GESTRA TRS 5-8 User manual

1
TRS 5-8
Installation Instructions 810709-02
Temperature Switch
TRS 5-8
GESTRA Steam Systems


2
Contents
Usage for the intended purpose ..............................................................................................................4
Safety note .............................................................................................................................................4
Danger ...................................................................................................................................................4
Attention.................................................................................................................................................4
PED (Pressure Equipment Directive)........................................................................................................4
ATEX (Atmosphère Explosible).................................................................................................................4
Important Notes
Page
Explanatory Notes
Scope of supply ...................................................................................................................................... 4
Description .............................................................................................................................................5
Function .................................................................................................................................................5
System components ...............................................................................................................................5
Design.................................................................................................................................................... 5
TRS 5-8................................................................................................................................................12
Attention...............................................................................................................................................12
Tools.....................................................................................................................................................12
Key.......................................................................................................................................................12
Examples of Installation ........................................................................................................................13
Installation
TRS 5-8..................................................................................................................................................6
Corrosion resistance ...............................................................................................................................7
Name plate/ marking ..............................................................................................................................7
Dimensions.............................................................................................................................................8
Technical Data
TRS 5-8..................................................................................................................................................9
Key.......................................................................................................................................................11
Design
TRS 5-8................................................................................................................................................10
Key.......................................................................................................................................................11
Functional Elements

3
Wiring
TRS 5-8................................................................................................................................................14
Attention...............................................................................................................................................14
Note .....................................................................................................................................................14
Tools.....................................................................................................................................................14
Key.......................................................................................................................................................14
Wiring diagram ..................................................................................................................................... 15
Check wiring ........................................................................................................................................18
Apply mains voltage.............................................................................................................................. 18
Contents - continued -
Commissioning
Page
Temperature controller .........................................................................................................................18
Note .....................................................................................................................................................18
Operation
Danger .................................................................................................................................................19
Fault-finding list for troubleshooting......................................................................................................19
Operation Malfunctions
Danger .................................................................................................................................................20
Disposal................................................................................................................................................20
Decommissioning
TRS 5-8................................................................................................................................................18
Performance test
Declaration of Conformity .....................................................................................................................21
Annex
Basic Settings
Adjusting temperature limit...................................................................................................................16
Example 1 ...........................................................................................................................................16
Example 2 ...........................................................................................................................................16
Example 3 ...........................................................................................................................................16
Tools .................................................................................................................................................... 16
Code switch settings ............................................................................................................................17

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Important Notes
Danger
The terminal strip of the equipment is live during operation.
This presents the danger of electric shock.
Cut off power supply before mounting or removing the terminal strips
and the housing cover.
Usage for the intended purpose
Use temperature switch TRS 5-8 only in conjunction with resistance thermometers TRG 5-53, TRG 5-54,
TRG 5-55 and TRG 5-57 for signalling limit temperature.
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.
Explanatory Notes
Scope of supply
TRS 5-8
1 Temperature switch TRS 5-8
1 Installation manual
ATEX (Atmosphère Explosible)
The equipment constitutes a simple item of electrical equipment as defined in DIN EN 50020 section
5.4. According to the European Directive 94/9/EC the equipment must be equipped with approved
Zener barriers if used in potentially explosive areas. Applicable in Ex-zones 1, 2 (1999/92EC). The
equipment does not bear an Ex-marking. The suitability of the Zener barriers is certified in a separate
document.
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.
PED (Pressure Equipment Directive)
The equipment fulfills the requirements of the Pressure Equipment Directive PED 97/23/EC.
For applications with fluids of group 1 and 2.
With CE marking (apart from equipment according to section 3.3 that is excluded from the scope of this
directive).

