GESTRA LRG 16-4 Installation instructions

Original Installation &
Operating Manual
850700-00
Conductivity Electrode
LRG 16-4
EN (USA)
English

2LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Contents
Content of this Manual......................................................................................................................... 4
Scope of supply, 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.............................................................................................. 8
Improper use ........................................................................................................................................ 8
Basic safety information ...................................................................................................................... 9
Required personnel qualifications..................................................................................................... 10
Notes on product liability................................................................................................................... 10
Function .............................................................................................................................................. 11
Technical data .................................................................................................................................... 12
Rating plate, identification................................................................................................................. 12
Overall view ........................................................................................................................................ 13
Dimensions ......................................................................................................................................... 14
Preparing for installation ................................................................................................................... 15
Installation.......................................................................................................................................... 16
Installing the LRG 16-4 .................................................................................................................. 17
Installation examples with dimensions............................................................................................. 18
Electrical connection.......................................................................................................................... 19
LRG 16-4 with four-pole connector ................................................................................................ 19
Connecting a conductivity electrode............................................................................................... 20
Bringing into service .......................................................................................................................... 20
Assigning the four-pole connector of the LRG 16-4 ........................................................................ 20
Fault indications and troubleshooting............................................................................................... 21
Indications, diagnosis and corrective action ................................................................................... 21

3LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Contents
Maintenance ....................................................................................................................................... 22
Cleaning the measuring electrode.................................................................................................. 22
Taking out of service.......................................................................................................................... 23
Disposal .............................................................................................................................................. 24
Returning decontaminated equipment.............................................................................................. 24
UL components................................................................................................................................... 24

4LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Content of this Manual
Product:
■ Conductivity Electrode LRG 16-4
First edition:
BAN 850700-00/08-2021cm
© 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
LRG 16-4
1 conductivity electrode LRG 16-4
1 Installation & Operating Manual

5LRG 16-4 - USA - Installation & Operating Manual - 850700-00
How to use this Manual
This Installation & Operating Manual describes the correct use of the LRG 16-4 conductivity
electrode. 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
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 &
Read the relevant
Installation & Operating Manual
Hazard symbols in this Manual
Danger zone, dangerous situation
Operating Manual.
Illustrations and symbols used
1. Action to be taken
2.
■ Lists
◆ Bullet points in lists
A Keys to illustrations
Additional
information

6LRG 16-4 - USA - Installation & Operating Manual - 850700-00
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.

7LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Specialist terms, abbreviations
Here, we explain some abbreviations, specialist terms, etc., which are used in this Manual.
NRGT .. / NRR.. / NRS.. / URS .. / URB .. / SRL .. / etc.
Equipment and type designations of GESTRA AG.
SELV
Safety Extra Low Voltage
Operating point (of the plant)
The operating point describes the operating parameters within which a plant or boiler is operated
in its nominal range. In a steam boiler, for example, these parameters would be output, pressure,
and temperature.
The design data may be a lot more stringent, however.
A boiler that is operated at 145psi (10bar) and 356°F (180°C) may be designed to withstand a
pressure of 870psi (60bar) and a temperature of 527°F (275°C), for example, which is therefore
not necessarily its operating point.

8LRG 16-4 - USA - Installation & Operating Manual - 850700-00
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.
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.
Usage for the intended purpose
The LRG 16-4 conductivity electrode may only be used in conjunction with LRS 1-.. conductivity
switches or LRR 1-.. conductivity controllers for measuring conductivity in liquid conductive media.
The LRG 16-4 conductivity electrode can be used as a conductivity limiter or blowdown controller
in steam boilers in combination with the following equipment:
Conductivity switch LRS 1-50
Conductivity controller LRR 1-50
Conductivity controller LRR 1-52
To ensure perfect function, pay attention to the recommendations of the ABMA & ASME regarding
boiler water limits.
The equipment may only be used within the admissible pressure and temperature ratings.
Applicable directives and standards
The equipment has been tested and approved for use in the scope governed by the following
directives and standards:
Standards:
■ UL 60730-1 and CAN/CSA E60730-1
General Requirements for Automatic Electrical Controls

9LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Danger to life from scalding! Do not remove the conductivity electrode under pres-
sure. Steam or hot water can spurt forcefully out of the equipment.
■ Only remove the conductivity electrode at 0psi (0bar) boiler pressure.
Risk of severe burns! Do not perform work on a conductivity electrode that is still
hot. The conductivity electrode gets very hot during operation.
■ Allow the conductivity electrode to cool down.
■ Always wait for the conductivity electrode to cool before performing any installation
and maintenance work.
There is a risk of electric shock during work on electrical systems.
■ Always switch off the voltage to the plant before performing connection work.
■ Check that the plant is not carrying live voltage before commencing work.
Danger to life! Hot steam or hot water can suddenly escape from a faulty LRG 16-4
conductivity electrode.
Shocks and impacts during transport or installation can result in damage to or leaks in
the conductivity electrode, causing pressurized hot steam or hot water to escape through
the pressure relief hole.
■ To prevent damage during transport and installation, do not expose the electrode
rod to major shocks or impacts.
■ Before and after installation, check that the conductivity electrode is undamaged.
■ When bringing the conductivity electrode into service, check that it is leak-tight.
Attempts to repair the equipment will cause the plant to become unsafe.
■ The LRG 16-4 conductivity electrode may only be repaired by the manufacturer,
GESTRA AG.
■ Only replace faulty equipment with identical equipment from GESTRA AG.
Basic safety information

