GESTRA NRR 2-40 User manual

1
Installation Instructions 810369-03
Level Controller Type NRR 2-40
NRR 2-40 

2
Contents
Page
Important Notes
Usage for the intended purpose .....................................................................................7
Safety note / Warning ......................................................................................................7
Explanatory Notes
Scope of supply ..............................................................................................................8
System description ......................................................................................................... 8
Function ..........................................................................................................................8
Technical data ................................................................................................................9
Installation
NRR 2-40 ......................................................................................................................10
Example of installation .................................................................................................35
Wiring
Wiring diagram............................................................................................... 3, 4, 10, 11
Basic Adjustments
CAN bus........................................................................................................................12
Node ID .........................................................................................................................12
Factory setting ..............................................................................................................13
Controller NRR 2-40 .....................................................................................................13
Commissioning
NRR 2-40 ......................................................................................................................14
Control range ................................................................................................................14
Adjusting the control range.................................................................................... 14, 15
Establishing switchpoints and proportional band .................................................. 16–19
Calibrating the feedback potentiometer of an external control valve ..........................20
Operation
Normal operation ..........................................................................................................21
Alarm / High-level alarm / Low-level alarm ..................................................................21
Relay test high/low level alarm ....................................................................................22
System Malfunctions
Systematic fault finding prodedure ...............................................................................23
System malfunctions 1 to 4 ................................................................................... 24–26
Operation Malfunctions
Fault-finding list for troubleshooting ...................................................................... 26–27
Annex
Factory set default node ID ................................................................................... 28, 29
Assigning/changing node ID.........................................................................................28
Neutral band .................................................................................................................30
Establishing / changing neutral band .................................................................... 30–32
Declaration of conformity..............................................................................................34

3
Wiring Diagram
NRR 2-40 as three-position stepping controller
Fig. 1
Fig. 2
Paired cable
Paired cable

4
Fig. 4
Fig. 3
Paired cable
Paired cable
NRR 2-40 as continuous controller
Wiring Diagram
Control terminal
and display unit
URB 1 Level controller NRR 2-40 Level electrode NRG16-42
Terminating resistor
120 Ω
Voltage supply CAN data line
Terminating resistor
120 Ω
Sensor
...
Level switch
NRS 1-42
CEP*)
*) CEP = central earthing point

5
Parts Drawings
Fig. 5
Fig. 6
1
234
5
6
AB
A
7
8

6
Key
LED 1 – Switchpoint 1
LED 2 – Control valve closing
LED 3 – Control valve opening
LED 4 – Switchpoint 4
LED “Bus status”
LED “Power”
Enter button / Test mode
Decrease button
Increase button
Program button
Code selector switch, 10 poles
Terminal strip
Screws for terminal strip
High-level
not allocated
not allocated
Low-level
Multifunction
Multifunction
Multifunction
MalfunctionAlarm
Multifunction
Indicator LED
1
2
3
4
5
6
7
8
A
B

7
Important Notes
Safety Note
The equipment must only be installed by qualified staff.
Qualified staff are those persons who – through adequate training in electrical
engineering, the use and application of safety equipment in accordance
with regulations concerning electrical safety systems, and first aid & accident
prevention – have achieved a recognised level of competence appropriate
to the installation and commissioning of this device.
Warning
The terminal strip of the NRR 2-40 is live during operation. This presents
the danger of electric shock. Cut off power supply before fixing or
removing the housing lid or terminal strips.
Usage for the intended purpose
Use level controller NRR 2-40 in combination with level electrode NRG 26-40 only
for controlling the liquid level of conductive fluids.

