6x - Installation & Operating Manual - 819878-01...
  • Page 24 Sealing ring D 33 x 39, form D, DIN 7603-2.4068, bright annealed Electrode thread Threaded pin M2.5 mm (LRG 16-60/LRG 17-60) Measuring tube with measuring electrode (LRG 16-60/LRG 17-60), measuring electrodes (LRG 16-61) Spacer disc LRG 1x-6x - Installation & Operating Manual - 819878-01...

  • Page 25: Dimensions Of The Lrg 16-60

    Dimensions of the LRG 16-60 w = 70 Size 41 Thermal insulation provided at the site x = available electrode lengths: 200 mm ■ 300 mm ■ 400 mm ■ 500 mm ■ 600 mm ■ 800 mm ■ 1000 mm ■...

  • Page 26: Dimensions Of The Lrg 17-60

    Dimensions of the LRG 17-60 w = 70 Size 41 Thermal insulation provided at the site x = available electrode lengths: 200 mm ■ 300 mm ■ 400 mm ■ 500 mm ■ 600 mm ■ 800 mm ■ 1000 mm ■...

  • Page 27: Dimensions Of The Lrg 16-61

    Dimensions of the LRG 16-61 w = 70 Size 41 Thermal insulation provided at the site x = available electrode lengths: 180 mm ■ 300 mm ■ 380 mm ■ 500 mm ■ 600 mm ■ 800 mm ■ 1000 mm ■...

  • Page 28: Installation

    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 20. Do not operate the equipment if the temperature is below freezing. ■...

  • Page 29: Additional Notes For Installation

    False measurement results are a risk to plant safety. Therefore, always adhere to the distances stated below. LRG 16-60, LRG 17-60 Provide spacing of approx. 30 mm between the lower end of the measuring tube and the ■...

  • Page 30: Example Lrg 1X-60

    Installation Sealing surface dimensions for Inspect the sealing surfaces of the tank stand- LRG 16-60/LRG 16-61/LRG 17-60 pipe or flange cover. Sealing surfaces must be perfectly machined, Ø 40 mm as shown in Fig. 11. Ra 3.2 Fig. 11 Push the supplied sealing ring H onto the...

  • Page 31: Detaching The Terminal Box From The Electrode

    Screw the conductivity electrode into the tank standpipe or flange cover, and tighten securely using a torque wrench (with size 41 open-ended spanner attachment). Tightening torque when cold: LRG 16-60/LRG 16-61/LRG 17-60 = 250 Nm ■ Installation examples with dimensions, see Fig. 14, Fig. 15, Fig. 16 on page ff. 34 Detaching the terminal box from the electrode When installing or removing the conductivity electrode (e.g.
  • Page 32 Installation Detaching the terminal box from the electrode You will need the following tools: Size 1 slotted screwdriver ■ Size 19 open-ended spanner ■ Undo and remove the rear panel of the terminal box opposite the operating unit. Interior view of terminal box: Do not twist or damage the connecting cables of the electrode.
  • Page 33 Installation Detaching the terminal box from the electrode During cleaning/maintenance (see page 66) or taking out of service (see page 65) Unscrew the conductivity electrode from the tank standpipe. When installing for the first time or after cleaning/maintenance Screw the conductivity electrode into the tank standpipe. To do so, proceed as described on pages 30 / 31 (points 1.

  • Page 34: Installation Examples With Dimensions

    Installation examples with dimensions Conductivity measurement Installing the conductivity electrode via a flange on the side. Key, see page 37 ~ 250 Sealing ring e.g. LRG 16-60 D 33 x 39 DIN 7603-2.4068, bright annealed * Minimum distances (R) LRG 16-60/LRG 17-60 R = 30 mm ■...

  • Page 35: Conductivity Measurement And Continuous Blowdown Control

    Installation examples with dimensions Conductivity measurement and continuous blowdown control Installing the conductivity electrode via a level pot with continuous blowdown valve connection. Key, see page 37 ~ 250 e.g. LRG 16-60 Sealing ring D 33 x 39 DIN 7603-2.4068, bright annealed...

  • Page 36: Conductivity Measurement And Continuous Blowdown Control Via A Separate Level Pot

    Key, see page 37 Outlet DN 15-40 Inlet DN 15-40 Sealing ring e.g. LRG 16-60 D 33 x 39 DIN 7603-2.4068, bright annealed Fig. 16 All lengths and diameters in mm LRG 1x-6x - Installation & Operating Manual - 819878-01...

  • Page 37: Key Fig. 14 To Fig. 16

    Installation examples with dimensions Key Fig. 14 to Fig. 16 Boiler drum Stop valve GAV Continuous blowdown valve BAE T-type connector Level pot 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 ≥...

