GESTRA TRV 5-60 Installation instructions

Installation & Operating Manual
819633-01
Temperature Transmitter
TRV 5-60
EN
English

2TRV 5-60 - Installation & Operating Manual - 819633-01
Contents
Content of this Manual....................................................................................................................................4
Scope of delivery/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
Admissible system components, dependent on the required safety integrity level .......................................8
Improper use ...................................................................................................................................................9
Basic safety notes ...........................................................................................................................................9
Required personnel qualifications................................................................................................................10
Notes on product liability..............................................................................................................................10
Functional safety, safety integrity level (SIL) ...............................................................................................11
Check the safety function regularly...........................................................................................................11
Reliability data to EN 61508 ..........................................................................................................................12
Function .........................................................................................................................................................13
Technical data ...............................................................................................................................................14
Factory settings.............................................................................................................................................15
Example name plate/Identification............................................................................................................... 16
Functional elements.............................................................................................................................. 17
Dimensions (with mounting bracket) ...........................................................................................................18
Mounting bracket with drill template...........................................................................................................18
Preparing for installation ..............................................................................................................................19
Installing the temperature transmitter......................................................................................................... 19
Connecting a TRG 5-6x temperature sensor ................................................................................................20
Connecting cable, cable type/cross-section and admissible cable length ..................................................20
Wiring diagram for TRG 5-6x temperature sensor .....................................................................................21
Connecting the CAN bus system...................................................................................................................22
Bus line, cable length and cross-section ...................................................................................................22
Example ...................................................................................................................................................22
Important notes on connecting the CAN bus system..................................................................................23
Pin assignment of the CAN bus connector and coupling for non pre-wired control cables..........................23

3TRV 5-60 - Installation & Operating Manual - 819633-01
Contents
Bringing into service .....................................................................................................................................24
Changing the factory settings if necessary................................................................................................24
Changing parameters with password protection enabled ..........................................................................24
Notes on changing communication parameters “bd.rt, Id”.........................................................................27
Changing the baud rate ............................................................................................................................27
Changing the limiter ID .............................................................................................................................28
Setting the AL.Hi limit (°C) (cutout temperature)........................................................................................28
Manually initiating a display test...............................................................................................................29
Viewing the software version and equipment type “InFo”..........................................................................29
Enabling/disabling password protection....................................................................................................30
Starting, operation and testing ..................................................................................................................... 31
System malfunctions.....................................................................................................................................34
Causes .....................................................................................................................................................34
Indication of system malfunctions using error codes.................................................................................35
Checking installation and function ............................................................................................................37
Taking out of service/Disassembly............................................................................................................... 38
Disposal .........................................................................................................................................................38
Returning decontaminated equipment.........................................................................................................38
Declaration of Conformity; Standards and Directives..................................................................................39

4TRV 5-60 - Installation & Operating Manual - 819633-01
Content of this Manual
Product:
Temperature transmitter TRV 5-60
First edition:
BAN 819633-00/08-2019cm
Applicable documents:
■ Installation & Operating Manual for Temperature Sensor TRG 5-6x
■ Installation & Operating Manual for Safety Control Unit URS 6x
You can find the latest Installation & Operating Manuals on our website:
http://www.gestra.com/documents/brochures.html
© 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 temperature transmitter TRV 5-60
■ 1 x Installation & Operating Manual
■ 1 x mounting bracket (preassembled)
■ 4 x screws M6 x 30 mm, 8 x washers M6; 4 x nuts M6
Accessories
■ 1 x M12 CAN bus connector, 5-pole, A-coded, with 120 Ωterminating resistor

5TRV 5-60 - Installation & Operating Manual - 819633-01
How to use this Manual
This Installation & Operating Manual describes the correct use of the TRV 5-60 temperature transmitter.
It applies to all persons who integrate this equipment into control systems, install, bring into service, op-
erate, 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 given.
■ 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 & 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
+
-
Press the rotary knob

6TRV 5-60 - Installation & Operating Manual - 819633-01
Types of warning
DANGER
Warning of a dangerous situation that will result 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 will result in damage to property or the environment.

7TRV 5-60 - Installation & Operating Manual - 819633-01
Specialist terms/Abbreviations
Here, we explain some abbreviations, specialist terms, etc., which are used in this Manual.
IEC 61508
International standard IEC 61508 describes both the type of risk assessment and actions taken to provide
appropriate safety functions.
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.
CAN (Controller Area Network) bus
Data transmission standard and interface for connecting electronic equipment, sensors and control sys-
tems. Data can be sent and received.
TRG .. / TRV .. / URS .. / URB .. / etc.
Equipment and type designations of GESTRA AG, see page 8.
SELV
Safety Extra Low Voltage