10 LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Required personnel qualifications
Activity Personnel
Integration in control system Specialist staff Plant designer
Installation/
electrical connection/
bringing into service
Specialist staff
The equipment may only be installed, wired
and brought into service by qualified and
competent staff.
Operation Boiler service technician Staff trained by the plant operator.
Maintenance work Specialist staff
Fitting and maintenance work may only be
performed by authorized staff who have
undergone specific training.
Refits Specialist staff Persons trained by the plant operator to work
with pressure and temperature.
Notes on product liability
The manufacturer cannot accept any liability for damages resulting from improper use of the
equipment.

11LRG 16-4 - USA - Installation & Operating Manual - 850700-00
The LRG 16-4 conductivity electrode is used as a conductivity limiter and blowdown controller in
steam boilers in combination with the following equipment:
Conductivity switch LRS 1-50
Conductivity controller LRR 1-50
Conductivity controller LRR 1-52
In addition, this equipment can monitor conductivity in condensate and feedwater circuits and in
cooling and cleaning water.
In combination with conductivity switches or controllers, the conductivity electrode measures
conductivity in conductive fluids.
In the event of a short circuit or broken wire in the conductivity electrode, an error signal is
generated in the conductivity switch or controller.
Function

12 LRG 16-4 - USA - Installation & Operating Manual - 850700-00
DN NL=
464psi (32 bar)
460°F (238°C)
Tamb = 150°F (70°C)
LRG 16-4
GESTRA AG Münchener Straße 77 28215 Bremen GERMANY
Pmax
Tmax
µS
ppm
Betriebsanleitung beachten
See installation instructions
Voir instructions de montage
3/8-18 NPT 1.4404/F316L IP 65
Mat-Nr.:
Input voltage: Up to 5VAC
Ambient temperature: 32-158°F (0-70°C)
Environmental rating: NEMA 1
Wiring: Use Copper Conductors Only,
use 60/75°C Conductors
Use with accessory:
LRS 1-50, LRR 1-50, LRR 1-52
OPERATING CONTROL
E513189
Service pressure
464psi at 460°F (32bar at 238°C)
Mechanical connection
Thread 3/8” 18 NPT
Materials
Screw-in body 1.4404 / F316L
Measuring electrode 1.4571, X6CrNiMoTi17-12-2
Insulation PTFE
Four-pole connector polyamide (PA)
Electrode length
3.94, 11.81, 15.75, 19.69, 23.62, 31.5, 39.37 and 47.24in
(100, 300, 400, 500, 600, 800, 1000 and 1200mm)
Cell constant
1 cm-1
Electrical connection
Four-pole connector, cable glands M 16
Protection
IP 65 according to DIN EN 60529
NEMA Type 1 according to NEMA 250
Admissible ambient temperature
Max. 158°F (70°C)
Weight
Approx. 1.1 lb (0.5 kg)
Other information
Incorporated Type 1 action operating control, passive sensor
Pollution degree 3, impulse voltage 500 V
Technical data
Fig. 1
Equipment designation Safety information
Disposal information
CE marking
Type approval
number
Manufacturer Pressure rating, thread type,
material number, protection
Area of
application
DN of T-type connector
NL = electrode length
Rating plate, identification

13LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Overall view
Fig. 2
Key
AFour-pole connector DElectrode thread
BCable lead-through EMeasuring electrode
CCover tube FEnlarged measuring surface
A
B
C
D
E
F

14 LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Dimensions
Fig. 3
LRG 16-4 with four-pole connector
7.48 in (190 mm)7.48 in (190 mm)
2.76 in (70 mm)
22
3/8” 18 NPT
Thermal insulation
provided on site
0.8 in (20 mm)0.8 in (20 mm)
XX
x = available electrode lengths:
■ 3.94 in (100 mm)
■ 11.81 in (300 mm)
■ 15.75 in (400 mm)
■ 19.69 in (500 mm)
■ 23.62 in (600 mm)
■ 31.50 in (800 mm)
■ 39.37 in (1000 mm)
■ 47.24 in (1200 mm)

15LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Preparing for installation
You will need the following tools:
■Open-ended wrench size 22

