GESTRA LRR 1-40 User manual

1
EN
English
Original Installation Instructions
818527-03
Control Unit
LRR 1-40

2
Contents
Usage for the intended purpose ..............................................................................................................4
Safety note .............................................................................................................................................4
ATEX (Atmosphère Explosible).................................................................................................................4
Danger ...................................................................................................................................................4
Important Notes
Page
Explanatory Notes
Scope of supply......................................................................................................................................5
Description .............................................................................................................................................5
Function ............................................................................................................................................. 5, 6
LRR 1-40..............................................................................................................................................13
Tools.....................................................................................................................................................13
Installation
Electrical Connection
Bus cable..............................................................................................................................................14
Changing baud rate ..............................................................................................................................14
Wiring terminal strip .............................................................................................................................14
Note .....................................................................................................................................................14
Wiring diagram LRR 1-40 .....................................................................................................................15
Wiring diagram for CAN bus system......................................................................................................16
Attention...............................................................................................................................................16
Note .....................................................................................................................................................17
Tools.....................................................................................................................................................17
LRR 1-40..........................................................................................................................................7 – 9
Name plate / marking .............................................................................................................................9
Dimensions...........................................................................................................................................10
Technical Data
LRR 1-40..............................................................................................................................................11
Key.......................................................................................................................................................12
Functional Elements
CAN bus ...............................................................................................................................................18
Node ID ................................................................................................................................................18
Factory setting......................................................................................................................................18
Danger .................................................................................................................................................19
Basic Settings

3
Start .....................................................................................................................................................19
Note .....................................................................................................................................................19
Performance of the continuous blowdown valve....................................................................................19
Note .....................................................................................................................................................19
Contents - continued -
Commissioning
Page
Normal operation..................................................................................................................................20
Continuous boiler blowdown.................................................................................................................20
Note .....................................................................................................................................................20
Intermittent boiler blowdown ................................................................................................................20
Note .....................................................................................................................................................20
Stand-by operation ...............................................................................................................................21
24 hr purging pulse ..............................................................................................................................21
MAX limit / MIN limit.............................................................................................................................22
MAX limit / MIN limit = Automatic intermittent boiler blowdown............................................................22
Note .....................................................................................................................................................22
Performance test ..................................................................................................................................23
Please note when using the equipment as conductivity limiter:.............................................................23
Performance test for relays 1 and 4 ......................................................................................................24
Operation
Fault finding list for troubleshooting......................................................................................................30
Malfunctions
Factory setting of node IDs ...................................................................................................................31
Establishing / changing node ID............................................................................................................31
Attention...............................................................................................................................................31
Table Node ID .......................................................................................................................................32
Changing factory settings .....................................................................................................................32
Note on the Declaration of Conformity / Declaration by the Manufacturer .......................................33
Annex
Causes .................................................................................................................................................25
Test ......................................................................................................................................................25
Danger .................................................................................................................................................25
Systematic malfunction analysis...........................................................................................................26
Fault finding list for troubleshooting system faults.................................................................................27
Action against high frequency interference ..................................................................................... 28, 29
Replacing control unit...........................................................................................................................29
Danger .................................................................................................................................................29
System Malfunctions

4
Important Notes
Usage for the intended purpose
Use blowdown controller LRR 1-40 only in conjunction with conductivity electrode LRG 16-40,
LRG 16-41, LRG 17-40 and an operating & display unit type URB or SPECTORcontrol for detecting and
monitoring electrical conductivity in liquids (TDS control).
Note that the application of the control unit LRR 1-40 for conductivity limiting purposes or continuous
boiler blowdown is only permissible if it is used in conjunction with the conductivity electrode
LRG 16-40 / LRG 16-41 / LRG 17-40 and an operating & display unit type URB or SPECTORcontrol.
To guarantee a trouble-free operation observe the requirements made on water as specified in the
pertinent TRD and EN regulations.
Any type of use differing from the usage described above must be considered as improper. The result-
ing risk will have to be borne by the user alone. The manufacturer hereby expressly rejects any claims
for any damage resulting from improper usage.
Safety note
The equipment must only be installed and commissioned by qualified and competent staff.
Retrofitting and maintenance work must only be performed by qualified staff who – through adequate
training – have achieved a recognised level of competence.
ATEX (Atmosphère Explosible)
According the the European Directive 2014/34/EU the equipment must not be used in potentially
explosive areas.
Attention
The name plate specifies the technical features of the equipment. Note that any piece of
equipment without its specific name plate must neither be commissioned nor operated.
Danger
The terminal strip of the control unit is live during operation. This presents the danger of
electric shock!
Cut off power supply to the equipment before mounting or removing the terminal strips!

