Related Manuals for GESTRA NRG 16-61
Summary of Contents for GESTRA NRG 16-61
- Page 1 Level Electrodes NRG 16-61 NRG 17-61 NRG 19-61 NRG 111-61 Installation & Operating Manual 819682-02 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 Screwing the level electrode and electrode extension together ..............26 Installation ..............................27 Sealing surface dimensions for NRG 16-61, NRG 17-61, NRG 19-61 ............28 Sealing surface dimensions for NRG 111-61 .....................28 Example ..............................29 Installing two level electrodes in a flange by detaching a terminal box ............30... - Page 3 Contents s ..........................37 Functional element Connecting the CAN bus system ........................38 Bus line, cable length and cross-section ....................38 Example ..............................38 Important notes on connecting the CAN bus system ..................39 Pin assignment of the CAN bus connector and coupling for non pre-wired control cables ......39 Bringing into service .............................40 Changing the factory settings if necessary ....................40 Changing parameters with password protection enabled ................40...
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Page 4: Content Of This Manual
1 x NRG 1x-61 level electrode ■ 1 x sealing ring ■ D 27 x 32, form D, DIN 7603-2.4068, bright annealed for NRG 16-61, NRG 17-61, NRG 19-61 ◆ D 33 x 39, form D, DIN 7603-2.4068, bright annealed for NRG 111-61 ◆... -
Page 5: How To Use This Manual
How to use this Manual This Installation & Operating Manual describes how to correctly use NRG 16-61, NRG 17-61, NRG 19-61 and NRG 111-61 level 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-mentioned 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. NRG .. / URS .. / URB .. / SRL .. / etc. Equipment and type designations of GESTRA AG, see page 8. SELV Safety Extra Low Voltage... -
Page 8: Usage For The Intended Purpose
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 NRG 1x-61 - Installation & Operating Manual - 819682-02... -
Page 9: Improper Use
Check that the level electrode is not leaking when bringing into service. ■ Attempts to repair the equipment will cause the plant to become unsafe. NRG 1x-61 level electrodes may only be repaired by the manufacturer, GESTRA AG. ■ Only replace faulty equipment with identical equipment from GESTRA AG. -
Page 10: 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 connection/ Specialist staff Directive) and may only be installed, electri- bringing into service cally connected and brought into service by suitable, trained staff. -
Page 11: Functional Safety, Safety Integrity Level (Sil)
Functional safety, safety integrity level (SIL) In combination with the URS 60/URS 61 safety control unit, NRG 16-61, NRG 17-61, NRG 19-61 and NRG 111-61 level electrodes are suitable for use with safety functions up to SIL 3. They are elements of a safety circuit up to SIL 3 as per IEC 61508 in the SPECTOR connect system, and can transmit alarm notifications. -
Page 12: Reliability Data To Iec 61508
Reliability data to IEC 61508 Description Characteristic values Safety integrity level SIL 3 Architecture 1oo1 Type of equipment Type B Hardware fault tolerance HFT = 0 λ Overall failure rate for dangerous undetected failures = < 20 * 10 λ Overall failure rate for dangerous detected failures = <... -
Page 13: Function
An NRG 1x-61 level electrode can be installed in a protective tube or level pot together with an NRG 1x-60 level electrode or continuous GESTRA NRG 26-60 level electrode. If a level electrode is installed outside the boiler in a level pot that can be shut off, the connecting pipes must be flushed regularly. - Page 14 Function Behaviour in the event of faults The safety functions of the equipment are monitored in the sensors through periodic self-tests. Fault indi- cations are updated with each self-test. If there are no faults, the display automatically goes blank. Alarm and fault indications are shown by LEDs or an operating unit.
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Page 15: Technical Data
◆ NRG 19-61 PEEK and PTFE ◆ NRG 111-61 Special ceramic ◆ Screw-in body: ■ NRG 16-61, NRG 17-61, NRG 19-61 1.4571, X6CrNiMoTi17-12-2 ◆ NRG 111-61 1.4529, X1NiCrMoCuN25-20-7 ◆ pH value NRG 111-61 Maximum admissible = 10 ■ Electrode lengths supplied 500 mm, 1000 mm, 1500 mm ■... - Page 16 - 40 °C – 80 °C ■ Transport temperature: - 40 °C – 80 °C ■ Air humidity: 10% – 95%, non-condensing ■ Weight NRG 16-61, NRG 17-61, NRG 19-61 approx. 2.1 kg ■ NRG 111-61 approx. 2.7 kg ■ Admissible installation positions Vertical ■...