16 LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Installation
DANGER
Danger to life! Escaped hot steam can cause scalding.
Hot steam or hot water can escape suddenly if the conductivity electrode is unscrewed
under pressure.
■ Reduce the boiler pressure to 0psi (0bar) and check the pressure before unscrewing
the conductivity electrode.
■ Only remove the conductivity electrode at 0psi (0bar) boiler pressure.
WARNING
The hot conductivity electrode can cause severe burns.
The conductivity electrode gets very hot during operation.
■ Always let the conductivity electrode cool down before performing installation and
maintenance work.
■ Only remove conductivity electrodes that have cooled down.
ATTENTION
Incorrect installation can lead to malfunctions in the plant or the conductivity
electrode.
■ Do not shorten the electrode rod.
■ Take care not to bend the conductivity electrode during installation.
■ Do not subject the electrode rod to hard impacts.
■ Do not install the upper part of the cover tube Cof the electrode in the boiler’s
thermal insulation!
■ Install the conductivity electrode horizontally or inclined. The measuring surface must
be permanently submerged.
■ Leave a distance of approx. ≥ 1.57in (≥ 40mm) between the lower end of the mea-
suring electrode and the boiler wall, the smoke tubes, any other metallic fittings, and
the low water level (LW), see installation example in Fig. 5
■ Installation examples can be found on page 18.

17LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Installation
Installing the LRG 16-4
■ Make sure that the internal and external threads are in perfect condition.
■ Do not apply more than three windings of PTFE insulating tape around the electrode thread.
WARNING
Do not use too much tape. Do not use fitting lubricants or pastes.
■ Fit the electrode and tighten first with your hand and then with a size 41 open-ended wrench. Do
not use a pipe wrench.
■ Recommendations for tightening torques cannot be given due to the conical/parallel type of
connection.
■ Avoid tightening excessively; part of the electrode thread should always remain visible.
The electrode body does not “sit” on the flange, i.e. the underside of the hexagon is not
in contact with the flange (also see Fig. 4). If it is in contact, the internal thread is outside
tolerance. In this case, the flange must be replaced.
After the electrode has been installed with PTFE sealing tape, you must ensure there is adequate
electrical contact between the electrode and the boiler wall.
To do this, after installation measure the resistance between the electrode body and the boiler with
a multimeter.
The reading must be < 10ohms.
If the reading is > 10ohms, connect the electrode to the boiler wall using a band grounding clamp.
(The band grounding clamp is available as an optional accessory)
Next, measure the resistance again.
The value must be < 10ohms and entered as followed:
Measured resistance: __________________________ ohms
Fig. 4
Boiler wall
Visible thread

18 LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Installation examples with dimensions
M
Fig. 5
9
6
For conductivity monitoring, the conductivity electrode is installed directly via a flanged
connection on the side, or is installed in a separate level pot
7
8
LRG 16-4
Fig. 6
For conductivity monitoring and continuous boiler blowdown, the conductivity electrode is
installed in the blowdown line via a separate level pot
0LRG 16-4
Key
6Shut-off valve GAV
7Continuous blowdown valve BAE
8Boiler drum
9Level pot
0Level pot
LW
≥ 100
≥ 40
≥ 40 ≥ 40

19LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Electrical connection
LRG 16-4 with four-pole connector
Fig. 7
aScrew M 4
bCover
cUpper part of connector
dConnection plate!
eInsulating plate
Key
fConductivity electrode contact plate
gCable clamp
hCable gland M 16 (PG 9)
iTerminal assignment
jMeasuring electrode
Tools
■Screwdriver 3/32in (2.4mm)
■Screwdriver 1/8in (3.2mm), fully insulated
31i
h
g
a
b
c
d
e
f
j
Fig. 8

20 LRG 16-4 - USA - Installation & Operating Manual - 850700-00
Connecting a conductivity electrode
Please use a TC-ER control cable with minimum wire size AWG18, e.g., OELFLEX CONTROL
TM CY 3G1 to connect the conductivity electrode.
Connect the shield just once to the central grounding point (CGP) in the control cabinet.
Connect the terminals of the connection plate as shown in Fig. 8.
Cable length between the conductivity electrode and the conductivity switch/controller
max. 98ft (30m), or max. 32ft (10m) with a conductivity of 0.5-5ppm (1-10µS/cm).
Electrical connection
1. Undo the screw a. Fig. 7
2. Remove the upper part c of the connector from the conductivity electrode, leaving the insu-
lating plate eon the contact plate f.
3. Remove the cover b.
4. Press the connection plate dout of the upper part cof the connector.
The upper part of the connector can be turned in increments of 90°.
5. Detach the cable gland hand cable clamp gfrom the upper part cof the connector.
6. Pull the cable through the cable gland hand upper part cof the connector and insert the
terminals of the connection plate das shown in the wiring diagram i.
7. Press the connection plate dinto the upper part of the connector, and correctly align the
cable.
8. Secure the cable with the cable clamp gand cable gland h.
9. Put on the cover band insert the screw a.
10.
Position the upper part of the connector on the conductivity electrode and secure with the
screw a.
11. If you are installing several electrodes in one steam boiler or tank, please indicate the elec-
trode type and function on the four-pole connector.
Assigning the four-pole connector of the LRG 16-4
Attention
■Please pay attention to the Installation & Operating Manuals of the LRS 1-50
conductivity switch and the LRR 1-50 and LRR 1-52 conductivity controllers.
■Route the connecting cable between items of equipment separately from power
lines.
■Check the connection of the shield to the central grounding point (CGP) in the
control cabinet.
Bringing into service