8
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,
adopting the CANopen protocol. The transmitted 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 of the level controller is constantly monitored. When 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 (alarm position).
GESTRA’s control terminal and display unit URB 1 enables advanced features such
as adjustable energizing and de-energizing delays of the output relays (1–25 s).
Explanatory Notes
Scope of supply
NRR 2-40
1 Level controller type NRR 2-40 (plug-in unit in plastic case with box terminals)
1 Terminating resistor 120 Ω
1 Installation manual
System Description
Use level controller type NRR 2-40 in combination with level electrode type
NRG 26-40 for level control and monitoring. The level controller has the following
functions:
■Two liquid level limits with one switchpoint each (HIGH-LEVEL alarm, LOW-LEVEL
alarm)
■Three-position stepping or modulating control within a predefined proportional
band
■Continuous level monitoring within the control band defined by two preset limits
The NRR 2-40 features an optional output for a standard signal 4 – 20 mA.
The level data are transferred from the electrode NRG 26-40 to the level controller
via a CAN data bus.

9
Technical Data
Type approval no.
NRR 2-40: TÜV .98-399
Input / Output
Interface for CAN bus to DIN ISO 11898 CANopen
Feedback potentiometer 1000 Ω
Output – voltage supply for electrodes
Power supply 24V DC, short-circuit protected.
Analogue output 4– 20 mA, load 500Ωfor display of actual value (option).
Analogue control output for manipulated variable 4– 20 mA, max. load 500Ω(option).
4 volt-free relay contacts.
Max. contact rating with switching voltages of 24V AC, 115 V AC and 230V AC:
4 A resistive, 0.75 A inductive at cos ϕ0.5
Max. contact rating with a switching voltage of 24V 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” 3 s
Indicators and adjustors
1 red LED for switchpoint “MAX”
1 red LED for switchpoint “MIN”
2 green LEDs for “CONTROL VALVE OPENING” and “CONTROL VALVE CLOSING”
1 green LED “OPERATION”
1 red LED “BUS MALFUNCTION”
1 ten-pole code selector switch for setting node ID and baud rate
4 pushbuttons
Proportional band Xp
1 % to 100 %
Valve position feedback
0Ωto 1000 Ω (only when used as three-position stepping controller)
Switching range (dead band) XSh
0 % (factory setting) up to 15 %
Supply voltage
230 V ± 10 %, 50/60 Hz
115 V ± 10 %, 50/60 Hz (option)
Power consumption
10 VA
Protection
Case: IP 40 to DIN ISO 60529
Terminal strip: IP 20 to DIN ISO 60529
Admissible ambient temperature
0 °C to 55 °C
Case material
Front panel: polycarbonate, grey
Enclosure: polycarbonate, black
Weight
Approx. 0.8 kg

10
Wiring
UNITRONIC®is a registered trademark of LAPP Kabelwerke GmbH, Stuttgart
NRR 2-40
Installation
Installation on mounting rail
1. Clip level controller onto mounting rail 35 x 15 mm (DIN EN 50022).
2. Align level controller, fig. 19, 20.
Tool
■Screwdriver (5.5/100)
Wiring diagram
See wiring diagrams on pages 3 and 4.
When a max. cable length of 1000 m is desired, make sure to modify the baud
rate accordingly. Refer to pages 28 and 29 for more details.
Note that screened multi-core twisted-pair control cable is required, e. g.
UNITRONIC®BUS CAN 2 x 2 x ... 2or RE-2YCYV-fl 2 x 2 x ... 2.
The baud rate (data transfer rate) dictates the cable length between the bus nodes
and the total current consumption of the measuring sensors dictates the conductor
size.
The baud rate is set via a code switch. Reduce baud rate if cable is longer than
specified in the table. Make sure that all bus nodes have the same settings.
To protect the switching contacts fuse circuit with 2.5 A (anti-surge fuse) or according
to TRD regulations (1.0 A for 72 hrs operation).
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11
Wiring – continued –
Attention
■Wire equipment in series. Star-type wiring is not permitted.
■Interlink screens of control cables such that electrical continuity is
ensured and connect them once to the central earthing point (CEP).
■To protect the switching contacts fuse circuit with 2.5 A (slow blow) or
according to TRD regulations.
■If more than one system components are connected to a CAN bus
network provide the first and last equipment with a terminating
resistor of 120 Ω. Fig. 4
■The CAN bus network must not be interrupted while operating.
Any interruption will result in HIGH/LOW level alarm!
If the level controller must be replaced, remove terminal
strip Fig. 6.
Before removing the CAN-bus line from the terminal strip disconnect all
relevant system components to avoid malfunction alarms.
■Screwdriver for slotted screws, size 2.5, completely insulated according to
VDE 0680.
Tool
Note
■Connect screen only to designated terminals.
■The loop resistance must be under 10 Ω.
■The rated voltage is stated on the name plate.
■When switching off inductive loads, voltage spikes are produced that
may impair the operation of control and measuring systems. Inductive
loads should therefore be provided with commercial arc suppressor
RC combinations.
■In spite of correct wiring H.F. interference caused by the installation
may lead to system breakdowns and malfunction messages. If
necessary refer to the “Fault finding list for troubleshooting” on
pages 26 and 27.
A