5
Scope of supply
LRR 1-40
1 Control unit LRR 1-40 (plug-in unit in plastic case)
1 Terminating resistor 120 Ω
1 Installation manual
Description
Continuous boilder blowdown (top blowdown)
As the boiler water evaporates, the concentration of non-volatile dissolved solids (TDS) left behind in
the boiler increases over time as a function of steam consumption. If the TDS (= total dissolved solids)
concentration exceeds the limit defined by the boiler manufacturer, foaming and priming occurs as the
density of the boiler water increases, resulting in a carry-over of solids with vapor into steam lines and
superheaters. As a result the operational safety is impaired and the steam boiler and/or pipelines can
be damaged. To keep the TDS concentration within admissible limits, a certain portion of boiler water
must be removed continuously or periodically (by means of a blowdown valve) and fresh make-up
water must be added to the boiler feed to compensate for the water lost through blowdown.
Intermittent boiler blowdown (bottom blowdown)
During the evaporation process fine sludge deposits settle on heating surfaces and in the lowest part of
the steam boiler. The accumulated sludge sediments form a thermally insulating layer and can damage
the boiler walls due to excessive heat.
The resulting suction effect occurs only at the moment when the valve is being opened, the opening
time should therefore not exceed 2 seconds.
The timed pulse/interval control of the intermittent blowdown valve optimises sludge removal while
minimising loss of boiler water.
The interval between the intermittent blowdown pulses can be set between 1 and 120 h (intermittent
blowdown interval). The duration of the intermittent blowdown can be set between 1 and 60 s.
For larger boilers it may be necessary to repeat the intermittent blowdown pulses. The intermittent
blowdown pulses can be repeated up to 5 times within 5 - 30 seconds (pulse interval).
The continuous and intermittent boiler blowdown is controlled by the control unit LRR 1-40 in
conjunction with the conductivity electrode LRG 16-40, LRG 16-41, LRG 17-40, the operating unit URB
or SPECTORcontrol and the continuous blowdown valve BAE 46, BAE 47.
In conjunction with the conductivity electrode and the operating unit you can also use the control unit
LRR 1-40 as conductivity limiter in steam boilers or for conducitivity monitoring in condensate and
feedwater systems.
The data exchange between the control unit LRR1-40, the conductivity electrode, the operating unit
and further equipment is effected via CAN bus according to ISO 11898, using the CANopen protocol.
Explanatory Notes
Note
The control unit LRR 1-40 can control the continuous blowdown valve BAE 46, BAE 47
with the actuator ARIS EF 1-1 either directly via the output relays or the continuous
blowdown valve BAE 46, BAE 47 with the actuator EF 1-40 via the CAN bus.

