GESTRA NRR 2-52 User manual

Original Installation &
Operating Manual
Level Controller NRR
Visual Display and Operating Unit URB
NRR 2-52
NRR 2-53
URB 55
850698-00
EN (USA)
English

2NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Contents
Content of this Manual.........................................................................................................................5
Scope of supply, product package.......................................................................................................5
How to use this Manual........................................................................................................................6
Illustrations and symbols used............................................................................................................6
Hazard symbols in this Manual............................................................................................................6
Types of warning ..................................................................................................................................7
Specialist terms, abbreviations ...........................................................................................................8
Usage for the intended purpose...........................................................................................................9
IT security and rules for the use of Ethernet devices ......................................................................10
Applicable directives and standards - NRR 2-52, NRR 2-53 ...........................................................10
Applicable directives and standards - URB 55................................................................................11
Improper use ......................................................................................................................................11
Basic safety information ....................................................................................................................12
Required personnel qualifications.....................................................................................................12
Notes on product liability...................................................................................................................12
Function ..............................................................................................................................................13
Possible combinations of functions and equipment ........................................................................13
Technical data of the NRR 2-52, NRR 2-53 ........................................................................................15
Technical data of the URB 55 .............................................................................................................17
Factory default settings of the NRR 2-52, NRR 2-53.........................................................................19
NRR 2-52 ......................................................................................................................................19
NRR 2-53 ......................................................................................................................................19
NRR 2-52, NRR 2-53 .....................................................................................................................19
Factory default settings of the URB 55..............................................................................................20
Rating plate, identification of the NRR 2-52......................................................................................21
Rating plate, identification of the NRR 2-53......................................................................................22
Rating plate, identification of the URB 55 .........................................................................................23
Functional elements and dimensions of the NRR 2-52, NRR 2-53 ...................................................24
Installing the NRR 2-52, NRR 2-53 level controller ...........................................................................25
Dimensions of the URB 55..................................................................................................................26
Required installation aperture in the control cabinet door or switch panel ......................................26
Installing the URB 55..........................................................................................................................27
Connecting the URB 55.......................................................................................................................28
Ports and sockets on the back of the unit.......................................................................................28
Connection for 24 V DC supply voltage - pin assignment................................................................28
Pin assignment of data line between URB 55 and NRR 2-52, NRR 2-53 .........................................28

3NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Contents
Safety information for electrical connection of the level controller ................................................29
Wiring diagram of the NRR 2-52 level controller ..............................................................................30
Wiring diagram of the NRR 2-53 level controller ..............................................................................31
Electrical connection of the NRR 2-52, NRR 2-53 .............................................................................32
Connecting the 24V DC power supply ...........................................................................................32
Connecting the output contacts......................................................................................................32
Notes on connecting inductive loads..............................................................................................32
Connecting the level electrode/level transmitter.............................................................................32
Connecting the actual value output OUT1 and analog output OUT2 (4 - 20 mA)..............................32
Connecting the digital input (terminals 29/30)................................................................................32
Connecting the potentiometer (0 - 1000 W)...................................................................................32
Connecting the data line between the level controller and the URB 55...........................................33
Connecting the SPECTORmodul system ........................................................................................33
Changing the equipment settings......................................................................................................34
Setting the measuring range .............................................................................................................36
Setting the measuring range for the NRGT 26-2 level transmitter...................................................36
Status display of the NRR 2-52, NRR 2-53.........................................................................................37
Visual display and operating unit URB 55 .........................................................................................38
Switching on the supply voltage.....................................................................................................38
Operation and navigation...................................................................................................................39
User interface (example) ................................................................................................................39
Color coding of input and status fields ...........................................................................................39
Automatic functions.......................................................................................................................40
Entering parameters using the virtual keypad ................................................................................40
Entering parameters with password protection ..............................................................................41
Scroll bar for long lists and menus.................................................................................................41
Icons and functions of the NRR 2-52, NRR 2-53 ...............................................................................42
Home screen of NRR 2-52, NRR 2-53 level controllers .....................................................................45
Alarm and fault indications................................................................................................................46
Opening the alarm history..............................................................................................................47
System settings..................................................................................................................................48
System information ............................................................................................................................48
Setting the date/time..........................................................................................................................49
Password ............................................................................................................................................49
Network settings ................................................................................................................................50
Data exchange via Modbus TCP .......................................................................................................50
VNC server / Remote software...........................................................................................................51

4NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Contents
Configuring the level controller .........................................................................................................52
Setting the MIN/MAX switchpoints and set point ............................................................................52
Automatic/Manual mode................................................................................................................53
Trend log .......................................................................................................................................54
Test - Testing the relays of the connected level controller...............................................................55
Valve calibration in manual mode when a feedback potentiometer is connected ............................56
Pump control *...............................................................................................................................57
Calibrate the boiler level (for NRG2.-.. ONLY) ..................................................................................58
Setting the level controller .............................................................................................................59
Guide to setting control parameters ...............................................................................................59
Setting the level controller for 3-element control............................................................................60
System malfunctions in the URB 55 ..................................................................................................61
Indication of system malfunctions in the alarm and error list using error codes..............................61
Common faults and issues during use of the URB 55 .....................................................................62
System malfunctions in the NRR 2-52, NRR 2-53 .............................................................................63
Causes ..........................................................................................................................................63
Check the installation and configuration before systematic troubleshooting ...................................63
What to do in the event of system malfunctions...............................................................................64
Checking installation and function .................................................................................................64
Taking the NRR 2-52, NRR 2-53 out of service..................................................................................64
Taking out of service URB 55 .............................................................................................................64
UL components...................................................................................................................................65
Disposal ..............................................................................................................................................65

5NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Content of this Manual
Product:
■ Level NRR 2-52
■ Level NRR 2-53
■ Visual display and operating unit URB 55
First edition:
BAN 850698-00/08-2021cm
Applicable documents:
You can find the latest Installation & Operating Manuals on our website:
http://www.gestra.com
© Copyright
All rights reserved. Any misuse, particularly reproduction and dissemination to third parties, is not
permitted. The General Terms & Conditions of GESTRA AG apply.
Scope of supply, product package
NRR 2-5x
■ 1 x Level NRR 2-52 or NRR 2-53
URB 55
■ 1 x visual display and operating unit URB 55
■ 4 x retaining clips
■ 1 x power supply connector
■ 1 x data cable URB 55
NRR 2-5x + URB 55
■ 1 x Installation & Operating Manual

6NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
How to use this Manual
This Installation & Operating Manual describes the correct use of the NRR 2-52, NRR 2-53 level
controller in combination with the URB 55 visual display and operating unit. 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 product package. Keep it in an easily acces-
sible 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

7NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Types of warning
DANGERDANGER
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.
CAUTIONCAUTION
Warning of a situation that may result in minor or moderate injury.
ATTENTIONATTENTION
Warning of a situation that results in damage to property or the environment.

8NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Specialist terms, abbreviations
Here, we explain some abbreviations, specialist terms, etc., which are used in this Manual.
NRR .. / NRG .. / NRGT ... / URB ...
GESTRA equipment and type designations, see page 8.
PI controller
Controller with proportional (P) and integral (I) control.
SELV
Safety Extra Low Voltage
Direction of corrective action
The direction of corrective action indicates whether the action involves filling (positive) or draining
(negative).
Pb (proportional band)
The proportional band enables the controller amplification to be adapted to suit the controlled
system. For further information, see page 8, guide to setting control parameters.
Ti (reset time)
The integral element ensures that control deviations can be fully corrected, with no remaining
deviation. For further information, see page 8, guide to setting control parameters.
Neutral zone
If the actual value reaches the (set point +/- of the neutral zone), the manipulated variable does
not change in this range, see page 8.

9NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Usage for the intended purpose
NRR 2-52 and NRR 2-53 level controllers can be used in combination with NRGT 26-x level trans-
mitters as water level controllers and limit switches, e.g., in steam boilers and hot water installa-
tions and in condensate and feedwater tanks.
Configuration, operation and visual display
The equipment is configured and operated and information is viewed via the URB55 visual display
and operating unit. The URB 55 is designed for installation in a control cabinet door or switch
panel. It may only be used when correctly installed.
Overview of possible equipment combinations
Level controller Level electrode Visual display and operating unit
NRR 2-52
NRR 2-53 NRGT 26-2 URB 55
Fig. 1
Key to Fig. 1:
NRR = level controller
NRG = level electrode
NRGT = level transmitter
URB = visual display and operating unit
To ensure proper use in all applications, please also read the Installation & Operating
Manuals for the system components used.
■ You can find the latest Installation & Operating Manuals for the system components
named in Fig. 1 on our website:
http://www.gestra.com

10 NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Usage for the intended purpose
IT security and rules for the use of Ethernet devices
The plant operator is responsible for the security of his/her IT network and must take appropriate
action to protect equipment, systems and components from unauthorized access.
Pay attention to the following instructions when using Ethernet devices in your plant:
■ Do not connect equipment, systems or components to an open network, such as the Internet,
without safeguards in place.
■ To fully protect a PLC runtime system on a control system that is available on the Internet, the
use of common security mechanisms (firewall, VPN access) is absolutely essential.
■
Restrict access to all components to authorized persons only.
■ Change default passwords before bringing into service for the first time!
■ Deploy defense in depth mechanisms in your plant security, to restrict access and control to
individual products and networks.
Applicable directives and standards - NRR 2-52, NRR 2-53
The NRR 2-52, NRR 2-53 level controller has been tested and approved for use in the scope gov-
erned by the following directives and standards:
Standards:
■ UL 60730-1 and CAN/CSA E60730-1
General Requirements for Automatic Electrical Controls
■ UL 60730-2-15 and CAN/CSA E60730-2-15
Requirements for Automatic Electrical Water Level Sensing Controls

11NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Usage for the intended purpose
Applicable directives and standards - URB 55
The URB 55 has been tested and approved for use in the scope governed by the following direc-
tives and standards:
Standards:
■ UL 61010-1 and CAN/CSA C22.2 No. 61010-1
Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use -
Part 1: General Requirements
■ UL 61010-2-201 and CAN/CSA C22.2 No. 61010-2-201
Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use -
Part 2-201: Particular Requirements for Control Equipment
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.
Do not bring any equipment into service that does not have its own specific rating
plate.
The rating plate indicates the technical features of the equipment.

12 NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Basic safety information
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 plant is not carrying live voltage before commencing work.
Faulty equipment is a danger to plant safety.
■ If the NRR 2-52, NRR 2-53 level controller does not behave as expected, it may be
faulty.
■ Perform failure analysis.
■ 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
The manufacturer cannot accept any liability for damages resulting from improper use of the
equipment.

13NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Function
In the level controller, the actual value is compared with the set point, and a corrective signal is
formed to compensate the control deviation. In addition, switching operations can be triggered by
the output contacts when defined switchpoints are reached.
Possible combinations of functions and equipment
Combining the NRR 2-52, NRR 2-53 level controller with level electrodes and the URB 55 visual display
and operating unit provides the following common functions:
Level controller NRR 2-52 NRR 2-53
Evaluation of the current signal of a connected NRGT 26-2 level transmitter l l
3-position stepping controller with proportional-plus-integral control action (PI
controller) and actuation of an electrically operated control valve l
Continuous PI controller for actuating an electro-pneumatically operated
control valve l
Continuous PI controller for actuating frequency-controlled pumps l
MIN/MAX water level alarm l l
Current inputs for steam and feedwater flowrate
(3-element control) (optional) l l
Indication of valve position by connecting a potentiometer
(in the control valve) l
Actual value output 4-20 mA l l
2 x pump enable (ON/OFF) with actuation of a frequency-controlled pump * l
* Controller software version 311178.13 or later
Fig. 3