  • Page 38: Functional Element S

    Functional element Fig. 17 Terminal box Cover screws M4 x 16 mm Operating panel with 4-digit LCD, alarm and status LEDs and rotary knob, see page 55 M12 CAN bus socket, 5-pole, A-coded M12 CAN bus connector, 5-pole, A-coded LRG 1x-6x - Installation & Operating Manual - 819878-01...

  • Page 39: Connecting The Can Bus System

    Connecting the CAN bus system Bus line, cable length and cross-section Use a shielded, multi-core, twisted-pair control cable, e.g. UNITRONIC BUS CAN 2 x 2 x .. mm ® ■ RE-2YCYV-fl 2 x 2 x .. mm as the bus line. Pre-wired control cables (with connector and coupling) are available as accessories in various lengths.

  • Page 40: 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 41: 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 each terminal devices of the CAN bus line? ■...
  • Page 42 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.
  • Page 43 Bringing into service Without password entry: Set the desired value. reduce/increase the value Each parameter has an individual, admissible value range. By pressing the knob briefly, you can skip to the next digit. This is a more convenient way of making large changes to values. If you do not set a parameter within 10 seconds, the process is aborted (“quit”) and the old parameter value is retained.

  • Page 44: Notes On Changing Communication Parameters "Bd.rt, Id.hi Or Grp

    Alternatively, you can initiate the display test by pressing “diSP”, see page 51. Notes on changing communication parameters “bd.rt, Id.Hi or GrP” All CAN bus equipment from GESTRA AG has default ex-works parameter settings, which enab- le a standard system to be brought into operation without making any changes.

  • Page 45: Changing The Limiter Id

    Bringing into service Changing the limiter ID To set the limiter ID, please also read the instructions in the Installation & Operating Manual of the URS 60/URS 61 safety control unit. Pay attention to the setting instructions on page 42 and proceed as follows: Select the parameter “Id.Hi”.

  • Page 46: Changing The Alarm Limit Of The Limiter Function

    Faulty equipment jeopardises plant safety. If numbers or decimal points are displayed incorrectly or not at all, you must replace the ■ conductivity electrode with an identical one from GESTRA AG. LRG 1x-6x - Installation & Operating Manual - 819878-01...

  • Page 47: Changing The Cell Constant

    Bringing into service Changing the cell constant Notes on calibrating the cell constant The cell constant of each LRG 1x-6x conductivity electrode is precisely set at the factory. If recalibration is necessary at the installation site due to the conditions there, (see page 53, comparing the reading with a reference reading), you may change the cell constant on site.

  • Page 48: Using The "Cal" Function

    Bringing into service Using the “CAL” function The CAL function enables convenient readjustment of the cell constant “CF” when deposits build up on the electrode during operation. To do this, the reference reading of a reliable sample is converted into the indicated value at the operating point.

  • Page 49: Using The "Filt" Feature

    Bringing into service Using the “FiLt” feature The aim of this feature is to “smooth” the reading for the controller function and the 4-20 mA actual output on the LRR1-60. If the limiter is deactivated (Id.Hi = 0), the adjustable time constant (1-30 seconds) also has an effect ■...
  • Page 50 Bringing into service Measuring ranges of the LRG 1x-60 based on the setting of the “Sout” parameter Conductivity measuring ranges/ Measuring ranges Current output actual value output (μS/cm at 25 °C) (mA = µS/cm) Adjustable via the rotary knob on 4 mA 20 mA the operating panel.

  • Page 51: Changing The Display Unit (Μs/Cm Or Ppm)

    Faulty equipment jeopardises plant safety. If numbers or decimal points are displayed incorrectly or not at all, you must replace the ■ conductivity electrode with an identical one from GESTRA AG. LRG 1x-6x - Installation & Operating Manual - 819878-01...

  • Page 52: Viewing The Signal Reserve "Sgnl" (For Lrg 16-61 Only)

    Bringing into service Viewing the signal reserve “SGnL” (for LRG 16-61 only) Pay attention to the setting instructions on page 42 and proceed as follows: Select the parameter “SGnL”. The signal quality is shown in 0-100%. This continually declines as the build-up of deposits on the electrode tips increases.

  • Page 53: Comparing The Reading With The Reference Reading From A Reliable Sample

    “tC” until the indicated reading matches the reference measurement. Also see the descrip- tion of parameter “tC” on page 47. LRG 1x-6x conductivity electrodes may only be repaired by the manufacturer, GESTRA AG. ■ Only replace faulty equipment with identical equipment from GESTRA AG.

  • Page 54: Checking The Al.hi Alarm Limit By Initiating A Test Function

    Bringing into service Checking the Al.Hi alarm limit by initiating a test function Check the Al.Hi alarm limit of the limiter function by initiating the test function with the rotary knob; see page 58. In this case, the equipment must behave as if there were an alarm. Lockout function If the installation requires a lockout function, this must be implemented in the downstream (safety) circuit.