6
Explanantory Notes - continued -
Function
The control unit LRR 1-40 features the following functions:
2-position controller for the control of the continuous blowdown valve via output relays or via CAN
bus,
3-position stepping controller for the control of the continuous blowdown valve via output relays or
via CAN bus,
Triggering of daily purging pulse (24 h) to actuate the continuous blowdown valve,
De-activation of control function during stand-by operation of steam boiler,
Alarm signal in the event of a malfunction in the conductivity electrode,
MAX limit alarm for conductivity (TDS) limiting,
MIN limit alarm or
Automatic blowdown control with timed actuation of the intermittent blowdown valve,
Analog actual value output (4-20 mA) for external conductivity indication (optional).
For these functions the control unit must evaluate at regular intervals the data telegrams sent off by the
conductivity electrodes LRG 16-40, LRG 16-41, LRG 17-40 and the the actuator EF 1-40 (continuous
blowdown valve BAE 46, BAE 47).
For the visual display of the process and the control of the continuous blowdown valve via CAN bus the
control unit will send a separate data telegram with the following content:
Type of conductivity electrode used with the CAN bus
MIN / MAX limit,
Continuous blowdown valve: setpoint of valve position,
Times for automatic intermittent blowdown control.
Use operating & display unit URB or SPECTORcontrol to commission, operate and monitor the conduc-
tivity electrode LRG, the control unit LRR and the actuator EF.
The control unit can only test the switching of the MIN / MAX output relays.
System components
LRG 16-40
Conductivity electrode LRG 16-40, PN 40, measurement with two electrodes
LRG 16-41
Conductivity electrode LRG 16-41, PN 40, measurement with four electrodes
LRG 17-40
Conductivity electrode LRG 17-40, PN 63, measurement with two electrodes
BAE 46, BAE 47
Continuous blowdown valve with actuator ARIS EF 1-1 or EF 1-40
Design
LRR 1-40
Plug-in unit in plastic case for installation in control cabinets. The terminals are externally accessible.
For mounting on a standardised supporting rail TS 35 x 15 DIN EN 50022.
External dimensions: 73 x 100 x 118

7
LRR 1-40
Technical Data
Type approval no.
TÜV.WÜL.xx-007
Input / output
Interface for CAN bus according to ISO 11898 CANopen.
Inputs
One analog control input for signalling the valve position via a feedback potentiometer 1000 Ω,
320° angle of rotation, supply voltage 5 V DC.
One voltage input 18-36 V AC (50/60 Hz) or DC for external command:
control OFF, valve CLOSED, intermittent blowdown OFF. With DC protected against polarity reversal.
Outputs
Current supply for CAN bus 18-36 V DC, short-circuit protected.
Four volt-free relay contacts.
Max. contact rating with switching voltages of 24 V AC/DC, 115 V AC and 230 V AC:
resistive / inductive 4 A.
Contact material AgNi 0,15.
Connected contactors must be provided with suppressors such as RC combinations as specified by the
manufacturer.
One current output 4-20 mA as actual value, max. load 500 Ω (optional).
Indicators and adjustors
Four pushbuttons as operating elements.
Four LEDs (red/green) for indicating the operationg modes.
One red LED “Bus Status”
One green LED “Power”
One 10-pole code switch: 7 poles for node ID, 3 poles for baud rate setting.
Setpoint W
Adjustable within the measuring range between the MIN/MAX limits.
Control range (configuration as proportional controller)
Beginning: 0.5 x setpoint W up to 1.5 x setpoint W
Dead band (configuration as proportional controller)
Based on setpoint W:
Setpoint W below 2000 μS/cm (1000 ppm) DB = 3 %
Setpoint W above 2000 μS/cm (1000 ppm) DB = 1 %
Switching hysteresis of controller output (configuration as 2-position controller)
Adjustable between 1 and 25 % of the adjusted setpoint.
Operating position of the continuous blowdown valve
Adjustable as a function of the continuous blowdown valve.
Proportional band Xp
From 1 to 150 % relative to setpoint W (configuration as proportional controller), adjustable,
0 % (configuration as 2-position controller).
MIN/MAX limits
Measuring range up to 200 µS/cm (100 ppm):
MIN limit adjustable between 0.5 μS/cm (0.25 ppm) and MAX limit –2 μS/cm (1 ppm),
MAX limit adjustable between 200 μS/cm (100 ppm) and MIN limit +2 μS/cm (1 ppm).

