GESTRA NRG 16-60 Installation instructions

Original Installation &
Operating Manual
EN
English
Level Electrodes
NRG 16-60
NRG 17-60
NRG 19-60
NRG 111-60
819681-00

2NRG 1x-60 - Installation & Operating Manual - 819681-00
Contents
Content of this Manual....................................................................................................................................4
Scope of delivery/Product package................................................................................................................4
How to use this Manual...................................................................................................................................5
Illustrations and symbols used.......................................................................................................................5
Hazard symbols in this Manual.......................................................................................................................5
Types of warning .............................................................................................................................................6
Specialist terms/Abbreviations.......................................................................................................................7
Usage for the intended purpose...................................................................................................................... 8
Applicable directives and standards............................................................................................................8
Admissible system components, dependent on the required safety integrity level .......................................9
Improper use .................................................................................................................................................10
Basic safety notes .........................................................................................................................................10
Required personnel qualifications................................................................................................................11
Notes on 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
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

3NRG 1x-60 - Installation & Operating Manual - 819681-00
Contents
Installation examples with dimensions........................................................................................................31
Positioning the terminal box.........................................................................................................................35
Functional elements.............................................................................................................................. 36
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
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 malfunctions using fault codes..................................................................................48
Common faults during use........................................................................................................................50
Checking installation and function ............................................................................................................51
Emergency mode for water level limiter systems........................................................................................51
Taking out of service.....................................................................................................................................52
Disposal .........................................................................................................................................................53
Returning decontaminated equipment.........................................................................................................53
EU Declaration of Conformity........................................................................................................................ 54

4NRG 1x-60 - Installation & Operating Manual - 819681-00
Content of this Manual
Product:
 NRG 16-60 level electrode
 NRG 17-60 level electrode
 NRG 19-60 level electrode
 NRG 111-60 level electrode
First edition:
BAN 819681-00/08-2019cm
© 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 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 Installation & Operating Manual
Accessories
 1 x M12 CAN bus connector, 5-pole, A-coded, with 120 Ωterminating resistor

5NRG 1x-60 - Installation & Operating Manual - 819681-00
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 & Operating Manual and understood its
contents.
 Read this Manual 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, please also hand over the Installation & Operating
Manual.
Hazard symbols in this Manual
Danger zone/Dangerous situation
Illustrations and symbols used
1. Action to be taken
2.
 Lists
 Bullet points in lists
A Keys to illustrations
Additional
information
Read the relevant
Installation & Operating Manual

6NRG 1x-60 - Installation & Operating Manual - 819681-00
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.

7NRG 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

8NRG 1x-60 - Installation & Operating Manual - 819681-00
Usage for the intended purpose
NRG 1x-60 level electrodes are used in conjunction with the URS 60 / URS 61 control unit as water level
limiters for pressurised steam and hot-water plants.
 Water level limiters switch off the heating when the water drops below the set minimum level (LW).
 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:
 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 Water-tube boilers, requirements for limiting devices
 EN 60730-1 Automatic electrical controls – Part 1:
General requirements
 EN 61508 Functional safety of electronic systems
Standards documents:
 VdTÜV Bulletin BP WASS 0100-RL
Requirements for water level control and limiting equipment

9NRG 1x-60 - Installation & Operating Manual - 819681-00
Usage for the intended purpose
Admissible system components, dependent on the required safety integrity level
In accordance with EU Pressure Equipment Directive 2014/68/EU and standards EN12952, EN12953
and EN61508, and the technical rules of VdTÜV Bulletin BP WASS 0100-RL, the level electrodes can be
operated with the following system components, as suitable for the required safety integrity level.
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 = SPECTOR
connect safety control unit
URB = visual display and operating unit
SRL = monitoring unit
To ensure the proper use of equipment during all types of use, you must also read the Installa-
tion & 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

10 NRG 1x-60 - Installation & Operating Manual - 819681-00
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.
Basic safety notes
Danger to life from scalding if the level electrode is removed under pressure. Steam or
hot water can spurt forcefully out of the equipment.
 Only remove the level electrode at 0 bar boiler pressure.
Risk of severe burns when working on level electrodes that have not been allowed to
cool. Level electrodes become very hot during operation.
 Always allow level electrodes to 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 escape
of hot steam or hot water.
Mistakes during transport or installation can cause the ceramic in the NRG 111-60 level
electrode to break, so that hot steam or hot water escapes through the vent hole.
 Before and after installation, check that the level electrode is completely undamaged.
 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.