GESTRA URS 60 User manual

Original Installation &
Operating Manual
EN
English
Safety Control Unit
URS 60
URS 61
819634-00

2URS 60, URS 61 - Installation & Operating Manual - 819634-00
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............................................................................................................9
Admissible accessories, dependent on the required safety integrity level ..................................................10
Improper use .................................................................................................................................................11
Basic safety notes .........................................................................................................................................11
Required personnel qualifications................................................................................................................11
Notes on product liability..............................................................................................................................11
Functional safety, safety integrity level (SIL) ............................................................................................... 12
Perform an annual function test................................................................................................................12
Reliability data to EN 61508 ..........................................................................................................................13
Function .........................................................................................................................................................14
Possible combinations of functions and equipment...................................................................................15
Technical data ...............................................................................................................................................17
Name plate/identification of URS 60 / URS 61 .............................................................................................19
Factory settings.............................................................................................................................................20
Safety control unit URS 60 ........................................................................................................................20
Safety control unit URS 61 ........................................................................................................................20
Functional elements and dimensions...........................................................................................................21
Installing the URS 60 / URS 61 safety control unit.......................................................................................22
Wiring diagram of the URS 60 / URS 61 safety control unit.........................................................................23
Electrical connection.....................................................................................................................................24
Bus line, cable length and cross-section...................................................................................................24
Connecting the 24V DC power supply .......................................................................................................24
Connecting the 24V DC I/O interface .........................................................................................................24
Instructions for connecting the safety circuit.............................................................................................24
Notes on connecting inductive loads.........................................................................................................24
Wiring diagram of CAN bus system.............................................................................................................. 25
Example ...................................................................................................................................................25
Important notes on connecting the CAN bus system..................................................................................25

3URS 60, URS 61 - Installation & Operating Manual - 819634-00
Contents
Changing the equipment settings.................................................................................................................26
Changing the baud rate ............................................................................................................................26
Configuring the limiter function.................................................................................................................27
Configuring the delay time and baud rate..................................................................................................28
Bringing into service – start, operation, alarm and test..............................................................................29
Checking installation and function ............................................................................................................30
System malfunctions.....................................................................................................................................31
Causes .....................................................................................................................................................31
Check the installation and configuration before systematic troubleshooting: .............................................31
Indication of system malfunctions.............................................................................................................32
What to do in the event of system malfunctions..........................................................................................34
Checking installation and function ............................................................................................................34
Emergency mode........................................................................................................................................... 34
Emergency mode for water level limiter systems ......................................................................................34
Taking out of service.....................................................................................................................................35
Disposal .........................................................................................................................................................35
Returning decontaminated devices.............................................................................................................. 35
EU Declaration of Conformity........................................................................................................................ 36

4URS 60, URS 61 - Installation & Operating Manual - 819634-00
Content of this Manual
Product:
 Safety control unit URS 60
 Safety control unit URS 61
First edition:
BAN 819634-00/08-2019cm
© 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 Safety control unit URS 60 or URS 61
 1 x Installation & Operating Manual

5URS 60, URS 61 - Installation & Operating Manual - 819634-00
How to use this Manual
This Installation & Operating Manual describes the correct use of URS 60 and URS 61 safety control units.
It applies to persons who integrate this equipment in 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 & 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
Danger of death from electric shock
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

6URS 60, URS 61 - Installation & Operating Manual - 819634-00
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.

7URS 60, URS 61 - Installation & Operating Manual - 819634-00
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
systems. Data can be sent and received.
TRV .. / NRG .. / LRG ... / SRL ...
Equipment and type designations of GESTRA AG, see page 10.
PhotoMOS output
PhotoMOS are a special kind of semiconductor relay, which use a light-emitting diode on the input side
that is optically coupled to an output transistor. This type of electrically non-conductive connection makes
sure the input and output circuits are electrically isolated from each other.
SELV
Safety Extra Low Voltage

