GESTRA LRG 16-4 Service manual

1
LRG 16-4
Installation Instructions 818854-01
Conductivity Electrode LRG 16-4
GESTRA Steam Systems
EN
English

2
Contents
Page
Important notes
Usage for the intended purpose...............................................................................................................4
Function..................................................................................................................................................4
Safety note..............................................................................................................................................5
Directives and standards
EC Pressure Equipment Directive 97/23/EC.............................................................................................6
VdTÜV Bulletin "Water Monitoring 100"...................................................................................................6
ATEX (Atmosphère Explosible) .................................................................................................................6
Note on the Declaration of Conformity / Declaration by the Manufacturer ..........................................6
Technical data
LRG 16-4 ................................................................................................................................................7
Scope of supply ......................................................................................................................................7
Name plate / marking .............................................................................................................................7
Installation
Dimensions LRG 16-4 .............................................................................................................................8
Mounting conductivity electrode..............................................................................................................9
Key .........................................................................................................................................................9
Tools.......................................................................................................................................................9
Examples of installation
LRG 16-4 ..............................................................................................................................................10
Key .......................................................................................................................................................11
Electrical connection
LRG 16-4 with four-pole connector .......................................................................................................12
Key .......................................................................................................................................................12
Tools.....................................................................................................................................................12
Connecting the conductivity electrode...................................................................................................13
LRG 16-4, connecting the four-pole connector .....................................................................................13
Troubleshooting
Indication, diagnosis and remedy ..........................................................................................................14

3
Contents
Page
- continued -
Maintenance
Safety note............................................................................................................................................15
Cleaning measuring electrode...............................................................................................................15
Removing and disposing of the conductivity electrode
Remove and discard conductivity electrode LRG 16-4. ..........................................................................15

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Important notes
Usage for the intended purpose
The conductivity electrode LRG 16-4 together with the conductivity switch LRS 1-.. or conductivity
controller LRR 1-.. is designed for measuring and monitoring electrical conductivity in conductive
fluids.
If used as conductivity limiter or continuous blowdown controller in steam boilers, the conductivity
electrode LRG 16-4 can be used with the following equipment:
Conductivity switch LRS 1-50
Conductivity controller LRR 1-50
Conductivity controller LRR 1-52
To guarantee a trouble-free operation observe the requirements made on water as specified in the
pertinent TRD and EN regulations.
The equipment must only be used within the admissible pressure and temperature ratings.
Function
The conductivity electrode LRG 16-4 is used in combination with the following equipment as conductivity
limiter and continuous blowdown controller in steam boilers:
Conductivity switch LRS 1-50
Conductivity controller LRR 1-50
Conductivity controller LRR 1-52
In addition the equipment can monitor conductivity in condensate and feedwater systems and in cooling
and cleaning water.
The conductivity electrode works according to the conductivity measurement principle and, in conjunc-
tion with conductivity switches or controllers, monitors the conductivity in conductive fluids.
A short circuit or wire breakage in the conductivity electrode will trigger an error message in the con-
ductivity switch or controller.

5
Important notes
Attention
The name plate specifies the technical features of the equipment. Do not commission or
operate any item of equipment that does not bear its specific name plate.
Safety note
Danger
When loosening the conductivity electrode steam or hot water might escape!
This presents the risk of severe scalding all over the body!
It is therefore essential not to dismantle the conductivity electrode unless the boiler
pressure is verified to be 0 bar.
The conductivity electrode becomes hot during operation.
Risk of severe burns to hands and arms.
Before carrying out installation and maintenance work make sure that the equipment is
cold.
The equipment must only be installed, wired 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.
- continued -

