GESTRA NRR 2-40 User manual

1
EN
English
Level Controller
NRR 240
Original Installation Instructions
81036906

2
Contents
Usage for the intended purpose ..............................................................................................................5
Safety note .............................................................................................................................................5
Danger ...................................................................................................................................................5
Attention.................................................................................................................................................5
LV (Low Voltage) Directive and EMC (Electromagnetic Compatibility) .......................................................5
ATEX (Atmosphère Explosible).................................................................................................................5
Important Notes
Page
Explanatory Notes
Scope of supply......................................................................................................................................6
Description .............................................................................................................................................6
Function .................................................................................................................................................6
System components ...............................................................................................................................6
Design....................................................................................................................................................6
NRR 240 .............................................................................................................................................12
Tools.....................................................................................................................................................12
Example of Installation..........................................................................................................................13
Key.......................................................................................................................................................12
Installation
NRR 240 ...............................................................................................................................................7
Corrosion resistance...............................................................................................................................8
Name plate / marking .............................................................................................................................8
Dimensions.............................................................................................................................................9
Technical Data
NRR 240 .............................................................................................................................................10
Key.......................................................................................................................................................12
Design
NRR 240 .............................................................................................................................................11
Key.......................................................................................................................................................12
Functional Elements

3
Electrical Connection
Control cable ........................................................................................................................................14
Note .....................................................................................................................................................15
CAN bus voltage supply ........................................................................................................................15
Attention ..............................................................................................................................................15
Wiring diagram............................................................................................................................... 16, 17
Key.......................................................................................................................................................18
CAN bus wiring diagram .......................................................................................................................19
Attention...............................................................................................................................................19
Note .....................................................................................................................................................20
Tools.....................................................................................................................................................20
Using operating device URB for parameter setting.................................................................................26
NRR 240 .............................................................................................................................................26
Measuring range...................................................................................................................................26
Setting measuring range................................................................................................................. 26, 27
Switchpoints and proportional range.....................................................................................................28
Establishing switchpoints and proportional range..........................................................................29 – 31
Calibrating the feedback potentiometer of an external control valve......................................................31
Attention...............................................................................................................................................31
Contents – continued –
Commissioning Procedure
Page
NRR 240 .............................................................................................................................................32
Operation
Bus cable..............................................................................................................................................20
Node ID ................................................................................................................................................21
Factory setting......................................................................................................................................22
Function of the controller......................................................................................................................22
Establishing / changing node ID............................................................................................................23
Attention...............................................................................................................................................23
Code switch settings.............................................................................................................................23
Dead band............................................................................................................................................24
Code switch settings.............................................................................................................................24
Establishing / changing the dead band............................................................................................ 24, 25
Basic Settings

4
Danger .................................................................................................................................................35
NRR 240 .............................................................................................................................................35
Danger .................................................................................................................................................36
Systematic malfunction analysis...........................................................................................................36
System malfunction 1...........................................................................................................................37
System malfunction 2...........................................................................................................................37
System malfunction 3...........................................................................................................................38
System malfunction 4...........................................................................................................................39
System Malfunctions
Danger .................................................................................................................................................39
Disposal................................................................................................................................................39
Decommissioning
Contents – continued –
Page
NRR 240 .............................................................................................................................................33
MAX alarm............................................................................................................................................33
MIN alarm.............................................................................................................................................33
Alarm
NRR 240 .............................................................................................................................................32
Test
Note on the Declaration of Conformity / Declaration by the Manufacturer .............................................39
Annex
Fault finding list for troubleshooting......................................................................................................34
Operational malfunctions

5
Important Notes
Danger
The terminal strips of the equipment are live during operation.
This presents the danger of electric shock.
Cut off power supply before mounting or removing the terminal strips and the housing
cover.
Usage for the intended purpose
Use the level controller NRR 240 only in conjunction with GESTRA level electrode NRG 2640 for
controlling liquid levels of conductive fluids.
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.
LV (Low Voltage) Directive and EMC (Electromagnetic Compatibility)
The level controller NRR 240 meets the requirements of the Low Voltage Directive 2014/35/EU
and the EMC Directive 2014/30/EU.
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.
ATEX (Atmosphère Explosible)
According to the European Directive 2014/34/EU the equipment must not be used in potentially explo
sive areas.