12
Node ID
Basic Adjustments
CAN bus
All level and conductivity controllers and associated electrodes are interconnected
by means of a CAN bus using the CANopen protocol. Every item of equipment
features an electronic address (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 1and 123.
The NRR 2-40 is configured at our works and ready for service with other GESTRA
system components without having to set the node ID.
If several systems of the same kind are to communicate in one CAN bus
network, be sure to assign one node ID for each individual system component.
Refer to pages 28 and 29 for more details.

13
■Switchpoint 1: 80%
■Switchpoint 4: 20%
The level controller features the following factory set default values:
■Relay with de-energizing delay switchpoint 1: 3s
■Relay with de-energizing delay switchpoint 4: 3s
■Baud rate: 250 kb/s
■Proportional band XP: 20%
■Node ID: 040
100%
80 %
60%
40 %
20 %
Fig. 7
Basic Adjustments – continued –
Factory setting
20 %
0%
The controller type NRR 2-40 is specially designed for level control in steam boilers
and feedwater deaerators. The NRR 2-40 is a proportional controller with steady-
state deviation. The positive and negative deviation lies within the proportional band
(Xp) preselected by the user.
It is possible to control electric and pneumatic actuators. The control of electric
actuators is accomplished by an analogue signal which, in combination with an
active position feedback coming from the valve, is converted in the controller into a
three-position stepping signal. The control pulses for the electric actuator are
transmitted by a relay incorporated in the controller.
The control of pneumatic actuators is effected by an analogue signal 4 –20 mA.
The analogue signal is transmitted directly from the proportional controller to the
positioner of the pneumatic control valve, which means that an active position
acknowledgement is not possible.
XP values:
XP> large permanent deviation, valve reacts sluggishly
XP< no permanent deviation, valve may be hunting
recommended XPvalue 30 % – 100 %.
Controller NRR 2-40

14
Indicator LEDs flash rapidly
NRR 2-40
Apply power to the unit.
The four indicator LEDs flash rapidly.
The LED “Power” lights up.
The test cycle takes about two seconds.
Commissioning
LED “Power” illuminated.
37
Desired control range [mm]
Max. control range
Lower measuring point
26
Determine the appropriate level
control range for your
system.
Press button briefly.
Note:
In the event of a system malfunction, the
LED(s) “Bus status” and/or “Power” will
be flashing rapidly when in program
mode. Quit program mode and
analyse the system malfunction
(see pages 22 – 26).
Press button for 3 sec.
Lower liquid level until the lower limit of
the control range is reached.
If necessary first use button to
adjust the upper limit of the control
range.
Adjusting the control range
NRG 26-40
Control Range
LEDs illuminated LEDs flash slowly
LED “Power”
3 sec.
briefly
LEDs flash LEDs flash rapidly
Fig. 8