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Page 17: Example Name Plate/Identification Of Nrg 1X-61
L/H= Disposal information & Manufacturer Protection class " Material number-serial number § GESTRA AG & Münchener Str.77 28215 Bremen Made in Germany The date of production (quarter and year) is stamped on the screw-in body of each level electrode. Fig. 5... -
Page 18: Overall View
Overall view NRG 16-61, NRG 17-61 NRG 19-61 Fig. 6 NRG 1x-61 - Installation & Operating Manual - 819682-02... -
Page 19: Nrg 111-61
Overall view NRG 111-61 Fig. 7 NRG 1x-61 - Installation & Operating Manual - 819682-02... - Page 20 For NRG 16-61 and NRG 17-61 with a simplified view of the different designs. Seal seat for sealing ring Sealing ring D 27 x 32, form D, DIN 7603-2.4068, bright annealed for NRG 16-61, NRG 17-61, NRG 19-61 Sealing ring D 33 x 39, form D, DIN 7603-2.4068, bright annealed for NRG 111-61...
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Page 21: Dimensions Of The Nrg 16-61, Nrg 17-61
Dimensions of the NRG 16-61, NRG 17-61 w = 70 Size 41 Thermal insulation provided at the site G ¾ x = available electrode extensions: 500 mm ■ 1000 mm ■ 1500 mm ■ Fig. 8 All lengths in mm... -
Page 22: Dimensions Of The Nrg 19-61
Dimensions of the NRG 19-61 w = 70 Size 41 Thermal insulation provided at the site G ¾ x = available electrode extensions: 500 mm ■ 1000 mm ■ 1500 mm ■ Fig. 9 All lengths in mm NRG 1x-61 - Installation & Operating Manual - 819682-02... -
Page 23: Dimensions Of The Nrg 111-61
Dimensions of the NRG 111-61 w = 70 Size 41 Thermal insulation provided at the site x = available electrode extensions: 500 mm ■ 1000 mm ■ 1500 mm ■ Fig. 10 All lengths in mm NRG 1x-61 - Installation & Operating Manual - 819682-02... -
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 16. 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 high water. Electrodes must not be shorter than the permitted high water switchpoint. NRG 16-61, NRG 17-61, NRG 19-61, NRG 111-61 Manually screw the electrode extension M into the electrode tip K. -
Page 26: Screwing The Level Electrode And Electrode Extension Together
Preparing for installation Screwing the level electrode and electrode extension together NRG 16-61, NRG 17-61, NRG 19-61, NRG 111-61 Following a visual inspection, firmly screw the Size 13 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 boiler pressure before you unscrew the ■... -
Page 28: Sealing Surface Dimensions For Nrg 16-61, Nrg 17-61, Nrg 19-61
Installation Sealing surface dimensions for Inspect the sealing surfaces of the tank stand- NRG 16-61, NRG 17-61, NRG 19-61 pipe or flange cover. Sealing surfaces must be perfectly machined as shown in Fig. 13 and Fig. 14. Ø 33 mm G ¾... -
Page 29: Example
Screw the level electrode into the threaded coupling 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 16-61, NRG 17-61, NRG 19-61 = 160 Nm ■ NRG 111-61 = 350 Nm ■... -
Page 30: Installing Two Level Electrodes In A Flange By Detaching A Terminal Box
Installation Installing two level electrodes in a flange by detaching a terminal box When installing or removing the level electrode (e.g. when installing for the first time, during annual cleaning/maintenance or when taking out of service), you may need to detach the terminal box from the electrode because of space issues. - Page 31 Installation Installing two level electrodes in a flange by detaching a terminal box Fit the first electrode as described above. Undo and remove the rear panel of the second electrode terminal box opposite the operating unit. Interior view of terminal box: Do not twist or damage the connecting cables of the electrode.
- Page 32 Installation Installing two level electrodes in a flange by detaching a terminal box Rotate the terminal box so that it is correctly orientated. Ensure the terminal box is correctly orientated/aligned – position it correctly in advance. Tighten the nut in the terminal box to a torque of 25 Nm. Re-insert the connector in the terminal block until you hear it click into place.
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Page 33: Installation Examples With Dimensions
Installation examples with dimensions Use as an internal safety high-level limiter with protective tube provided on site. Illustration not to scale. Dimensions marked * apply to the NRG 111-61 Key, see page 36 G ¾ (G1 *) DN 80 ≥14 ≤... - Page 34 Installation examples with dimensions Use as an internal safety high-level limiter with protective tube provided on site, combined with water level control or water level limiter. Illustration not to scale. Key, see page 36 G ¾ G ¾ DN 100 24.5-26.0 24.5-26.0 ≥14 ≤...