6
System components
NRG 2640
Level electrode NRG 2640, PN 40
Design
NRR 240
Enclosure of insulating material with terminals for installation in control cabinets.
The terminals are externally accessible.
Clipping onto a 35 mm standardized supporting rail (DIN EN 50022).
External dimensions: 73 x 100 x 118
Scope of supply
NRR 240
1 Level controller NRR 240 plugin unit in plastic case with box terminals
1 Terminating resistor 120 Ω
1 Installation & operating manual
Description
The level controller NRR 240 in conjunction with level electrode NRG 2640 is designed for level
control and monitoring. The level controller features the following functions:
nTwo level limit values with one switchpoint each (highlevel alarm, lowlevel alarm).
nThreeposition or modulating control within a predefined proportional band.
nWater level is maintained within the defined control band of the electrode.
The NRR 240 features an optional output for a standard signal 4 – 20 mA.
The level data are transferred from the level electrode NRG 2640 to the level controller or an additional
system component via a CAN data bus.
Explanatory Notes
Function
At regular intervals the level electrode NRG 2640 sends a data telegram to the level controller
NRR 240. The data are transferred via a CAN bus to DIN ISO 11898 using the CANopen protocol. The
transmitted measuring data are then evaluated and allocated to the manually adjusted switchpoints.
Optionally a standard signal 4 – 20 mA is established for external level indication. A relay deenergizing
delay can be set manually with the control terminal and display unit URB 1. To guarantee the correct
functioning and safety of the system the data transmitting cycle is constantly monitored by the level
controller. If the CAN bus line is interrupted the level controller sends a visual signal to indicate a
malfunction and the relays 1 and 4 will be instantaneously deenergized. (fail safe position).
GESTRA's control terminal & display units URB enable advanced features such as adjustable energizing
and deenergizing delays of the output relays (1 to 25sec.)

7
NRR 240
Technical Data
Type approval no.
NRR 240: TÜV .XX399
Input/Output
Interface for CAN bus to DIN ISO 11898 CANopen.
Feedback potentiometer 1000 Ω.
Output voltage supply for electrodes
Power supply 24 V DC, shortcircuit protected.
Analog output 420 mA, load 500 Ω for indication of actual value (optional).
Analog control output for manipulated variable, 420 mA, max. load 500 Ω (optional).
4 voltfree relay contacts. Max. contact rating with switching voltages of 24 V AC, 115 V AC and 230 V
AC: 4 A resistive, 0.75 A inductive at cos ϕ0.5.
Max. contact rating with a switching voltage of 24 V DC: 4 A. Contact material: silver, hardgold plated.
Interference suppression
Provide contactor with an external RC combination (100 Ω / 47 nF).
Relay deenergizing delay
Output “MIN”, “MAX” 3s
Indicators and adjustors
1 red LED for switchpoint “MAX”
1 red LED for switchpoint “MIN”
2 green LEDs for “Opening control valve” and “Closing control valve”
One green LED “Power”
1 red LED “Bus malfunction”
1 tenpole code switch for setting node ID and baud rate
4 pushbuttons
Proportional range Xp
1 % to 100 %
Valve position feedback
0 Ω to 1000 Ω (only when used as threeposition stepping controller)
Switching range (dead band Xsh
0 % (factory setting) up to 15 %
Mains voltage
230 V +/– 10 %, 50/60 Hz
115 V +/– 10 %, 50/60 Hz (optional)
Power consumption
10 VA
Protection
Housing: IP 40 to DIN ISO 60529
Terminal strip: IP 20 to DIN ISO 60529
Admissible ambient temperature
0 °C to 55 °C
Body material
Front panel: polycarbonate, grey
Housing: polycarbonate, black
Weight
approx. 0.8 kg

8
Corrosion resistance
If the equipment is used for the intended purpose, its safety is not impaired by corrosion.
Technical Data – continued –
Name plate / marking
Fig. 1 Seriennummer
Steuergerät
control device
appareille de commande
Tamb = 55 °C ( 131 °F)
IN / OUT: CAN-Bus
18-36 V DC
IP 40 (IP20)
230V -15/+10%10VA
Betriebsanleitung
beachten
See installation
instructions
Voir instructions de
montage
Node ID:___ ___ ___
Münchener Str. 77
D-28215 Bremen
TÜV . WR . xx-399
NRR 2-40
12345
S
24V
DC CAN-BUS
-CH CL+
1716
LN
1110
9 12
S S
+-
M
Serial number

