GESTRA NRG 16-11S User manual

1
Installation Instructions 818790-00
Level Electrode
NRG 16-11S
GESTRA Steam Systems
NRG 16-11S EN
English

2
Contents
Usage for the intended purpose ..............................................................................................................4
Safety note .............................................................................................................................................4
Danger ...................................................................................................................................................4
Attention................................................................................................................................................. 4
Important Notes
Page
Explanatory Notes
Scope of supply ...................................................................................................................................... 5
Description NRG 16-11S.........................................................................................................................5
Function .................................................................................................................................................5
System components ...............................................................................................................................5
Design.................................................................................................................................................... 5
NRG 16-11S, step 1..............................................................................................................................12
NRG 16-11S, step 2..............................................................................................................................12
Attention............................................................................................................................................... 12
Important notes ....................................................................................................................................12
Tools.....................................................................................................................................................12
Installation
NRG 16-11S ...........................................................................................................................................6
Corrosion resistance ...............................................................................................................................7
Sizing .....................................................................................................................................................7
Name plate / marking .............................................................................................................................7
Dimensions NRG 16-11S ........................................................................................................................8
Technical Data
NRG 16-11S ...........................................................................................................................................9
Key.......................................................................................................................................................11
Design
NRG 16-11S .........................................................................................................................................10
Key.......................................................................................................................................................11
Functional Elements

3
Electrical Connection
NRG 16-11S .........................................................................................................................................14
Wiring diagram .....................................................................................................................................15
Voltage table.........................................................................................................................................16
Note .....................................................................................................................................................16
Tools.....................................................................................................................................................16
Check wiring ........................................................................................................................................16
Apply mains voltage.............................................................................................................................. 16
Contents – continued –
Commissioning
Page
Low-level limiter...................................................................................................................................17
Note .....................................................................................................................................................17
Operation
Fault-finding list for troubleshooting......................................................................................................17
Operational Malfunctions
Danger .................................................................................................................................................18
Disposal................................................................................................................................................18
Decommissioning
NRG 16-11S .........................................................................................................................................13
Key.......................................................................................................................................................14
Examples of Installation

4
Important Notes
Danger
When loosening the electrode steam or hot water might escape.
This presents the danger of severe scalds to the whole body.
It is essential not to mount or dismantle the electrode unless the boiler pressure is
verified to be 0 bar.
The electrode becomes hot during operation.
Touching the hot equipment presents the risk of severe burns to hands and arms.
All installation and maintenance work must only be performed when the equipment is
cold.
Usage for the intended purpose
Use level electrode NRG 16-11S only in conjunction with level switch NRS 1-7 for low-level limiting
(low level alarm) on board of seagoing vessels, mobile offshore platforms or river boats. The equipment
must not be used in explosion risk areas.
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.
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.

5
Explanatory Notes
Scope of supply
NRG 16-11S
1 Level electrode NRG 16-11S, PN 40
1 Disk with set screw (measuring surface extension) – optional
1 Retaining ring – optional
1 Installation manual
Function
The water level limiter comprises a level electrode type NRG 16-11S and a level switch type NRS 1-7.
The level electrode NRG 16-11S consists of two concentrically arranged electrodes (measuring elec-
trode and compensating electrode) which are isolated from each other by special insulating seals.
The level limiter operation is based on the conductive measuring principle using the electrical
conductivity of water for signaling water level. During normal, trouble-free operation the level electrode
tip is immersed in boiler water and no low level alarm is given. A low level alarm will only be raised if
the electrode tip is exposed for more than 15 (25) seconds. A low level alarm will also be activated if
the insulating seals placed between the electrodes and the body are no longer pressure tight, allowing
water to penetrate into the body. However confirmation should always be done by checking if there
is water in the gauge glass. The equipment combination NRG 16-11S and NRG 1-7 provides fail safe
protection against a first fault in accordance with TRD 604.
System components
NRS 1-7
Level switch NRS 1-7. Two channel level limiter (redundancy) with periodic self-checking routine to
EN 50156-1.
Description NRG 16-11S
The level electrode NRG 16-11S is exclusively designed for seagoing vessels, mobile offshore platforms
and river boats. The level electrode NRG 16-11S detects the min. liquid level (low level alarm) in a
steam boiler. The operation of the electrode is based on the conductivity measuring principle using the
electrical conductivity of water for signaling one liquid level:
■ Low level alarm
The NRG 16-11S is designed for use in conjunction with level switch NRS 1-7 (15 sec.) as a self-
monitoring low level limiter with periodic self-checking (SMART) feature.
Application in steam and pressurised hot-water plants in accordance with TRD 604, sheet 1 and
sheet 2 (24 h/72 h operation) as well as EN 12952 and EN 12953.
The electrical equipment meets the requirements of the Regulations on Protection Circuits EN 50156-1.
Design
NRG 16-11S
End connection: Flanged PN 40, DN 50
Electrical connection: Four-pole connector