8
Technical Data - continued -
LRR 1-40 - continued -
Other measuring ranges:
MIN limit (only via URB) adjustable between 0.5 μS/cm (0.25 ppm) and MAX limit –20 μS/cm (10 ppm),
MAX limit (only via URB) adjustable between end of measuring range and MIN limit +20 μS/cm (10 ppm).
MIN/MAX limit,
switching hystereses
MIN limit: +1 % of the adjusted MIN limit,
MAX limit: –1 % of the adjusted MAX limit.
Conductivity measuring ranges for actual value output 4 - 20 mA
LRG 16-40, LRG 17-40
Measuring ranges*) (µS/cm at 25 °C) Current output mA = µS/cm
Preferred measuring range up to 500 µS/cm 4 mA
corresponds to
20 mA
corresponds to
0.5
20
0.5
20
100 100
200 200
500 500
1000 1000
2000 2000
6000 6000
12000 12000
LRG 16-41
Measuring ranges*) (µS/cm at 25 °C) Current output mA = µS/cm
4 mA
corresponds to
20 mA
corresponds to
100
3000
100
3000
5000 5000
7000 7000
10000 10000
*) Conversion µS/cm in ppm (parts per million): 1 µS/cm = 0.5 ppm
Note
The electrical conductivity is measured in µS/cm. For ppm (parts per million) use the
following conversion: 1 μS/cm = 0.5 ppm.

9
Technical Data - continued -
LRR 1-40 - continued -
24 h purging pulse
Forced opening of the continuous blowdown valve every 24 hours, adjustable.
Automatic intermittent blowdown
Intermittent blowdown interval (duration of break): 1 - 120 hours, adjustable in steps of one hour.
Duration of intermittent boiler blowdown: 1 - 60 seconds, adjustable in steps of one second.
Pulses of intermittent boiler blowdown: 1 - 5, adjustable in steps of one.
Pulse interval: 5 - 30 seconds, adjustable in steps of one second.
Mains voltage
230 V +10 / –15 %, 50 – 60 Hz
115 V +10 / –15 %, 50 – 60 Hz (optional)
24 V +10 / –15 %, 50 – 60 Hz (optional)
Power consumption
10 VA
Protection
Housing: IP40 to EN 60529
Terminal strip: IP20 to EN 60529.
Max. admissible ambient temperature
0 – 55 °C
Body material
Front panel: polycarbonate, grey
Body: polycarbonate, black
Weight
approx. 0.8 kg

10
Technical Data - continued -
Name plate / Marking
Fig. 1
Steuergerät
control device
appareille de commande
Tamb = 55 °C ( 131 °F)
IN / OUT: CAN-Bus
18-36 V DC
IP 40 (IP20)
115V -15/+10%10VA
Betriebsanleitung
beachten
See installation
instructions
Voir instructions de
montage
Node ID:___ ___ ___
GESTRA AG
Münchener Str. 77
D-28215 Bremen
TÜV . WÜL . xx-007
LRR 1-40
12345
S
24V
DC CAN-BUS
-CH CL+
1716
LN
1110
9 12
S S
+-
M
1514
13
78
24V AC/DC
stand-by
+
-
+
X ext
4-20 mA
S
Seriennummer

11
Technical Data - continued -
Dimensions
1
2
3
4Test
P
123E
4
µS
ppm
GESTRA
LRR1-40
2716
12345678
17 18 19 20 21 22 23 24
9
25
10
26
11 12
28
13
29
14
30
15
100
118
73
Fig. 2
Fig. 3
1
2
3
4Test
P
123E
4
µS
ppm
GESTRA
LRR 1-40
123456789101112131415
1
2716 17 18 19 20 21 22 23 24 25 26 28 29 30
1
ON 234567890

12
Functional Elements
LRR 1-40
Fig. 4
Fig. 5
1
765 8 2 3
1
2
3
4Test
P
123E
4
µS
ppm
GESTRA
LRR 1-40
2716 17 18 19 20 21 22 23 24 25 26 28 29 30
1
2
3
4Test
P
123E
4
µS
ppm
GESTRA
LRR 1-40
1
ON 234567890

13
Design / Functional Elements - continued -
Key
1Status LED Alarm Malfunction
LED 1 MAX alarm Malfunction message
LED 2 Continuous blowdown valve CLOSED Malfunction message
LED 3 Continuous blowdown valve OPEN Malfunction message
LED 4 MIN alarm / continuous blowdown Malfunction message
2LED Bus status
3LED Power
4
5Program button
6Increase button
7Decrease button
8
Enter / Test
9Code switch, 10 poles
0Terminal strip
!Screws for terminal strip
"Case
§Supporting rail TS 35 x 15 DIN EN 50022