9
Technical Data – continued –
Dimensions
Fig. 2
118
100
73

10
Design
0
Fig. 3
9
NRR 240
9
a

11
Functional Elements
NRR 240
Fig. 5
Fig. 4
1
7 6 5 4 3 2
8

12
Design / Functional Elements / Installation
Key
1Status LED Alarm Malfunction
LED 1 Switchpoint 1 MAX alarm Multifunction
LED 2 Closing control valve Not assigned Multifunction
LED 3 Opening control valve Not assigned Multifunction
LED 4 Switchpoint 4 MIN alarm Multifunction
2LED Bus status
3LED Power
4Enter / Test
5Increase button
6Increase button
7Program button
8Code switch, 10 poles
9Terminal strip
0Screws for terminal strip
aBody
bSupporting rail TS 35 x 15 DIN EN 50022
Tools
nScrewdriver (5.5/100)
Installation
NRR 240
Mounting on supporting rail
1. Clip control unit onto the supporting rail.
Supporting rail TS 35 x 15, DIN EN 50022.
2. Align level controller. Fig. 7

13
Installation – continued –
Fig. 6
Example of Installation
b
9 0
0
Fig. 7
20 20
a

14
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. UNI
TRONIC®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 avail
able 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 socket) 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.
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
Set baud rate via code switch 8. Make sure that all bus nodes feature the same settings.
UNITRONIC®is a registered trademark of LAPP Kabelwerke GmbH, Stuttgart.

15
Electrical Connection – continued –
Note
nThe specified max. baud rates and cable lengths 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.
nThe type and design of the data cable has a strong influence on the electromag
netic compatibility (EMC) of the equipment. Take special care when connecting the
equipment.
nIf 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

16
Wiring diagram
Electrical Connection – continued –
Fig. 8
NRR 2-40 as 3-position stepping controller
Fig. 9
Valve actuator
d
e g
f
l
l
kh j
f
m
n1000 Ω

17
Fig. 10
NRR 2-40 as continuous controller
Wiring diagram
Electrical Connection – continued –
d
e g
lh
k
i
l

18
d Mains supply
e MAX limit contact (MAX alarm)
f Activation control of valve actuator
Fill control: = Valve CLOSED 23
= Valve OPEN 25
Discharge control: = Valve OPEN 23
= Valve CLOSED 25
e MIN limit contact (MIN alarm)
h Actual value output 420 mA (optional)
i Controller output, analogue, manipulated variable Y, 420 mA
j Input for feedback potentiometer 1000 Ω
k Terminating resistor 120 Ω, RES 1 or RES 2
l CAN bus line, twisted pair control cable
m Valve actuator
n Feedback potentiometer 1000 Ω for actuator
Key
Electrical Connection – continued –

19
Electrical Connection – continued –
CAN bus wiring diagram
Fig. 11
RES 2
CEP NRS, NRR, LRR,
TRS, URB 1
URB 2 NRG, LRG,
EF, URZ TRV
RES 1
Attention
nWire equipment in series. Startype wiring is not permitted!
nLink 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
separated from the central earthing point (CEP).
nTo protect the switching contacts fuse circuit with T 2.5 A or according to TRD
regulations (1.0 A for 72 h operation).
nIf 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. 11
nDo not interrupt the CAN bus network during operation with one or more system
components!
If the CAN bus network is interrupted the safety circuit will be opened.
If the control unit has to be replaced, detach terminal strips 9.
Fig. 3
Before taking the CAN bus line from the terminal strip, make sure that all connected
system components are out of service.

20
Electrical Connection – continued –
Tools
nScrewdriver for slotted screws, size 2.5, completely insulated according to VDE 0680
Note
nLink screen only to terminal 3, ensure electrical continuity and connect it once to the
central earthing point (CEP).
n The loop resistance must be below 10 Ω.
n The rated voltage is indicated on the name plate.
nWhen switching off inductive loads, voltage spikes are produced that may impair the
operation of control and measuring systems. Provide connected contactors with RC
combinations, e. g. 0.1µF/100 Ω.
nEven in correctly wired systems high frequency interference caused by the installation
can lead to system outages and malfunction alarms. For more information please refer
to the faultfinding list in the section Malfunctions – Troubleshooting.
Bus cable
All devices (level, conductivity) are interconnected via CAN bus. The CANopen protocol is used for the
data exchange between the equipment groups. All devices have an electronic address – the node ID.
The fourcore bus cable serves as power supply and data highway for highspeed data exchange.
The CAN address (node ID) can be set between 1 – 123.
The equipment has already been configured at our works for operation with other GESTRA components
and can be used straight away without having to set the node ID.
If several identical systems are to communicate in a CAN bus network, set a different node ID for
each system (e. g. limiter, controller, etc).
If the length of the CAN bus cable exceeds 125 m change the settings of the code switch 8,
Fig. 15. Note that the baud rate setting must be identical for all busbased equipment!
For more information on switch positions see Basic Settings Switch positions.
Basic Settings