8URS 60, URS 61 - Installation & Operating Manual - 819634-00
Usage for the intended purpose
URS 60 and URS 61 safety control units can be used in combination with various safety sensors of types
NRG 1..., NRG 2…, LRG 1… and TRV 5… to act as safety limiters for steam boiler systems and water
boilers.
The equipment can be used as:
 Water level limiters, in combination with level electrode NRG 1x-60 / NRG 26-61.
Water level limiters switch off the heating when the water drops below the set minimum level.
 Safety high level limiters, in combination with level electrode NRG 1x-61 / NRG 26-61.
Safety high level limiters switch off the feedwater supply when the water exceeds the set maximum
level.
 Conductivity limiters, in combination with conductivity electrode LRG 1x-6x.
Conductivity limiters switch off the heating when conductivity exceeds the set maximum level.
 Safety temperature monitors/limiters, in combination with temperature transmitter TRV 5-60.
Safety temperature limiters or monitors switch off the heating when the maximum admissible temper-
ature is reached. Method of operation TYPE 2.BKP (+JV, with external lock) to EN 60730-1.
 The above functions may be combined.
 Monitoring logic unit SRL 6-60 is available for monitoring the regular, separate flushing process when
level electrodes are used in external measuring pots.
 Visualisation and operation take place via a choice of operating terminals: the URB60 and
SPECTOR control .

9URS 60, URS 61 - Installation & Operating Manual - 819634-00
Usage for the intended purpose
Applicable directives and standards
The URS 60 / URS 61 safety control unit has been tested and approved for use in the scope 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 14597 Temperature control devices and temperature limiters for heat
generating systems
 DIN 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
 VdTÜV Bulletin BP WAUE 0100-RL
Requirements for the testing of monitoring equipment
 VdTÜV Bulletin BP TEMP 0100-RL
Requirements for the testing of temperature monitors and limiters
Technical rules for steam boilers - as a knowledge base:
This Manual occasionally refers to the TRD regulations as a knowledge base.
These regulations have not been in force since 1 March 2019 and are no longer updated.
They are replaced by the TRBS (German Technical Rules for Industrial Health & Safety).
Always observe the current regulations (EU directives, EN standards, information from
employers’ liability insurance associations, etc.) in order to comply with the current state
of the art.

10 URS 60, URS 61 - Installation & Operating Manual - 819634-00
Usage for the intended purpose
Admissible accessories, dependent on the required safety integrity level
In accordance with EU Pressure Equipment Directive 2014/68/EU,standards EN12952,EN12953, EN14597 and
EN 61508 and the technical rules of VdTÜV Bulletin W100, WÜ100, the URS 60 / URS 61 safety control unit
can be operated with the following accessories, as suitable for the required safety integrity level.
Water level
limiter
Safety high
level limiter
Conductivity
limiter
Temperature
limiter
Operating
unit
Monitoring
logic unit
SIL 3
to
EN 61508
NRG 16-60
NRG 17-60
NRG 19-60
NRG 111-60
NRG 16-61
NRG 17-61
NRG 19-61
NRG 111-61
– TRV 5-60
URB 60
SPECTOR
control
SRL 6-60
SIL 2
to
EN 61508
NRG 26-61
NRG 16-60
NRG 17-60
NRG 19-60
NRG 111-60
NRG 26-61
NRG 16-61
NRG 17-61
NRG 19-61
NRG 111-61
LRG 16-60
LRG 16-61
LRG 17-60
TRV 5-60
URB 60
SPECTOR
control
SRL 6-60
Fig. 1
Key to Fig. 1:
NRG = level electrode
LRG = conductivity electrode
TRV = temperature transmitter
URB = visual display and operating unit
SRL = monitoring logic unit
To ensure the proper use of equipment in all applications, you must also read the operating
instructions for the sensors and operating units used.
 You will find the current operating instructions for the safety sensors and operating units in
Fig. 1 on our website:
http://www.gestra.com/documents/brochures.html

11URS 60, URS 61 - Installation & Operating Manual - 819634-00
Improper use
There is a danger of death due to explosion if the equipment is used in potentially
explosive atmospheres.
Do not use the equipment in potentially explosive atmospheres.
Basic safety notes
There is a risk of electric shock during work on electrical systems.
 Always switch off the voltage to the equipment before performing work on the terminal
strips.
 Check that the system is not carrying live voltage before commencing work.
Attempts to repair the equipment will cause the system to become unsafe.
 Do not repair the URS 60 / URS 61 safety control unit.
 Only replace faulty equipment with identical equipment from GESTRA AG.
Required personnel qualifications
Activity Personnel
Integration in control system Specialist staff Plant designer
Installation/electrical
connection/bringing into service Specialist staff Electrician/installer
Operation Boiler service technician Staff trained by the
plant operator
Maintenance work Specialist staff Electrician
Setup work Specialist staff Plant construction
Fig. 2
Notes on product liability
We the manufacturer cannot accept any liability for damages resulting from improper use of the
equipment.