14
Tools
Screwdriver, size 5.5/100
Installation
LRR 1-40
Mounting on supporting rail
1. Clip control unit onto the supporting rail.
Supporting rail TS 35 x 15, DIN EN 50022.
2. Align control unit. Fig. 7

15
Installation - continued -
Fig. 6
Example of Installation
Fig. 7
2716
12345678
17 18 19 20 21 22 23 24
9
25
10
26
11 12
28
13
29
14
30
15
1
2
3
4Test
P
123E
4
µS
ppm
GESTRA
LRR 1-40
1
2
3
4Test
P
123E
4
µS
ppm
GESTRA
LRR1-40
2716
12345678
17 18 19 20 21 22 23 24
9
25
10
26
11 12
28
13
29
14
30
15
100
118
73
20
20

16
Electrical Connection
Control cable
NRS, NRR, LRR, TRS, URB 1
To wire the equipment, multi-core twisted-pair control cable must be used for the bus line,
e. g. UNITRONIC®BUS CAN 2 x 2 x ... mm2or RE-2YCYV-fl 2 x 2 x ... mm2.
Control cable assemblies (2 x 2 x 0.32 mm² cable with plug and connector) of various lengths are
available as add-on equipment.
NRG, LRG, EF, URZ, TRV, URB 2
The equipment is fitted with sensor plug-in connectors (5 poles, A-coded). For connecting the bus
devices control cable assemblies (with plug and connector) of various lengths are available as add-on
equipment.
Note that the recommended control cables are not UV-resistant and must be protected by a UV-
resistant plastic tube or cable duct if the equipment is installed outdoors (except for URB 2).
The baud rate (data transfer rate) dictates the cable length and size between the bus nodes. The total
power consumption must also be taken into consideration when selecting the conductor size. The total
power consumption is obtained from the number of bus nodes.
If the cable length between the steam boiler and the control cabinet exceeds 15 m, we recommend that
you fit a branching box that is resistant to electromagnetic interference (stock code 1501214) and use a
control cable with a larger conductor size for the distance to the control cabinet.
Set baud rate via code switch 9. Make sure that all bus nodes feature the same settings.
S 8 S 9 S 10 Baud rate Cable length Number of pairs
and conductor size [mm2]
OFF ON OFF 250 kBit/s 125 m 2 x 2 x 0.32
Factory setting
ON ON OFF 125 kBit/s 250 m 2 x 2 x 0.5
OFF OFF ON 100 kBit/s 335 m 2 x 2 x 0.75
ON OFF ON 50 kBit/s 500 m on request, depending on
bus configuration
OFF ON ON 20 kBit/s 1000 m
ON ON ON 10 kBit/s 1000 m
UNITRONIC®is a registered trademark of LAPP Kabelwerke GmbH, Stuttgart.
0 Terminal strips
! Screws for terminal strip
" Case
§ Supporting rail TS 35 x 15 DIN EN 50022
Key
Installation - continued -