  • Page 55: Starting, Operation, Alarm And Testing

    Starting, operation, alarm and testing Fig. 22 The operating panel: Actual value display/error code/limit value, green, 4 digits LED 1, alarm/fault, red LED 3, unit µS/cm, green LED 4, unit ppm, green LED 2, function OK, green Rotary knob/pushbutton for operation and settings Notes on the priority of the various indications Fault indications and alarms are displayed based on their priority.
  • Page 56 Starting, operation, alarm and testing Relationship between display and LEDs and the operating state of the conductivity electrode: Starting All LEDs light up - Test The system is started and tested. The LEDs and display are tested. Indication: S-xx = software version Switch on t-04 = equipment type LRG supply voltage...
  • Page 57 Starting, operation, alarm and testing Behaviour in the event of a malfunction (error code display) Indication: An error code is continuously displayed, e.g. E005 error code display see page 60 LED 1: The conductivity electrode Alarm LED lights up red A fault indication is active is immersed or not immersed.
  • Page 58 If the conductivity electrode does not behave as described above, it may be faulty. ■ Perform failure analysis. ■ LRG 1x-6x conductivity electrodes may only be repaired by the manufacturer, GESTRA AG. ■ Only replace faulty equipment with identical equipment from GESTRA AG. ■...

  • Page 59: 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 60: Indication Of System Malfunctions Using Error Codes

    System malfunctions Indication of system malfunctions using error codes Fig. 23 Actual value display/error code/limit value, green, 4 digits Error code table Internal Error code Possible errors Remedy designation Check the installation location. Have the minimum distances been adhered to? Short circuit in conductivity E.001 LFKurzschlussErr...
  • Page 61 System malfunctions Error code table Internal Error code Possible errors Remedy designation Test signal measuring voltage E.007 USIGTSTErr Replace the conductivity electrode outside tolerance Test signal measuring current E.008 ISIGTSTErr Replace the conductivity electrode outside tolerance Pt1000 test measuring voltage E.009 ADCTSTErr Replace the conductivity electrode...
  • Page 62 System malfunctions Error code table Internal Error code Possible errors Remedy designation E.022 V1Err System voltage 1 V outside limits Replace the conductivity electrode System voltage 12 V outside E.023 V12Err Replace the conductivity electrode limits Check the baud rate, wiring and terminating E.024 CANErr Communication failure...

  • Page 63: Errors That Do Not Provoke A Shutdown

    Has the electrode been correctly insulated to prevent ■ leakage? Only replace the conductivity electrode with identical ■ equipment from GESTRA AG. The inner seals of the electrode rods Only replace the conductivity electrode with identical ■ are damaged. equipment from GESTRA AG.

  • Page 64: Checking Installation And Function

    The code “SG.Lo” flashes on the display Possible causes if no error codes are shown Remedy Remove the conductivity electrode, ■ see page 65 The measurement signal is too low and below the Check and clean the electrode, see page 66 ■...

  • Page 65: Taking Out Of Service/Disassembly

    Taking out of service/Disassembly DANGER Danger to life from scalding caused by the sudden escape of hot steam. Hot steam or hot water can escape suddenly if the conductivity electrode is unscrewed under pressure. Reduce the boiler pressure to 0 bar and check the pressure before unscrewing the conduc- ■...

  • Page 66: Cleaning The Conductivity Electrode

    Clean the measuring electrodes Move on to the points below: = key to overall view, see page 24 LRG 16-60, LRG 17-60, LRG 16-61 Wipe off loose deposits with a grease-free cloth. Scrub off stubborn deposits using sandpaper (medium grain).

  • Page 67: Disposal

    GESTRA AG. Such media include solid, liquid or gaseous substances, mixtures of these, or 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 68: Declaration Of Conformity; Standards And Directives

    You can find details on the conformity of the equipment and the applicable standards and directives in the Declaration of Conformity and associated certificates. You can download the Declaration of Conformity from www.gestra.com and request relevant certificates by writing to the following address: GESTRA AG Münchener Straße 77...
  • Page 69 LRG 1x-6x - Installation & Operating Manual - 819878-01...
  • Page 70 LRG 1x-6x - Installation & Operating Manual - 819878-01...
  • Page 71 LRG 1x-6x - Installation & Operating Manual - 819878-01...
  • Page 72 Tel. +49 421 3503 0 Unit 1 Sopwith Park, Royce Close, +49 421 3503 393 West Portway Business Park, Andover, e-mail info@de.gestra.com Hampshire SP10 3TS Website www.gestra.com United Kingdom 819878-01/10-2022cm (808950-01) · GESTRA AG · Bremen · Printed in Germany...

This manual is also suitable for:

Lrg 16-61Lrg 17-60

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