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Description
Temperature switch designed for use with resistance thermometers type TRG 5-53, TRG 5-54,
TRG 5-55 or TRG 5-57.
The equipment works as temperature monitor. An alarm is given as soon as the temperature ex-
ceeds a preset limit. Application in steam boilers and pressurized hot-water plants operating without
constant supervision (TRD 604) as well as any other kind of heat generating units.
Explanantory Notes - continued -
Function
The temperature switch TRS 5-8 is a two-channel temperature monitoring system used in conjunction
with a standardized platinum resistance thermometer Pt 100 to IEC 751. A power source fitted with a
variable resistor supplies the resistance thermometer Pt 100 with a constant current.
The desired cut-off temperatures are adjusted by means of an eight-pole code switch. To ensure a fail-
safe alarm signal as soon as the temperature exceeds the max. limit the output contact relays of the
TRS 5-8 are of the normally closed type. In the event of a power supply failure the temperature switch
will raise an alarm.
The temperature switch can signal the following two operating conditions:
■Normal operation (temperatures within permissible range)
■Alarm (temperatures above/below limit)
A green LED indicates mains supply ON. Two red LEDs are illuminated if the temperature exceeds or
falls below the limit.
System components
TRG 5-53
Temperatue sensor with threaded connection piece ½", PN 40
TRG 5-54
Temperatue sensor with threaded connection piece ½", PN 40
TRG 5-55
Temperature sensor with weld-in protection ∅18 mm, PN 160
TRG 5-57
Temperature sensor with weld-in protection ∅18 mm, PN 160
Design
TRS 5-8
Plug-in unit in plastic case for installation in contol cabinets The terminals in the case are accessible
after loosening two screws and unplugging the unit from its base. Thanks to the code plug the
equipment cannot be connected inadvertently to wrong GESTRA equipment. The equipment may be
clipped onto a 35 mm supporting rail or screwed into position on a mounting panel.

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TRS 5-8
Technical Data
Type approval
DIN TW 106807
Input
Connection for resistance thermometer (Pt 100):
TRG 5-5..., PN 40-160, Tmax 400 °C – 540 °C.
Output
2 volt-free relay contacts. Max. contact rating with switching voltages of 24 V, 115 V and 230 V AC:
4 A resistive, 0.75 A inductive at cos ϕ0.5.
Max. contact rating with a switching voltage of 24 V DC: 4 A.
Contact material: silver, hard-gold plated.
Temperature limit range
30 °C to 540 °C, adjustable via code switch in steps of 2 °C.
Switching hysteresis
At MAX limit –5 °C,
At MIN limit 5 °C.
Indicators and adjustors
Two LEDs “Alarm”, one LED “Power”,
one code switch for “MIN temperature”, one code switch for “MAX temperature”.
Mains supply
230 V +/– 10 %, 50/60 Hz.
Special voltages 115 V +/– 10 %, 50/60 Hz or 24 V +/– 10 %, 50/60 Hz.
Power consumption
5 VA
Protection
TRS 5-8 b:
IP 20 to DIN EN 60529
Admissible ambient temperature
0 °C to 55 °C
Body materials
TRS 5-8 b:
Base ABS, black. Cover: Polystyrol, highly shock resistant, stone grey.
Front panel: Aluminium.
Weight
Approx. 0.6 kg

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GESTRA AG
Münchener Str. 77
D-28215 Bremen
Vor Öffnen des Gehäuses
Gerät freischalten
TRS 5-8b
115V24V
Temperaturschalter
230V
50 / 60 Hz 5VA IP 20
Tamb = 55°C (131°F)
Wirkweise Typ 2B
250 V ~ T 2,5 A
Before opening the equipment
cut off power supply.
Avant d'ouvrir l appareil
couper l'alimentation secteur.
'
Temperature switch
Commutateur de température
Corrosion resistance
If the unit is used for the intended purpose, its safety is not impaired by corrosion.
Technical Data - continued -
Name plate/ marking
Fig. 1
Mains supply
Protection
External fuse
Equipment designation