- Page 35 Installation examples with dimensions Level pot ≥ DN 80 as an external safety high-level limiter Illustration not to scale. Dimensions marked * apply to the NRG 111-61 Key, see page 36 G ¾ (G 1*) ≥14 ≥ DN 20 Fig. 19 All lengths and diameters in mm NRG 1x-61 - Installation &...
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Page 36: Positioning The Terminal Box
Installation examples with dimensions Key Fig. 17 to Fig. 19 Fig. 17: Flange (PN 40, 63, 160, 320) EN 1092-1 Fig. 18: Flange (PN 40, 63, 160) EN 1092-1 Fig. 19: Flange (PN 40, 63, 60, 320) EN 1092-1 Standpipe Pressure relief hole (locate as close to the boiler wall as possible!) High water (HW) Electrode rod, d = 8 mm... -
Page 37: Functional Element S
Functional element Fig. 20 Terminal box Cover screws M4 x 16 mm Operating panel with 4-digit LED display/alarm LEDs and rotary knob, see page 47 M12 CAN bus socket, 5-pole, A-coded M12 CAN bus connector, 5-pole, A-coded NRG 1x-61 - Installation & Operating Manual - 819682-02... -
Page 38: 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 39: 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 40: 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 device of the CAN bus line? ■... - Page 41 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 current value, e.g.
- Page 42 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.
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Page 43: Notes On Changing Communication Parameters "Bd.rt, Id
Bringing into service Notes on changing communication parameters “bd.rt, Id” 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. Please follow the steps below if you need to make changes to communication parame- ters: Set the same baud rate for all bus nodes. -
Page 44: Manually Initiating A Display Test
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. Viewing the software version and equipment type “InFo” Pay attention to the setting instructions on page 41 ff. and proceed as follows: Select the parameter “InFo”. -
Page 45: Enabling/Disabling Password Protection
Bringing into service Enabling/disabling password protection The default ex-works password cannot be changed The default password is “1902”. ■ Password protection is available from software version S-16 onwards. ■ Pay attention to the setting instructions on page 41 ff. and proceed as follows: Select the parameter “PW”. -
Page 46: Checking The High Water Switchpoint By Raising The Level
Never start up any plant that has not passed the high water switchpoint check. ■ NRG 1x-61 level electrodes may only be repaired by the manufacturer, GESTRA AG. ■ Only replace faulty equipment with identical equipment from GESTRA AG. -
Page 47: Starting, Operation And Testing
Starting, operation and testing Fig. 23 The operating panel: Actual value display/error code/limit value, green, 4 digits LED 1, alarm/fault, red LED 2, function OK, green/flashing during self-test 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 48 Starting, operation and testing Relationship between equipment status, display and alarm LEDs: Starting LED test, all LEDs light up Indication: Switch on The system is started and tested. S-xx = software version supply voltage The LEDs and display are tested. t-02 = equipment type NRG 1x-61 Operation...
- Page 49 If the level electrode does not behave as described above, it may be faulty. ■ Perform failure analysis. ■ NRG 1x-61 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 50: 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 51: Indication Of System Malfunctions Using Error Codes
System malfunctions Indication of system malfunctions using error codes Fig. 24 Actual value display/error code/limit value, green, 4 digits Error code display Internal Error code Possible errors Remedy designation EMC or Check the installation location E.008 Ch1Ch2DiffErr internal error Replace the level electrode Contamination or loss of Remove, check and clean the level E.009... - Page 52 System malfunctions Error code display Internal Error code Possible errors 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 53: Common Application And Usage Errors
System malfunctions Common application and usage errors Non-immersion of the level electrode is not detected (“o.P.E.r.” is not displayed) Possible causes if no error codes are shown Remedy Switch on the supply voltage. ■ Possible supply voltage failure. Check that the wiring conforms to the ■... -
Page 54: Checking Installation And Function
System malfunctions Checking installation and function When you have remedied system malfunctions, perform a function test as follows. Check the high water (HW) switchpoint by allowing the water to rise above the set 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-61 level electrode is ■... -
Page 55: Taking Out Of Service/Disassembly
Taking out of service/Disassembly DANGER Danger to life from scalding caused by escaping hot steam. Hot steam or water can escape suddenly if the level electrode is unscrewed under pressure. Reduce the boiler pressure to 0 bar and check the pressure before unscrewing level elec- ■... -
Page 56: 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 57: 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 58 NRG 1x-61 - Installation & Operating Manual - 819682-02...
- Page 59 NRG 1x-61 - Installation & Operating Manual - 819682-02...
- Page 60 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 819682-02/02-2023cm (808948-02) · GESTRA AG · Bremen · Printed in Germany...
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