6
Directives and standards
VdTÜV Bulletin "Water Monitoring 100"
The conductivity electrode LRG 16-4 in conjunction with the following conductivity switches and
controllers is type approved according to VdTÜV Bulletin "Water Level 100": LRS 1-50, LRR 1-50 and
LRR 1-52.
The VdTÜV Bulletin "Water Monitoring 100" states the requirements made on water monitoring
equipment.
ATEX (Atmosphère Explosible)
The conductivity electrode LRG 16-4 is a simple item of electrical equipment as specified in
EN 60079-11 section 5.7. 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 (1999/92/EC). The equipment is not Ex marked.
The suitability of the Zener barriers is certified in a separate wiring diagram provided by the
manufacturer.
Note on the Declaration of Conformity / Declaration by the Manufacturer
For details on the conformity of our equipment according to the European Directives see our Declaration
of Conformity or our Declaration of Manufacturer.
The current Declaration of Conformity and Declaration of Manufacturer are available in the Internet under
www.gestra.com documents
or can be requested from us.
EC Pressure Equipment Directive 97/23/EC
The conductivity control and monitoring equipment LRG 1.-.., LRS 1-.., LRR 1-5. meet the safety re-
quirements of the Pressure Equipment Directive (PED). The conductivity control & monitoring equipment
is EC type approved according to EN 12952/EN 12953. These Directives state, among other things, the
requirements made on limiting systems and equipment for steam boiler plants and (pressurised) hot-
water installations.

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LRG 16-4
Service pressure
PN 40, 32 bar at 238°C
Mechanical connection
Screwed G 3/8A, ISO 228
Materials
Screw-in body: 1.4571, X6CrNiMoTi17-12-2
Measuring electrode: 1.4571, X6CrNiMoTi17-12-2
Insulation PTFE
Four-pole connector: polyamide (PA)
Length of measurement & installation
100, 300, 400, 500, 600, 800, 1000 and 1200 mm
Cell constant
1 cm-1
Electrical connection
Four-pole connector, cable gland M 16
Protection
IP 65 to DIN EN 60529
Admissible ambient temperature
Max. 70°C
Weight
Approx. 0.5 kg
Approvals:
TÜV certificate VdTÜV Bulletin "Wasserüberwachung 100" (= Water Monitoring 100):
Requirements made on water level monitoring equipment
Type approval no. TÜV . WÜL . 12-017, 12-018 (see name plate)
Technical data
Name plate / marking
Fig. 1
LRG 16-4
1 Conductivity electrode LRG 16-4
1 Joint ring 17 x 21, form D, DIN 7603, 1.4301, bright annealed
1 Installation manual
Scope of supply
Mat-Nr.:
DN NL=
TÜV . WÜL . 12 - 017 / 12 - 018
32 bar (464psi)
238°C (460°F)
T amb = 60°C (140 °F)
LRG 16-4
GESTRA AG Münchener Straße 77 D-28215 Bremen
Pmax
Tmax
µS
ppm
Betriebsanleitung beachten
See installation instructions
Voir instructions de montage
PN 40 G 3/8 1.4571 IP 65
Equipment designation Safety note
Disposal note
CE Marking
Type approval no.
Manufacturer Pressure rating, thread type,
material number, protection
Application
range
DN of T-type connector
NL = Measuring length and length of
installation

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Installation
Dimensions LRG 16-4
Ra 3.2
0.5
∅ 23
G
3/8
A, ISO 228
Ra 12.5
Fig. 3
Fig. 4 LRG 16-4 with T-type connector
170
DN ABC
15 118 95 16
20 129 105 18
25 137 115 18
40 180 150 18
B
A
C
B
C
Fig. 2
LRG 16-4 with four-pole connector
1
2
3
4
Screwed G 3/8A,
ISO 228
190
70
22