8
Technical Data - continued -
Dimensions
Fig. 2
106 7
Fig. 3
37.5
75
158
95

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Design
Fig. 6
2 3
4
Fig. 4 Fig. 5
DIN TW
106805
TRS 5-8
MADE BY GESTRA
2
256
128
64
32
16
8
4°CMAX
MIN
2
256
128
64
32
16
8
4
°C
1
1
TRS 5-8
7
6
5

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Functional Elements
TRS 5-8
MAX 55°C
MAX 95%
%
IP 20
DIN TW
106805
TRS 5-8
MADE BY GESTRA
2
256
128
64
32
16
8
4°CMAX
MIN
2
256
128
64
32
16
8
4
°C
"
9
0
!
§
Fig. 7

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1 Cover screws
2Base
3Upper part of the housing
4Mounting clip
5Cable entry (flexible)
6Cable entry (housing)
7Fixing holes d = 4.3 mm
8Supporting rail TS 35 x 15 DIN EN 50022
9LED “MAX temperature alarm”
0LED “MIN temperature alarm”
"LED “Power”
"Code switch for MIN temperature setting
§Code switch for MAX temperature setting
Design/Functional Elements
Key

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Tools
■Screwdriver (5.5/ 100)
Attention
■To provide sufficient ventilation, ensure a minimum spacing of 20 mm between
adjacent units.
Installation
TRS 5-8
On supporting rail
1. Clip temperature switch onto supporting rail.
2. Loosen cover screws 1and detach cover 3from its base 2.
3. Select cable entry 5and remove corresponding seal.
On mounting panel
1. Loosen cover screws 1and detach cover 3from its base 2.
2. Unscrew mounting clip 4.
3. Drill hole 7marked in the base to ∅4.3 mm.
4. Select cable entry 5/ 6and remove corresponding seal.
5. Fix base with two M4 screws onto mounting panel.
1 Cover screws
2Base
3Upper part of the housing
4Mounting clip
5Cable entry (flexible)
6Cable entry (housing)
7Fixing holes d = 4.3 mm
8Supporting rail TS 35 x 15 DIN EN 50022
Key

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Installation - continued -
Examples of Installation
C
E
DIN TW
106805
TRS 5-8
MADE BY GESTRA
2
256
128
64
32
16
8
4°CMAX
MIN
2
256
128
64
32
16
8
4
°C
4 2
5
8
6
6
3
1
MAX 55°C
MAX 95%
%
IP 20
Fig. 9
Fig. 8
7
7

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Wiring
TRS 5-8
Note that screened four-core cable, e. g I-IY(St)Y 2 x 2 x 0.8 or LIYCY 4 x 0.5 mm2is required.
Tools
■Screwdriver for slotted screws, size 2.5 completely insulated according to DIN VDE 0680-01
Attention
■To protect the switching contacts fuse circuit with T 2.5 A or according to
TRD-regulations (1A for 72h operation).
■The screen must not make any other electrical contact
Note
■Connect screen only to terminal 10 of the temperature switch.
■The loop resistance must be below 10 Ω.
■The rated voltage is indicated 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 be provided with
commercial arc suppressor RC-combinations, e.g. 0.1 µF/100 W.
$Switching relay for MAX temperature
%Mains
&Switching relay for MIN temperature
/ Terminal, red
( Terminal, red
) Terminal, black
= Terminal, black
a Terminal, red
b Terminal, red
c Terminal, yellow
Key

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Electrical Connection - continued -
Wiring diagram
Fig. 10
Fig. 11
TRG 5-53, TRG 5-54
5
3 6
/
(
5
3
2
6
)
=
a
b
c
Fig. 12
TRG 5-55, TRG 5-57
TRS 5-8
Pt 100
IEC 751
TRG 5-53
TRG 5-54
TRG 5-55
TRG 5-57
°CMIN °CMAX
L N
$%&