12 URS 60, URS 61 - Installation & Operating Manual - 819634-00
Functional safety, safety integrity level (SIL)
The URS 60 / URS 61 safety control unit is suitable for safety functions up to SIL 3.
It is an element of a safety circuit up to SIL 3 as per EN 61508 in the SPECTOR
connect system, and can
process alarm information from up to four safety sensors.
Combinations with accessories constitute a type B subsystem. The technical and safety characteristics in
Fig. 4 are based on the URS 60 / URS 61 safety control unit including output contacts.
Breakdown of safety function failure rates
Sensor
probe
The CANopen interface is a “Black Channel” type, and can be ignored during calculation due to
the low failure rate of < 1FIT.
CANopen URS 60,
URS 61
Burner safety circuit
Sensor
electronics
Fig. 3
Perform an annual function test
Check the function of the URS 60 / URS 61 safety control unit at least once annually by triggering the
safety circuit (T1 = 1 year). You can check the function either by pressing buttons 1-4 (see page 29) or
by exceeding the limit values.
Sensor

13URS 60, URS 61 - Installation & Operating Manual - 819634-00
Reliability data to EN 61508
Description Characteristic values
Safety integrity level SIL 3
Architecture 1oo1
Type of device Type B
Hardware error tolerance HFT = 0
Overall failure rate for dangerous undetected failures λDU < 20.0 * 10-9 1/h
Overall failure rate for dangerous detected failures λDD < 2000 * 10-9 1/h
Safe failure fraction SFF > 99.0 %
Test interval T1 = 1 year
Probability of failure on demand PFD < 20.0 * 10-5
Diagnostic coverage. Percentage of dangerous failures
detected by a test. DC > 99.0 %
Mean time to failure MTTFD> 90 a
Diagnostic interval T2 = 1 hour
Performance level (to ISO 13849) PL = d
Probability of failure per hour PFH < 20 * 10-9 1/h
Ambient temperature as a basis for calculation Tu = 45 °C
Mean time to repair MTTR = 0 (no repair)
Fraction of undetected dangerous failures that have a
common cause beta = 2 %
Fraction of detected dangerous failures that have a com-
mon cause beta d = 1 %
Fig. 4

14 URS 60, URS 61 - Installation & Operating Manual - 819634-00
Function
The URS 60 / URS 61 safety control unit cyclically evaluates data telegrams from up to four safety sensors
of types NRG 1..., NRG 2…, LRG 1… and TRV 5. The data are transferred to an ISO 11898 CAN bus via
the CANopen protocol and saved. The safety functions are monitored by cyclical self-tests. The two inte-
grated relays are switched off in the event of alarms or failures. Function tests and failure diagnosis can
be conducted using either the control unit or the operating terminal.
The data telegrams contain the following information:
 Alarms from sensors if limit values are exceeded
 Error signals in the event of faults in electronic or mechanical parts
 Excessive temperature in the sensor terminal boxes
Behaviour on the occurrence of alarms
When level, temperature or conductivity alarms are received, both output contacts are opened after a
power-off delay, and this interrupts the safety circuit (fail-safe position). In this case, the safety control
unit does not lock independently; this function must be implemented in the downstream circuit. The URS
60 or URS 61 can only activate one safety circuit (heating or pump) at any one time.
The safety circuit is interrupted without delay if the following error messages are received:
 Fault in sensors (negative self-test, excessively high temperature in terminal box)
 Fault in control unit (negative self-test)
 Communication failure
Behaviour on the occurrence of error messages
Cyclical self-tests monitor the safety functions of the equipment in the safety control unit and sensors.
Error messages are updated with each self-test. If there are no faults, the malfunction indication is auto-
matically deleted and the output contacts are closed once more. Alarms and error messages are displayed
by LEDs or an operating unit.
In addition, you can choose to display alarms on an external signalling device via signalling outputs, either
with or without a delay. Faults are always indicated without a delay, however.
Alarm simulation
You can simulate alarms by pressing the button or via external 24 V DC signals.
Monitoring flushing processes
If a level electrode is installed in a lockable level pot outside the boiler, the connecting pipes must be
flushed regularly. During this flushing, no water level is measured in the level pot for up to five minutes.
Therefore, the URS 60 / URS 61 safety control unit bridges the level electrode as prompted by an SRL
6-60 monitoring logic unit, and monitors the maximum bridging time.
If the steam pipe is ≥ 40 mm and the water pipe is ≥ 100 mm, installation is regarded as internal. In this
case, upstream monitoring of flushing processes can be dispensed with.