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Note
For the approval of the boiler standpipe the relevant regulations must be considered.
Refer to pages 10 and 11 for typical installation examples.
If installed outdoors the level electrode must be equipped with a GESTRA weather
protection cover.
Installation
Attention
Install conductivity electrode horizontally or with a vertical inclination. The measuring
surface must be permanently submerged.
The seating surfaces of the standpipe or the flange provided on the vessel must be
accurately machined, see Fig. 3 .
Do not subject measuring electrode to physical shocks.
 Use only the supplied ring joint 17 x 21, form D, DIN 7603, made from 1.4301, bright
annealed!
Do not lag electrode body above the hexagonal section.
Do not insulate electrode thread with hemp or PTFE tape!
Do not apply conductive paste or grease to the electrode thread!
Provide a spacing of approx. 40 mm between the lower end of the measuring elec-
trodes and the boiler wall, the smoke tubes and any other metallic fittings and the low
water level (LW).
Observe the specified tightening torque.
Key
1Measuring length and length of installation
2Thermal insulation, provided on site, d = 20 mm,
(outside of thermal insulation of steam boiler)
Mounting conductivity electrode
1. Check seating surfaces. Fig. 3
2. Place the supplied ring joint 4onto the seating surface of the threaded standpipe or flange.
3. Apply a light smear of heat resistant silicone grease (e. g. WINIX® 2150) to the electrode thread 3.
4. Screw conductivity electrode into threaded standpipe and tighten with an open-end spanner
A. F. 22 mm. The torque required when cold is 63 Nm.
Tools
Open-end spanner 22 mm A. F.
3Electrode thread G 3/8A, ISO 228
4Joint ring 17 x 21,
form D, DIN 7603, 1.4301, bright annealed
- continued -

10
M
NW
LW
NB
R*
Examples of installation
LRG 16-4
Conductivity monitoring and continuous boiler blowdown, direct installation of conductivity
electrode via T-type connector and connection of a continuous blowdown valve
Fig. 5
LRG 16-4
8
6
7
G 3/8A, ISO 228
4
R*: 40 mm
A
~ 250
170
8
5
M
Fig. 6 9
6
Conductivity monitoring, direct installation of conductivity electrode via flanged standpipe on the side of
the boiler or installation of electrode in an external level pot
≥ 40
≥ 100
≥ 40 ≥ 40
7
LW
8
LRG 16-4

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Examples of installation
LRG 16-4
Key
4Joint ring 17 x 21,
form D, DIN 7603, 1.4301, bright annealed
5T-piece connector
6Shut-off valve GAV
7Continuous blowdown valve BAE
8Boiler drum
9Level pot 3 MF 88.0
0Level pot 4 DB 372
Fig. 7
Conductivity monitoring and continuous boiler blowdown, installation of conductivity electrode in top
blowdown line via separate level pot
0LRG 16-4
- continued -
- continued -

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Electrical connection
LRG 16-4 with four-pole connector
Fig. 8
aScrews M 4
bCover
cUpper part of terminal box
dConnecting plate!
eInsulating plate
Key
fContact plate of conductivity electrode
gCable strain relief
hCable gland M 16 (PG 9)
iWiring of terminals
jMeasuring electrode
Tools
Screwdriver, size 1
Screwdriver, size 2.5, completely insulated according to DIN VDE 0680-1
31i
h
g
a
b
c
d
e
f
j
Fig. 9