17
Electrical Connection - continued -
Note
The max. baud rates and cable lengths indicated above are based on empirical values
obtained by GESTRA. In certain cases it may be necessary to reduce the baud rate in
order to ensure operational safety.
The type and design of the data cable has a strong influence on the electromagnetic
compatibility (EMC) of the equipment. Take special care when connecting the equip-
ment.
If you do not use the control cable assemblies connect the connectors and jacks for
the control cables as indicated in the assignment diagram for sensor plug-in unions.
CAN bus voltage supply
To ensure the troublefree operation of the CAN bus system make sure that the voltage supply for all bus
devices is sufficient.
Please use the following table to check the voltage supply of your bus system.
Control units with
voltage supply
Qty. xPower output per item = Sum
x6 W = W
Please enter data. Sum 1 = W
Sensor, transmitter, control
units, operating & display unit
URB 1
Qty. xPower consumption per item = Sum
x3 W = W
Operating & Display Unit
URB 2 x5 W =W
Please enter data. Sum 2 = W
If sum 2 exceeds sum 1 supply the CAN bus with 24 V DC coming from a separate and stabilized safety
power supply unit (e. g. SITOP Smart 24 V 2.5 A).
The power supply unit must be electrically isolated from dangerous contact voltages and must meet at
least the requirements on double or reinforced isolation acc. to DIN EN 50178 or DIN 61010-1 or
DIN EN 60730-1 or DIN EN 60950 (safe isolation).
The power supply unit must be provided with an overcurrent protective device in accordance with
EN 61010-1.
Attention
If a safety power supply unit (e. g. SITOP smart, 24 V, 2.5 A) is used for the voltage supply
of the CAN bus do not tap the supply voltage from the terminals 1 and 5 of the GESTRA
control devices.
SITOP smart is a registered trademark of Siemens AG, Munich

18
N
10
12
11
2325
123
18 19 29
N
20
2716
12345678
17 18 19 20 21 22 23 24
9
25
10
26
11 12
28
13
29
14
30
15
1
2
3
4Test
P
123E
4
µS
ppm
GESTRA
LRR1-40
S
+
120
Ω
Electrical Connection - continued -
Wiring diagram LRR 1-40
Fig. 7
Fig. 6
18-36 V DC
CAN bus
Feedback potentiometer 1000 Ω
LOPENLCLOSED
Actuator
Continuous blowdown valve BAE 36-1
2.5 V DC with potentiometer
5 V DC no-load voltage without potentiometer
N L
CL
CH
L N
L
L
Continuous blowdown control
= Valve OPEN 25
= Valve CLOSED 23
$%&
/
(
)
=
a
b
b
c
d

19
Wiring diagram for the sensor plug-in connectings
Fig. 9 g
Electrical Connection - continued -
Fig. 10 RES 1 Fig. 11 RES 2
$
Mains supply
% MAX limit, safety circuit
& Continuous blowdown valve CLOSED / OPEN
/ MIN limit / intermittent blowdown
( Actual value output 4-20 mA (optional)
) Feedback potentiometer
= Contact in burner control, if stand-by function is
desired. Terminal 7/8 ävoltage input 24 V AC/DC
for external command; contact closed, control
OFF, valve CLOSED, intermittent blowdown OFF
[stand-by] (May come from the bus supply).
For DC: Observe polarity!
a Terminating resistor 120 Ω, RES 1 or RES 2
b
CAN bus line, twisted pair control cable
c Intermittent blowdown valve
Key
d Continuous blowdown valve
e Pin 1: Screen
f Pin 2: Voltage supply 24 V DC+ (red)
g Pin 3: Voltage supply 24 V DC– (black)
h Pin 4: CAN data line CH(white)
i Pin 5: CAN data line CL(blue)
h e i f f g e i h aa

20
Electrical Connection - continued -
CAN bus wiring diagram
Fig. 12
RES 2
CEP NRS, NRR, LRR,
TRS, URB 1
URB 2 NRG, LRG,
EF, URZ TRV
RES 1
Attention
Wire equipment in series. Star-type wiring is not permitted!
Make sure that the bus line is separated from mains and signal lines.
Link screens of control cables such that electrical continuity is ensured and connect
them once to the central earthing point (CEP). If equipotential bonding currents are to
be expected, for instance in outdoor installations, make sure that the screen is sepa-
rated from the central earthing point (CEP).
To protect the switching contacts fuse circuit with T 2.5 A or according to TRD
regulations (1.0 A for 72 h operation).
If two or more system components are connected in a CAN bus system, provide the
first and the last device with a terminating resistor of 120 Ω, Fig. 10, Fig. 11
Note that in a CAN bus network only one water-level limiting system may be used.
Do not interrupt the CAN bus network during operation with one or more system
components!
In the event of an interruption a malfunction alarm is raised.
If the control unit has to be replaced, detach terminal strips 0. Fig. 3
Before taking the CAN bus line from the terminal strip, make sure that all connected
system components are out of service.