15URS 60, URS 61 - Installation & Operating Manual - 819634-00
Function
Possible combinations of functions and equipment
The following common functional combinations are achieved by connecting the sensors and safety control
units in one circuit:
Abbreviations used in Fig. 5 and Fig. 6
SLLL = safety low level limiter
STL/STM = safety temperature limiter/safety temperature monitor
SHLL = safety high level limiter
SCL = safety conductivity limiter
URS 60
e.g. heating safety circuit
Function 1 Function 2 Function 3 Function 4
SLLL 1 with
level electrode
NRG 1x-60
SLLL 1 with
level electrode
NRG 1x-60
SLLL 2 with
level electrode
NRG 1x-60
NRG 26-61
SLLL 1 with
level electrode
NRG 1x-60
SLLL 2 with
level electrode
NRG 1x-60
NRG 26-61
STL (STM) 1 with
temperature transmitter
TRV 5-60
SCL 1 with
conductivity electrode
LRG 1x-6x
SLLL 1 with
level electrode
NRG 1x-60
SLLL 2 with
level electrode
NRG 1x-60
NRG 26-61
STL (STM) 1 with
temperature transmitter
TRV 5-60
SLLL 1 with
level electrode
NRG 1x-60
SLLL 2 with
level electrode
NRG 1x-60
NRG 26-61
SHLL 1 with
level electrode
NRG 1x-61
NRG 26-61
STL (STM) 1 with
temperature transmitter
TRV 5-60
SLLL 1 with
level electrode
NRG 1x-60
SLLL 2 with
level electrode
NRG 1x-60
NRG 26-61
STL (STM) 1 with
temperature transmitter
TRV 5-60
STL (STM) 2 with
temperature transmitter
TRV 5-60
STL (STM) 1 with
temperature transmitter
TRV 5-60
STL (STM) 2 with
temperature transmitter
TRV 5-60
STL (STM) 1 with
temperature transmitter
TRV 5-60
STL (STM) 2 with
temperature transmitter
TRV 5-60
STL (STM) 3 with
temperature transmitter
TRV 5-60
STL (STM) 4 with
temperature transmitter
TRV 5-60
Fig. 5

16 URS 60, URS 61 - Installation & Operating Manual - 819634-00
Function
URS 61
e.g. safety circuit for feedwater pump
Function 1 Function 2 Function 3 Function 4
SHLL 1 with
level electrode
NRG 1x-61
NRG 26-61
SHLL 1 with
level electrode
NRG 1x-61
NRG 26-61
STL (STM) 1 with
temperature transmitter
TRV 5-60
SHLL 1 with
level electrode
NRG 1x-61
NRG 26-61
SHLL 1 with
level electrode
NRG 1x-61
NRG 26-61
STL (STM) 2 with
temperature transmitter
TRV 5-60
STL (STM) 3 with
temperature transmitter
TRV 5-60
SCL 1 with
conductivity electrode
LRG 1x-6x
STL (STM) 3 with
temperature transmitter
TRV 5-60
STL (STM) 3 with
temperature transmitter
TRV 5-60
STL (STM) 4 with
temperature transmitter
TRV 5-60
STL (STM) 5 with
temperature transmitter
TRV 5-60
STL (STM) 6 with
temperature transmitter
TRV 5-60
STL (STM) 7 with
temperature transmitter
TRV 5-60
STL (STM) 8 with
temperature transmitter
TRV 5-60
Fig. 6
Further connections are possible
and permitted.

17URS 60, URS 61 - Installation & Operating Manual - 819634-00
Technical data
Supply voltage
 24V DC +/-20 %
Power consumption
 max. 7 VA
Current input
 max. 0.3 A
Internal fuse
 T2A
Input/output
 Interface for CAN bus to ISO 11898, CANopen, insulated
Safety circuit output
 2 volt-free changeover contacts, connected externally in series. Contact material AgNi
 Maximum switching current at switching voltages of 24 V AC/DC, 115 V AC and 230 V AC: resistive/
inductive 6 A
 Connected contactors must have interference suppression (RC combination) as per the manufacturer's
specification
Required external fuse for safety circuit
 T 2 A or T 1A (T = slow blow) for (TRD 604 *), 72 hrs of operation
* see page 9
Signal output
 4 PhotoMOS outputs for external signalling, with or without delay
 24 DC, max. current load 100 mA, NO characteristic
Test input
 4 opto-coupler inputs for external test triggering, high active, 24 V DC +/- 20 %
Output relay switch-off delay
 Factory default setting 3 seconds.
 Option of 10 seconds and 15 seconds
Indicators and controls
 4 x buttons for operation/for initiating test function in sensor
 4 x green LEDs for indicating the active channels
 4 x red LEDs for indicating a malfunction/alarm
 3 x yellow LEDs for indicating internal errors and external sensor errors
 1 x 10-pole code switch for setting the number of limiters, the delay and baud rate