6
NRG 16-11S
Type approval
SEE-BG GL-WB-93-349001
GL 88091 HH
RINA N° ELE/96695/1
LR 98/20076
BV 10618/Bo
KR HMB06190-MS001
NKK 02A 012
Service pressure
NRG 16-11S: 32 bar at 238°C
Connection
Flange, PN 40, DN 50
Materials
Flange: 1.0460 C22.8
Measuring electrode: 1.4401, X5CrNiMo17-12-2
Electrode insulation: Gylon®
Four pole connector: Polyamid (PA)
Lengths available
500 mm, 1000 mm, 1500 mm, 2000 mm
Cell constant C
0.13 cm-1 with measuring surface extension
0.3 cm-1 without measuring surface extension
Response sensitivity
10 µS/cm at 25 °C, cell constant 0.3 cm-1
0.5 µS/cm at 25 °C, cell constant 0.13 cm-1
Electrical connection
Four-pole connector, cable gland M 16
Protection
IP 65 to EN 60529
Max. admissible ambient temperature
70 °C
Weight
Approx. 6.0 kg
Technical Data
Gylon®is a registered trademark of Garlock Sealing Technologies, Palmyra NY, USA

7
Corrosion resistance
Provided that the equipment is used for its intended purpose, its safety is not impaired by
corrosion.
Sizing
The body must not be subjected to sharp increases in pressure. Welds and flanges of the electrode are
designed to withstand dynamic loading (bending and alternating stress). The dimensional allowances
for corrosion and anti-corrosive additives reflect the latest state of technology.
Technical Data – continued –
Name plate / marking
Equipment designation
Fig. 1
Fig. 2

8
Technical Data – continued –
Dimensions NRG 16-11S
Fig. 3
NRG 16-11S for marine applications
200
45
≥500

9
Fig. 4
Design
1
5
7
2
3
4
6
NRG 16-11S
Fig. 5
8
9
80
!

10
Fig. 6
(
/
%
$
"
§
9
&
Functional Elements
NRG 16-11S

11
1Electrode rod
2Bore
3Spring
4Electrode tip
5Grub screw
6Disk (Measuring surface extension)
7Retaining ring
8Flange seal
9Upper part of terminal box
0Seating surface
!Connecting standpipe
"Screw M 4
§Cover
$Connection plate
%Sealing element
&Contact plate for level electrode
/Cable clamp
(Cable gland M 16 (PG 9)
Design / Functional Elements – continued –
Key

12
Attention
■Do not bend the electrode tip when mounting.
■Do not lag the electrode body.
■Provide a min. spacing of 14 mm between electrode and earth (flange, boiler wall),
Fig. 7, Fig. 8
■Observe the minimum distances for the installation of the electrode.
Installation
NRG 16-11S, step 1
1. Screw electrode tip 4into measuring electrode 1, Fig. 4
2. Carefully determine required measuring length, taking minimum length into account.
3. Mark length of electrode tip 4.
4. Unscrew electrode tip 4from measuring electrode 1and cut tip.
5. Screw electrode tip 4into measuring electrode 1and tighten. Slide spring 3along electrode
tip 4, so that its bent end completely enters into small bore 2.
6. Slip disk 6onto electrode tip 4ensuring that the electrode tip protrudes 2 mm from disk.
Fasten disk with grub screw 5. Push retaining ring 7from below over electrode tip against disk 6.
NRG 16-11S, step 2
1. Check seating surfaces of flange provided on boiler standpipe.
2. Place flange seal 8onto the connecting standpipe !, Fig. 5
3. Mount level electrode onto the connecting standpipe and fasten with bolts.
4. Tighten bolts uniformly in diagonally opposite pairs.
Important notes
■For the approval of the boiler standpipe observe the relevant regulations.
■For typical installation examples refer to page 13 and 14.
Tools
■Scriber
■Hacksaw
■Flat file, cut 2, DIN 7261, form A

13
Examples of Installation
NRG 16-11S
DN 20
Fig. 8
≤20
Centre distance
DN 20
DN 20
b
c
f
=
a
c
d
e
g
f
DN 50
≤3000
∅20
≤90°
∅20
≥ 14
≥10
Fig. 7
)

14
)Flange PN 40, DIN 2501-1
=For the approval of the boiler standpipe the relevant regulations must be considered.
aVent hole Provide bore as close as possible to the boiler wall!
bHigh water HW
cElectrode rod d = 8 mm
dProtection tube DN 80
eElectrode distance ≥ 14 mm (creepage distances and clearances)
fLow water LW
gReducer DIN 2616-2, K-88.9 x 3.2 – 42.4 x 2.6 W
Examples of Installation – continued –
Key
NRG 16-11S
Electrical connection via four pole connector.
Note that screened four-core cable, e. g. I-Y(St)Y 2 x 2 x 0.8 or LIYCY 4 x 0.5 mm² is required for wiring
the electrode.
Max. length 100 m with conductivites from 10 µS/cm.
Max. length 30 m with conductivites from 0.5 µS/cm.
Max. length 15 m with conductivites from 0.5 µS/cm and application of the ancillary unit URN 1
(24 V DC).
1. Unscrew screw ",Fig. 6
2. Take the terminal box off the level electrode, leaving the sealing element %on the contact
plate &.
3. Remove cover §.
4. Press connecting plate $out of the upper part of the terminal box 9.
The upper part of the terminal box can be turned in steps of 90°.
5. Detach cable gland (and cable clamp /from the upper part of the terminal box 9.
6. Run cable through cable gland (and upper terminal box 9and connect the terminals of the
connecting plate $according to the wiring diagram.
7. Press connecting plate $into the upper part of the terminal box and align the cable.
8. Hold cable with cable clamp /and cable gland (in position.
9. Mount cover §and insert screw ".
10. Put upper part of the terminal box onto the level electrode and fix it firmly with screw ".
Electrical Connection