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Connecting the conductivity electrode
To connect the conductivity electrode use screened multi-core control cable with a min. conductor size
0.5 mm², e.g. LiYCY 3 x 0.5 mm² .
Connect the screen only once to the central earthing point (CEP) in the control cabinet. Wire the
terminals on the connecting plate according to Fig. 9.
Max. cable length between conductivity electrode and controller: 30 m, with conductivities from
1 to 10 μS/cm: max. 10 m.
Electrical connection
1. Loosen screws a. Fig. 8
2. Remove upper part c of the terminal box from the level electrode but leave insulating plate eon
contact plate f.
3. Remove cover b.
4. Press connecting plate dout of the upper part of the terminal box c.
The upper part of the terminal box can be turned in steps of 90°.
5. Detach cable gland hand cable strain relief gfrom upper part cof the terminal box.
6. Run cable through cable gland hand upper part of the terminal box cand wire terminals of the
connecting plate din accordance with wiring diagram i.
7. Press connecting plate dinto the upper part of the terminal box and align cable.
8. Fix cable with cable strain relief gand cable gland h firmly into position.
9. Replace cover band insert screw a.
10. Put upper part of the terminal box onto the level electrode and fix it with screw a.
11. If several electrodes are installed in a steam boiler or vessel, please note the type of electrode and
its function on the four-pole connector.
LRG 16-4, connecting the four-pole connector
Attention
Please observe the installation & operating manuals for the conductivity switch
LRS 1-50 and the conductivity controllers LRR 1-50 and LRR 1-52.
Make sure that connecting cables leading to the equipment are segregated and run
separately from power cables.
Check the connection of the screen to the central earthing point (CEP) in the control
cabinet.
- continued -

14
Attention
Before carrying out the fault diagnosis please check:
Supply voltage:
Is the conductivity switch / controller supplied with the mains voltage specified on the name
plate?
Wiring:
Is the wiring in accordance with the wiring diagram?
Troubleshooting
Indication, diagnosis and remedy
Conductivity switch / controller does not work
Error Remedy
Power failure. Switch on supply voltage. Check all electrical connections.
The earth connection to the vessel is interrupted.
Clean seating surfaces and screw in the conductivity
transmitter together with the joint ring 17 x 21, form D,
DIN 7603 (made from 1.4301), bright annealed. Do not
insulate the electrode with hemp or PTFE tape!
Conductivity electrode defective, measured value too
low. Electrode lines interrupted or measuring surface
exposed.
Check connection of electrode lines. If necessary, replace
equipment. Check water level and installation.
Conductivity electrode defective, measured value too
high. Short circuit in electrode lines.
Check connection of electrode lines.
If necessary, replace equipment.
Malfunctions
Conductivity switch / controller does not work accurately.
Error Remedy
Indicated conductivity reading is larger than the
measured reference value. Reduce the correction factor CF.
Indicated conductivity reading is smaller than the
measured reference value. Increase the correction factor CF.
Measuring result cannot be adjusted by changing the
correction factor.
Remove conductivity electrode and clean measuring
surface.
Attention
For commissioning and troubleshooting also observe the installation & operating
manuals for LRS 1-50, LRR 1-50 and LRR 1-52.

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If faults occur that are not listed above or cannot be corrected, please contact our service centre or
authorized agency in your country.
Cleaning measuring electrode
1. Loosen screws a. Fig. 8
2. Detach upper part of the terminal box cfrom the conductivity electrode.
3. Before removing the equipment make sure that is is neither hot nor under pressure.
Cleaning the measuring electrode (measuring surface):
Wipe off non-adhesive deposits with a grease-free cloth.
To remove adhesive deposits use emery cloth (medium grain).
Re-install the conductivity electrode. Observe the notes given in section "Installation" and "Electrical
Connection".
Maintenance
Safety note
Danger
When loosening the conductivity electrode steam or hot water might escape!
This presents the risk of severe scalding all over the body!
It is therefore essential not to dismantle the conductivity electrode unless the boiler
pressure is verified to be 0 bar.
The conductivity electrode becomes hot during operation.
Risk of severe burns to hands and arms.
Before carrying out installation and maintenance work make sure that the equipment is
cold.
The equipment must only be installed, wired 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.
Removing and disposing of the conductivity electrode
Remove and discard conductivity electrode LRG 16-4.
1. Loosen screw i. Fig. 22
2. Detach upper part of the terminal box kfrom the conductivity electrode.
3. Before removing the equipment make sure that is is neither hot nor under pressure.
For the disposal of the equipment observe the pertinent legal regulations concerning waste disposal.

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818854-01/05-2013cm (808793-01) · GESTRA AG · Bremen · Printed in Germany
GESTRA
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