18 URS 60, URS 61 - Installation & Operating Manual - 819634-00
Technical data
Protection class
 II double insulated
IP rating to EN 60529
 Housing: IP 40
 Terminal strip: IP 20
Admissible ambient conditions
 Service temperature: 0 °C – 55 °C - installed in control cabinet
 Storage temperature: - 40 °C – 80 °C
 Transport temperature: - 40 °C – 80 °C
 Air humidity: 10 % – 95 %, non-condensing
 Altitude: up to 2000 m
Body
 Body material: Lower section of black polycarbonate (glass-fibre reinforced), front of grey polycar-
bonate
 2 x 15-pole terminal strips, removable separately
 Max. cross-section per screw terminal:
 1 x 4.0 mm2solid or
 1 x 2.5 mm2stranded with sleeve, or
 2 x 1.5 mm2stranded with sleeve
 Body attachment: Mounting clip on support rail TH 35 (to EN 60715)
 Installation in control cabinet (IP54) required
Weight
 Approx. 0.4 kg

19URS 60, URS 61 - Installation & Operating Manual - 819634-00
Fig. 7
Fig. 8
Name plate/identification of URS 60 / URS 61
The date of production is printed on the back of the equipment.
Equipment
designation
Mains voltage/
Power
consumption/
IP rating/
Admissible
ambient
temperature
Disposal
information
Manufacturer
Safety
integrity level
Wiring
diagram
Safety
note
Equipment
function
CE marking
Appointed
authority
Universeller Sicherheitsbegrenzer
Universal safety limiter
Limiteur de sécurité universelle
T55°C (131°F)
IP 40 (IP20)
7 VA
Betriebsanleitung
beachten
See installation
instructions
Voir instructions de
montage
0525
TÜV . SWB/HWS STW(STB) SWÜL . XX-XXX
GESTRA AG
Münchener Str. 77
28215 Bremen
GERMANY
Steuergerät
evice
ppareille de commande
Control D
A
IEC 61508 SIL 3
24 V
± 20%
URS 60
250V
T 2,0A
3s
6101314157
2
CAN-Bus
1348
59 16 17 23 24 26 27
URS 60
In/Out
Supply
24V DC
Main
Supply
24V DC
11 2
Out 24V DC
Alarm
2
Test/Set
In 24V DC
33 44
Option
120Ω
CH CLChannel Channel
+- -+
Universeller Sicherheitsbegrenzer
Universal safety limiter
Limiteur de sécurité universelle
7 VA
Betriebsanleitung
beachten
See installation
instructions
Voir instructions de
montage
0525
TÜV . SWB/HWS STW(STB) SWÜL . XX-XXX
IEC 61508 SIL 3
24 V
± 20%
URS 61
GESTRA AG
Münchener Str. 77
28215 Bremen
GERMANY
250V
T 2,0A
3s
6101314157
2
1348
59 16 17 23 24 26 27
URS 61 120Ω
+- -+
CAN-Bus
In/Out
Supply
24V DC
Main
Supply
24V DC
11 2
Alarm
Out 24V DC
2
Test/Set
In 24V DC
33 44
Option CH CLChannel Channel
T55°C (131°F)
IP 40 (IP20)
Steuergerät
Control Device
Appareille de commande
Current approval
Serial number

20 URS 60, URS 61 - Installation & Operating Manual - 819634-00
Factory settings
Safety control unit URS 60
 Baud rate: 50 kBit/s (max. cable length 1000 m)
 Signalling delay: OFF
 Configuration:
Operation e.g. with two level electrodes NRG 1x-60
 Code switch setting, sliding switch, white
1
ON
2345678910
1
ON
2345678910
Safety control unit URS 61
 Baud rate: 50 kBit/s (max. cable length 1000 m)
 Signalling delay: OFF
 Configuration:
Operation e.g. with one level electrode NRG 1x-61
 Code switch setting, sliding switch, white