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Basic Settings
Adjusting temperature limit
To set the temperature use the 8-pole code switch on the front panel of the TRS 5-8.
Use code switch "to set the min. temperature limit and code switch §to set the max. temperature
limit.
Example 1
A temperature limit is to be set at Tmax = 176 °C.
The code switch indicates eight values from 2 to 256. The basic temperature is 30 °C.
Set the switches 2, 16 and 128 to the left by using a small screwdriver. The sum of the values gives a
temperature of 146 °C.
Plus 30 °C basic temperature makes the requested limit temperature Tmax = 176 °C. Fig. 13
Example 2
A temperature limit is to be set at Tmax = 446 °C.
Set the switches 32, 128 and 256 to the left by using a small screwdriver. The sum of the values gives a
temperature of 416 °C.
Plus 30 °C basic temperature makes the requested limit temperature Tmax = 446 °C.
Example 3
A temperature limit is to be set at Tmax = 79 °C.
Set the switches 16 and 32 to the left by using a small screwdriver.
The values add up to a temperature of 48 °C.
Plus 30 °C basic temperature makes the requested limit temperature Tmax = 78 °C. Note that tempera-
tures can only be adjusted in steps of 2 °C. Fig. 14
Tools
■Screwdriver for slotted screws, size 2.5, completely insulated according to VDE 0680

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Basic Settings - continued -
Code switch settings
Fig. 13 (Example 1) Fig. 14 (Example 3)
30 °C 176
S1 ON 2
S2 OFF 4
S3 OFF 8
S4 ON 16
S5 OFF 32
S6 OFF 64
S7 ON 128
S8 OFF 256
30 °C 78
S1 OFF 2
S2 OFF 4
S3 OFF 8
S4 ON 16
S5 ON 32
S6 OFF 64
S7 OFF 128
S8 OFF 256

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Apply mains voltage to temperature switch TRS 5-8.
Commissioning
Make sure that the TRS 5-8 is wired to its associated temperature sensor as indicated in the wiring
diagram. Fig. 10, Fig. 11, Fig. 12
Check wiring
Apply mains voltage
Performance test
1. When switching on the mains voltage the green LED !must be permanently illuminated.
2. Raise the temperature in the heat generator until the max. temperature limit is exceeded.
The red LED 9of the temperature switch must light up.
3. After lowering the temperature the red LED 9must extinguish.
4. Lower the temperature until it falls below the min. limit.
The red LED 0of the temperature switch must light up.
5. After raising the temperature the red LED 0must extinguish.
TRS 5-8
Operation
Operation only in conjunction with temperature sensors TRG 5-53, TRG 5-54, TRG 5-55 or TRG 5-57 in
(pressurized) hot-water and steam plants to TRD 401, TRD 602, TRD 604, EN 12952, EN 12953.
Temperature controller
Note
■To analyse and remedy malfunctions occurring during the commissioning procedure
refer to section Operational Malfunctions.

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Operation Malfunctions
Fault-finding list for troubleshooting
Normal operation – Temperature switch triggers an alarm
Fault: The temperature switch triggers an alarm during normal operation.
Remedy: Make sure that the green LED is illuminated. If this is not the case check whether the equip-
ment is supplied with mains voltage.
Remedy: Check whether the cable leading to the resistance thermometer is damaged.
Remedy: Check whether the resistance thermometer gives correct readings
(basic values of measuring resistor to DIN EN 60751 for Pt 100).
Danger
The terminal strip of the equipment is live during operation.
This presents the risk of severe cases of electric shock!
Cut off power supply before mounting or removing the terminal strips and the housing
cover.
If faults occur that are not listed above or cannot be corrected, please contact our service centre or
authorized agency in your country.

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Disposal
Decommissioning
Dismantle the equipment and separate the waste materials, using the material specification as a
reference.
Electronic component parts such as the circuit board must be disposed of separately! For the disposal
of the equipment observe the pertinent legal regulations concerning waste disposal.
Danger
The terminal strip of the equipment is live during operation.
This presents the risk of severe cases of electric shock!
Cut off power supply before mounting or removing the terminal strips and the housing
cover.