GESTRA URB 60 User manual

Original Installation &
Operating Manual
Visual Display and Operating Unit
URB 60
819699-00
EN
English

2URB 60 - Installation & Operating Manual - 819699-00
Contents
Content of this Manual....................................................................................................................................5
Scope of delivery/Product package................................................................................................................5
How to use this Manual...................................................................................................................................6
Illustrations and symbols used.......................................................................................................................6
Hazard symbols in this Manual.......................................................................................................................6
Types of warning .............................................................................................................................................7
URB 60 specialist terms and abbreviations ...................................................................................................8
Usage for the intended purpose.................................................................................................................... 11
IT security and rules for the use of Ethernet devices .................................................................................11
Applicable directives and standards..........................................................................................................11
Improper use .................................................................................................................................................12
Basic safety notes .........................................................................................................................................12
Required personnel qualifications................................................................................................................13
Notes on product liability..............................................................................................................................13
Function .........................................................................................................................................................14
Limitations................................................................................................................................................14
Technical data ...............................................................................................................................................15
Factory settings.............................................................................................................................................16
Name plate/identification..............................................................................................................................17
Dimensions of the URB 60.............................................................................................................................18
Installation instructions ................................................................................................................................18
Ports and sockets on the URB 60..................................................................................................................19
Connecting the supply voltage......................................................................................................................20
Connecting the CAN bus system...................................................................................................................20
Bus line, cable length and cross-section ................................................................................................... 20
Important notes on connecting the CAN bus system..................................................................................21
Pin assignment of the CAN bus connector and coupling for non pre-wired
control cables...........................................................................................................................................22
Operation and navigation..............................................................................................................................23
User interface (example) ...........................................................................................................................23
Operation..................................................................................................................................................23
Colour coding of input and status fields ....................................................................................................24
Automatic functions..................................................................................................................................24
Entering parameters using the virtual keypad ...........................................................................................25
Entering parameters with multilevel password security.............................................................................25
Scroll bar for long lists and menus............................................................................................................26
General recurring icons and functions....................................................................................................... 26

3URB 60 - Installation & Operating Manual - 819699-00
Contents
Starting up for the first time .........................................................................................................................27
Setup Wizard settings ............................................................................................................................... 27
Bringing the boiler, feedwater/condensate tank into service (Group 1..3) .................................................28
Home screen.................................................................................................................................................. 29
Alarms and error messages.......................................................................................................................... 31
Opening the Alarm History - the complete list of all alarms .......................................................................32
Opening the alarm and error list automatically ..........................................................................................32
System settings.............................................................................................................................................33
Viewing CAN bus nodes.................................................................................................................................34
Setting the date/time.....................................................................................................................................35
Password .......................................................................................................................................................35
Network settings ...........................................................................................................................................36
Remote maintenance/software.....................................................................................................................36
Device settings ..............................................................................................................................................37
System information .......................................................................................................................................39
Selecting the language..................................................................................................................................40
Configuring the level controller .................................................................................................................... 41
Testing the relays of the connected level controller ................................................................................... 42
Pump control ............................................................................................................................................42
Setting manual control or the control point for manual pump operation.....................................................43
Switching actuator operation between automatic and manual...................................................................43
Valve calibration in manual mode when a feedback potentiometer is connected to the NRR 2-60 ............44
Calibrating the boiler level ........................................................................................................................45
Setting the level controller ........................................................................................................................ 46
Guide to setting control parameters ..........................................................................................................46
Setting the level controller for 3-component control..................................................................................47
Configuring the conductivity controller........................................................................................................48
Standby mode ..........................................................................................................................................49
Testing the relays of the connected conductivity controller........................................................................49
Continuous blowdown valve...................................................................................................................... 50
Continuous blowdown valve - Calibrating the feedback potentiometer for the valve position display .........51
Setting the intermittent blowdown and automatic flush function ...............................................................52
Setting a correction factor and temperature compensation for the current conductivity reading ................53
Setting safety parameters.........................................................................................................................54
Setting the control parameters..................................................................................................................55
Guide to setting control parameters ..........................................................................................................55

4URB 60 - Installation & Operating Manual - 819699-00
Contents
Opening the limiter overview ........................................................................................................................56
Setting safety parameters.........................................................................................................................57
Testing the limiter.....................................................................................................................................58
System malfunctions.....................................................................................................................................59
Display of system malfunctions in the alarm and error list using fault codes .............................................59
Fault codes for the URS 60/URS 61 safety control unit .........................................................................59
Fault codes for the NRR 2-60 / NRR 2-61 level controller,
LRR 1-60 conductivity controller and URW 60 universal converter........................................................ 60
Common faults during use........................................................................................................................ 62
What to do in the event of system malfunctions..........................................................................................62
Checking installation and function ............................................................................................................62
Data exchange via Modbus TCP ...................................................................................................................63
Taking out of service.....................................................................................................................................63
Disposal .........................................................................................................................................................63
Returning decontaminated equipment.........................................................................................................64
EU Declaration of Conformity........................................................................................................................ 64

5URB 60 - Installation & Operating Manual - 819699-00
Content of this Manual
Product:
Visual Display and Operating Unit URB 60
First edition:
BAN 819699-00/08-2019cm
Applicable documents:
Eaton®Installation Manual MM/YY IL048007ZU
© Copyright
All rights reserved. Any misuse, particularly reproduction and dissemination to third parties, is not permit-
ted. The General Terms & Conditions of GESTRA AG apply.
Scope of delivery/Product package
 1 x URB 60 visual display and operating unit
 6 x retaining clips
 1 x power supply connector
 1 x URB 60 data cable with integrated 120 Ω terminating resistor
 1 x Eaton®Installation Manual MM/YY IL048007ZU
 1 x Installation & Operating Manual

6URB 60 - Installation & Operating Manual - 819699-00
How to use this Manual
This Installation & Operating Manual describes the correct use of the URB 60 visual display and operating
unit. It applies to all 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 equipment 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 & 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

7URB 60 - Installation & Operating Manual - 819699-00
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.