14 NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Function
Visual display and operating unit URB 55
Indication of actual value (bar chart in %) l
Indication of actual value for 3-element control (compensated/uncompensated reading) l
Indication of valve position (bar chart and in %) l
Measuring range standardization when an NRG 2.-.. level electrode is connected l
Indication/setting of control parameters l
Standardization and evaluation of current inputs for steam and feedwater flowrate
(3-element control) (optional) l
Trend log l
Indication and listing of errors, alarms and warnings l
Test of MIN/MAX output relays l
Manual/automatic mode l
Password protection l
Level and conductivity controllers can be operated simultaneously l
Fig. 4

15NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Technical data of the NRR 2-52, NRR 2-53
Supply voltage
■ 24 V DC +/-20%; PELV / CLASS2
Power consumption
■ Max. 5 W
Current input
■ Max. 0.3 A
Required external fuse
■ M0.5A (medium time-lag)
Input/output
■ Interface for data exchange with the URB 55 visual display and operating unit
Inputs
■ 1 x analog input for potentiometer 0 - 1000Ω, 2-wire connection
(indication of valve position, NRR 2-52 only)
■ 1 x analog input IN 2 / 4 - 20 mA (feedwater flowrate) (optional)
■ 1 x analog input IN 3 / 4 - 20 mA (steam flowrate) (optional)
■ 1 x 24 V DC digital input alarm signal (from control center)
Outputs of NRR 2-52 *
1 x MIN / 1 x MAX alarm
■ 2 x volt-free relay contacts (changeover relays) **
■ Maximum switching current - 8 A at 250 V AC / 30 V DC - cos ϕ = 1 **
2 x control valves (OPEN/CLOSED)
■ 2 x volt-free relay contacts (changeover relays) **
■ Maximum switching current - 8 A at 250 V AC / 30 V DC cos ϕ= 1 **
Outputs of NRR 2-53 *
2 x MIN / 2 x MAX alarm
■ 4 x volt-free relay contacts (changeover relays), MIN/MAX alarm **
■ Maximum switching current - 8 A at 250 V AC / 30 V DC - cos ϕ = 1 **
or
1 x MIN1 / 1 x MAX1 alarm and
2 x pump enable (ON/OFF) - (MIN2 / MAX2 = enable Pump 1/Pump 2)
■ 2 x volt-free relay contacts (changeover relays), MIN1/MAX1 alarm **
■ 2 x volt-free relay contacts (changeover relays), MIN2/MAX2 enable Pump 1/Pump 2 **
■ Maximum switching current - 8 A at 250 V AC / 30 V DC - cos ϕ = 1 **
* Inductive loads must have interference suppression (RC combination) in accordance with the
manufacturer's specification
** Contact material AgNi0.15, AgSnO2
Off delay of MIN/MAX alarm outputs
■ Factory default setting 3 seconds.

16 NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Technical data of the NRR 2-52, NRR 2-53
Analog outputs of NRR 2-52
■ 1 x actual value output OUT 1: 4 - 20 mA, e.g., for an actual value indication
■ Max. load resistance 500 W
Analog outputs of NRR 2-53
■ 1 x actual value output OUT 1: 4 - 20 mA, e.g., for an actual value indication
■ 1 x analog output OUT 2: 4 - 20 mA, manipulated variable Yw
■ Max. load resistance 500 W
Indicators and controls
■ 1 x multicolor LED (amber, green, red)
◆ amber = power up
◆ green = running
◆ red = malfunction
■ 1 x 4-pole code switch for configuration
Protection
■ Terminal box: IP40 according to EN 60529
■ Terminal strip: IP20 according to EN 60529
■ As a UL open type, the equipment must be installed in a control cabinet.
Electrical safety
■ Pollution degree 2, overvoltage category II according to UL 60730-1
Admissible ambient conditions
■ Service temperature: 14° - 131°F (-10° - 55°C)
[at power-on 32° - 131°F (0° - 55°C)]
■ Storage temperature: -4° - 158°F (-20° - 70°C) *
■ Transport temperature: -4° - 176°F (-20° - 80°C) (< 100hours) *
■ Air humidity: Max. 95%, non-condensing
* Only switch on after a defrosting period of 24 hours
Terminal box
■ Terminal box material: Lower section of black polycarbonate (glass-fiber reinforced), front of
gray polycarbonate
■ 2 x 15-pole terminal strips, removable separately
■ Max. wire size per screw terminal:
◆ 1 x AWG12 (4.0mm2) solid, or
◆ 1 x AWG14 (2.5mm3) stranded with sleeve, or
◆ 2 x AWG16 (1.5mm2) stranded with sleeve
■ Terminal box attachment: Mounting clip on support rail TH 35 (according to EN 60715)
Weight
■ Approx. 1.1 lb (0.5 kg)
Other information
■ Incorporated type 1 action operating control
■ Pollution degree 2, impulse voltage DC supply = 500 V, AC output = 2500 V

17NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Technical data of the URB 55
Supply voltage
■ 24 V DC ( ) +/- 20%; PELV / CLASS2
Power consumption
■ Max. 14.4 W
Current input
■ Max. 0.6 A (at 24 V)
Fuse
■ Internal, automatic
Interfaces for data transmission
■ 2 x Ethernet 10/100 Mbit switched (Modbus TCP/IP)
■ 1 x USB host port (versions 2.0 and 1.1)
■ 1 x slot for SD card
Indicators and controls
■ Capacitive 5" touchscreen with LED backlight
■ Resolution 800 x 480 pixels (WVGA)
■ Brightness 200 Cd/m2, dimmable
■ Size (screen) 4.33 in (110 mm) x 2.56 in (65 mm)
Protection
■ Front: IP66 according to EN 60529
■ Back: IP20 according to EN 60529
Admissible ambient conditions
■ Service temperature: 32° - 140°F (0° - 60°C)
■ Storage temperature: -4° - 158°F (-20° - 70°C)
■ Transport temperature: -4° - 158°F (-20° - 70°C)
■ Air humidity: 5 % – 85% relative humidity, non-condensing
Enclosure
■ Material: Front (metal/glass) / back (metal enclosure for electronics)
■ Enclosure attachment with the supplied fastening elements
■ Intended for installation in a control cabinet or switch panel
Dimensions, see page 17
■ Front panel (W x H) 5.79 in (147 mm) x 4.21 in (107 mm)
■ Switch panel cutout (W x H) 5.35 in (136 mm) x 3.78 in (96 mm)
■ Mounting depth 2.05 in (52 mm) + 0.32 in (8 mm) protruding

18 NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Technical data of the URB 55
Weight
■ Approx. 2.21 lb (1 kg)
Internal battery, permanently installed, non-replaceable
■ Type: Lithium-ion, charged automatically
If the equipment is out of service for six months or more, we recommend connecting it
to the supply voltage for one day, to recharge the battery.

19NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Factory default settings of the NRR 2-52, NRR 2-53
The level controller is delivered with the following factory default settings:
■ Code switch setting: Sliding switch, white (1 to 4 = OFF)
Controller configuration,
see page 19, Fig. 20.
■ Switch S3 must be switched to ON for operation with the NRGT 26-2 level transmitter.
■ Measuring range: 100%
NRR 2-52
■ MAX switchpoint: 80%
■ MIN switchpoint: 20%
NRR 2-53
■ MAX1 switchpoint: 80%
■ MAX2 switchpoint: 60%
■ MIN2 switchpoint: 40%
■ MIN1 switchpoint: 20%
NRR 2-52, NRR 2-53
■ Set point: 50% of measuring range
■ Direction of corrective action: Fill control
■ Proportional band (Pb): ± 20% of set point
■ Reset time (Ti): 0 seconds
■ Neutral zone: ± 5% of set point
■ Off delay for MIN/MAX alarm: 3 seconds (default)

20 NRR 2-52, NRR 2-53, URB 55 - USA- Installation & Operating Manual - 850698-00
Factory default settings of the URB 55
The visual display and operating unit is delivered with the following factory default settings:
■ PWL 1: 111
■ Conductivity in: µS/cm
■ Remote access: ON
■ Target IP: 192.168.0.84
■ Subnet: 255.255.255.0
■ Gateway: 192.168.0.1
■ Modbus TCP: Off