15
Commissioning – continued –
Adjusting the control range – continued –
Press button briefly.
Raise liquid level until the desired upper
limit of the control range is reached.
Press button briefly.
Press button twice briefly.
The upper limit of the desired control
range is now saved.
The NRR 2-40 is now again in operating
mode.
Press button briefly.
The lower limit of the desired control
range is now saved.
LEDs illuminated LEDs flash slowly
briefly
LEDs illuminated LEDs flash slowly
briefly
LEDs illuminated LEDs flash slowly
briefly
twice briefly

16
Switchpoint 1
Switchpoint 2
Switchpoint 3
Switchpoint 4
Selected control range
You can establish two switchpoints and a proportional band Xpwithin the control
range.
XP
NRG 26-40
Switchpoints and proportional band
Commissioning – continued –
Fig. 9
80 %
70%
50 %
20 %
20%
90 %
45%
35 %
10 %
10%
Fig. 10 (example) Fig. 11 (example)

17
Commissioning – continued –
Establishing switchpoints and proportional band
Press button briefly.
Raise or lower the liquid level in the
vessel until the desired value is reached.
Use button if you first want to
establish the proportional band or a
different switchpoint.
Press button briefly.
Lower the liquid level until switchpoint 4
within the desired control range is reached.
Note:
In the event of a system malfunction,
the LED(s) “Bus status” and/or “Power”
will be flashing rapidly when in program
mode.
LED illuminated LEDs flash slowly
briefly
LED flashes LEDs flash slowly
Press button briefly.
Switchpoint 4 is now saved.
Press button briefly.
The lower limit of the proportional band
Xpis now selected (switchpoint 3).
Press button slowly.
Raise the liquid level until switchpoint 3
within the desired control range is reached.
Example:
Liquid level switchpoint 3 = 40% and
liquid level switchpoint 2 = 60% make a
proportional band Xp(60 % – 40 %) = 20%
The setpoint is at approx. 50%.
LED illuminated LEDs flash slowly
briefly
LED illuminated LEDs flash slowly
briefly
LED flashes LEDs flash slowly
briefly
briefly

18
Press button briefly.
Switchpoint 3 is now saved.
Press button briefly.
The upper limit of the proportional band
Xpis now selected (switchpoint 2).
LED illuminated LEDs flash slowly
briefly
LED illuminated LEDs flash slowly
briefly
Commissioning – continued –
Establishing switchpoints and proportional band – continued –
LED illuminated LEDs flash slowly
Press button briefly.
Raise liquid level until switchpoint 2
within the desired control range is
reached.
Example:
Liquid level switchpoint 3 = 40% and
liquid level switchpoint 2 = 60% make a
proportional band Xpof 20%.
Press button briefly.
Switchpoint 2 is now saved.
Press button briefly.
Switchpoint 1 is now selected.
LED flashes LED flash slowly
briefly
LED illuminated LEDs flash slowly
briefly
briefly

19
Commissioning – continued –
Establishing switchpoints and proportional band – continued –
Press button briefly.
Raise liquid level until switchpoint 1
within the desired control range is
reached.
Press button twice briefly.
Switchpoint 1 is now saved.
The NRR 2-40 is now again in operating
mode.
LED flashes LEDs flash slowly
briefly
LED illuminated
twice briefly

20
Commissioning – continued –
Calibrating the feedback potentiometer of an external control valve
The feedback potentiometer of an external control valve with electric actuator has to
be manually calibrated before commissioning.
1. Ascertain the total resistance of the feedback potentiometer.
2. Set the control valve manually into mid-position.
3. Adjust manually the position of the feedback potentiometer until the partial
resistance values of the measured total resistance are equal.
■The GESTRA level controller type NRR 2-40 requires a 1000 ΩΩ
ΩΩ
Ω
feedback potentiometer.
■The NRR 2-40 works as two-position controller when the terminals for
the feedback potentiometer are not wired or the feedback potentiometer
is defective.
■Use the control and display unit URB 1 for semi-automatic calibration of
the feedback potentiometer of an external control valve without
measurement of the resistance value. For more details see the
installation instructions of the URB 1.
Fig. 12
Attention