8URB 60 - Installation & Operating Manual - 819699-00
URB 60 specialist terms and abbreviations
Here, we explain some abbreviations, specialist terms, etc., which are used in this Manual.
CAN (Controller Area Network) bus
Data transmission standard and interface for connecting electronic equipment, sensors and control systems.
Data can be sent and received.
NRG .. / URS .. / URB ... / SRL ... / NRS.. / etc.
Equipment and type designations of GESTRA AG.
SELV
Safety Extra Low Voltage
SIL (safety integrity level)
Safety integrity levels SIL 1 to 4 are used to quantify risk reduction. SIL 4 is the highest level of risk reduc-
tion. International standard IEC 61508 forms the basis for establishing, testing and operating technical
safety systems.
Continuous blowdown
As the boiler water begins to evaporate, the concentration of non-volatile dissolved solids (TDS) left
behind in the boiler increases over time as a function of steam consumption. If the TDS (= total dissolved
solids) concentration exceeds the limit defined by the boiler manufacturer, foaming and priming occur as
the density of the boiler water increases, resulting in the carry-over of solids with vapour into steam and
superheater lines.
The consequences are adverse effects on reliability and severe damage to steam generating units and
pipes.
To keep the TDS concentration within admissible limits, a certain portion of boiler water must be removed
continuously and/or periodically (by means of a continuous blowdown valve) and the boiler must be
replenished with fresh feedwater to compensate for the water lost through blowdown.
Intermittent blowdown
During the evaporation process, fine sludge is deposited on heating surfaces and on the floor of the steam
generating unit. The accumulated sludge sediments form a thermally insulating layer and can damage the
boiler walls due to excessive heat.
Intermittent blowdown is achieved by the abrupt opening of the intermittent blowdown valve. The result-
ing suction effect occurs only at the moment the valve is first opened. The opening time should therefore
not exceed about 2 seconds. Longer opening times result in a loss of water.
Time-based pulse/interval actuation of the intermittent blowdown valve optimises the removal of sludge
from the boiler. The interval between the intermittent blowdown pulses can be set between 1 and 120
hours (intermittent blowdown interval). The duration of intermittent blowdown can be set between 1 and
60 seconds.
For large boilers, repeated intermittent blowdown pulses may be required. Repetition can be set between 1
and 5 (intermittent blowdown pulses) with an interval from 5 – 30 seconds (pulse interval).

9URB 60 - Installation & Operating Manual - 819699-00
URB 60 specialist terms and abbreviations
Damping (filter constant, conductivity and level control)
This parameter is used to settle the oscillations of the input signal.
Standby mode (conductivity control)
To prevent loss of water, continuous blowdown control and automated intermittent blowdown
(if enabled) can be disabled in standby mode or when the burner is switched off.
The continuous blowdown valve moves to CLOSED position, triggered by an external control command. In
standby mode, the “MIN/MAX” limits and monitoring functions remain active. When the equipment is back
in normal mode, the continuous blowdown valve returns to the control position.
An intermittent blowdown pulse is also triggered (if automated intermittent blowdown is enabled and a
blowdown interval and blowdown time have been set).
Cell constant (conductivity control)
The cell constant is a geometric variable of the conductivity electrode and is taken into account when
calculating the conductivity. However, this constant may change during operation, e.g. due to dirt deposits
on the measuring electrode.
If a reference measurement yields a result that differs from the indicated conductivity value, first check
the temperature compensation.
Modify the cell constant only if the temperature coefficient setting is no longer adequate for correct com-
pensation. In this case, change the cell constant until the reading and the indicated conductivity match.
Flushing the continuous blowdown valve (conductivity control)
The continuous blowdown valve can be flushed automatically to prevent it from sticking. In this case, the
continuous blowdown valve is actuated at the flushing interval and opened for a defined flushing time.
After the flushing time, the valve moves to the position set by the control.
RefReading (reference reading)
The reference reading is the conductivity of the boiler water directly measured by the boiler service
technician. Using this parameter, the measured conductivity can be entered and the correction factor
automatically calculated (within its limits). This is then copied to the conductivity electrode and stored, so
that conductivity is then adjusted to the correct level.
Abbreviations for safety electrodes:
 SLLL = safety low-level limiter
 STL = safety temperature limiter
 SHLL = safety high-level limiter
 SCL = safety conductivity limiter

10 URB 60 - Installation & Operating Manual - 819699-00
URB 60 specialist terms and abbreviations
Control direction
The control direction indicates whether control is for supplying (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 46/55, 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 46/55, guide to setting control parameters.
Neutral zone
If the actual value reaches the (setpoint +/- of the neutral zone), the control point does not
change in this range.
Forced switchover
This parameter defines the level at which an automatic change of pump must take place. The assumption
here is that since the level cannot be maintained, the pump is faulty.