15
U- 1
U1-2
U- 2
NRS 1-7
123
3
2
1
458910 11 12
Electrical Connection – continued –
Wiring diagram
Fig. 9
U- 1
U1-2
U- 2
3
2
1
NRS 1-7
1234 568910 11 12
Fig. 10
This wiring diagram is only valid for France.
Fig. 11
NRG 16-11S
NRG 16-11S
NRG 16-11S

16
Apply mains voltage to level switch NRS 1-7.
Commissioning
Check whether the NRG 16-11S and the associated controller NRS 1-7 are wired in accordance with
the wiring diagram. Fig. 9, Fig. 10
Check wiring
Apply mains voltage
Electrical Connection – continued –
Tools
■Screwdriver for cross-recess head screws, size 1
■Screwdriver for slotted screws, size 2.5, completely insulated according to DIN VDE 0680-1
■Open-end spanner A. F. 18 (19)
Voltage table
Use this voltage table as a reference when checking whether the level electrode is submerged or if
there is a malfunction. Please take the wiring diagram of the electrode NRS 1-7 into account.
Fig. 9, Fig. 10
U1-2
U1-⊥U2-⊥
submerged exposed malfunction (submerged/alarm)
10 Veff 0.5 µS/cm,
C = 0.13 cm-1
2 Veff 10 µS/cm,
C = 0.3 cm-1
< U1-2
2
≥ U1-2
2 ≤ U1-⊥
Note
■The self-checking routine of the amplifier NRS 1-7 reduces U1-2 every 40 seconds to
0 volt!

17
Operational Malfunctions
Fault-finding list for troubleshooting
Level electrode submerged – low-level alarm
Fault: Mains voltage is not applied to level switch.
Remedy: Apply mains voltage. Wire electrode according to wiring diagram.
Fault: The electrode housing does not have earth connection to the boiler.
Remedy: Clean seating surfaces and insert suitable metal joint ring.
Do not insulate level electrode with hemp of PTFE tape.
Fault: The internal insulation of the electrode rod is damaged.
Remedy: Replace level electrode.
Water level below low level limit – no function
Fault: The electrode rods have earth contact.
Remedy: Check and change position of installation.
Fault: The vent hole in the protection tube does not exist, is obstructed or flooded.
Remedy: Check protection tube and, if necessary, provide vent hole.
Fault: The isolating valves of the external measuring pot (optional extra) are closed.
Remedy: Open isolating valves.
If faults occur that are not listed above or cannot be corrected, please contact our Technical Service
or authorized agency in your country.
Operation
Operation in combination with controller NRS 1-7 in steam and pressurised hot water plants to
TRD 401, TRD 602, TRD 604, EN 12952, EN 12953 or other national regulations.
Low-level limiter
Note
■Should malfunctions occur during the commissioning procedure refer to chapter
“Operational Malfunctions” on page 17 in order to analyse and correct them.

18
Disposal
Decommissioning
Remove the level electrode and separate the waste materials in accordance with the material
specification.
For the disposal of the level electrode observe the pertinent legal regulations concerning waste
disposal.
Danger
Risk of severe burns and scalds to the whole body!
Before removing the level electrode make sure that the vessel or measuring pot are
depressurised (0 bar) and cooled down to room temperature (20 °C).

19
For your notes

20
818790-00/108cm
·
2007 GESTRA AG
·
Bremen
·
Printed in Germany
Agencies all over the world:
www.gestra.de
GESTRA AG
Münchener Straße 77
28215 Bremen
Germany
Telefon +49 421 3503-0
Telefax +49 421 3503-393
E-mail [email protected]
Web www.gestra.de
Table of contents
Other GESTRA Laser Level manuals
Popular Laser Level manuals by other brands

TOOLCRAFT
TOOLCRAFT 1377541 operating instructions

Black & Decker
Black & Decker BullsEye BDL190S instruction manual

Johnson
Johnson 40-6646 instruction manual

Dinel
Dinel RFLS-53N instruction manual

Ametek
Ametek DR6300 SERIES Supplementary instructions

TOUGHBUILT
TOUGHBUILT TB-H2-LL-M30-L2 Operating/safety instructions