8TRV 5-60 - Installation & Operating Manual - 819633-01
Usage for the intended purpose
The TRV 5-60 temperature transmitter may be used in combination with TRG 5-63, TRG 5-64, TRG 5-65,
TRG 5-66, TRG 5-67 and TRG 5-68 temperature sensors solely for limiting excessive temperatures.
The temperature transmitter can be used as:
■ A safety temperature limiter/monitor in combination with a TRG 5-6x temperature sensor and URS 60/
URS 61 safety control units.
Safety temperature limiters or monitors switch off the heating when the maximum admissible
temperature is reached. Method of operation TYPE 2.BKP (+JV, with external lock) to
EN 60730-1.
■ Visualisation and operation take place via the URB 60 or the
SPECTOR control operating terminal.
Admissible system components, dependent on the required safety integrity level
The temperature transmitter can be operated with the following system components:
Temperature sensor
Safety
control unit
as a temperature
limiter
Operating unit
SIL 3
to
IEC 61508
TRG 5-63
TRG 5-64
TRG 5-65
TRG 5-66
TRG 5-67
TRG 5-68
URS 60
URS 61
URB 60
SPECTOR
control
Fig. 1
Key to Fig. 1:
TRG = temperature sensor
URS = SPECTOR
connect safety control unit
URB = visual display and operating unit
To ensure the proper use of equipment during all types of use, please also read the Installation
& Operating Manuals for the system components used.
■ You will find the latest Installation & Operating Manuals for the system components named
in Fig. 1 on our website: www.gestra.com

9TRV 5-60 - Installation & Operating Manual - 819633-01
Improper use
There is a danger of death due to explosion if the equipment is used in potentially explo-
sive atmospheres.
Do not use the equipment in potentially explosive atmospheres.
The TRV 5-60 temperature transmitter is not designed for marine use.
Do not bring any equipment into service that does not have its own specific name plate.
The name plate indicates the technical features of the equipment.
Basic safety notes
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.
Attempts to repair the equipment will cause the plant to become unsafe.
■ The TRV 5-60 temperature transmitter may only be repaired by the manufacturer, GESTRA AG.
■ Only replace faulty equipment with identical equipment from GESTRA AG.

10 TRV 5-60 - Installation & Operating Manual - 819633-01
Required personnel qualifications
Activity Personnel
Integration in control system Specialist staff Plant designer
Installation/electrical connection/
bringing into service Specialist staff
The unit is an item of equipment with a safe-
ty function (EC Pressure Equipment Directive)
and may only be brought into service by
suitable, trained staff.
Operation Boiler service technician Staff trained by the plant operator.
Maintenance work Specialist staff
Maintenance and refits may only be
performed by authorised staff who have
undergone specific training.
Refits Specialist staff Persons trained by the plant operator to work
with pressure and temperature.
Fig. 2
Notes on product liability
We the manufacturer cannot accept any liability for damages resulting from improper use of the equipment.

11TRV 5-60 - Installation & Operating Manual - 819633-01
Functional safety, safety integrity level (SIL)
In combination with the URS 60/URS 61 safety control unit, the TRV 5-60 temperature transmitter is
suitable for safety functions up to SIL 3.
It is an element of a safety circuit up to SIL 3 as per IEC 61508 in the SPECTOR
connect system, and can
transmit alarm notifications.
When combined with the accessories, you will have a type B subsystem in accordance with IEC 61508.
The technical and safety characteristics in Fig. 4 are based on the TRV 5-60 temperature transmitter with
TRG 5-6x temperature sensor.
Breakdown of safety function failure rates (Tmax cutout)
TRG 5-6x
Pt100 sensor
TRV 5-6x
electronics CANopen URS 60,
URS 61
Burner safety
circuit
The CANopen interface is a “black channel” type, and can be ignored during calculation due to
the low failure rate of < 1FIT.
Check the safety function regularly
Check the function of the temperature transmitter at least once a year by bringing the system to the set
limit (T1 = 1 year), see page 29 and 37.
Fig. 3

12 TRV 5-60 - Installation & Operating Manual - 819633-01
Reliability data to EN 61508
Description Characteristic values
Safety integrity level SIL 3
Architecture 1oo1
Type of equipment Type B
Hardware fault tolerance HFT = 0
Overall failure rate for dangerous undetected failures λDU < 20 * 10-9 1/h
Overall failure rate for dangerous detected failures λDD < 5000 * 10-9 1/h
Safe failure fraction SFF > 99.0%
Test interval T1 = 1 year
Probability of dangerous failure on demand PFD < 20.0 * 10-5
Diagnostic coverage. Percentage of dangerous failures
detected by a test. DC > 99.0%
Mean time to dangerous failure MTTFD> 30 a
Mean time to failure MTTF > 10 a
Diagnostic interval T2 = 1 hour
Performance level (to ISO 13849) PL = d
Probability of dangerous failure on demand
per hour PFH < 20.0 * 10-9 1/h
Ambient temperature as a basis for calculation Tu = 60 °C
Mean time to repair MTTR = 0 (no repair)
Fraction of undetected dangerous failures that have a
common cause beta = 2%
Fraction of detected dangerous failures that have a com-
mon cause beta d = 1%
Fig. 4

13TRV 5-60 - Installation & Operating Manual - 819633-01
Function
The TRV 5-60 temperature transmitter has a dedicated TRG 5-6x temperature sensor, the readings of
which are recorded and monitored redundantly. The actual temperature is displayed on the temperature
transmitter itself, as are any system malfunctions that occur.
Setting the limit value
The “AL.Hi” limit can be displayed and set, as desired, see page 28.
The temperature in the transmitter terminal box is continually monitored by a temperature sensor on the
PCB. An automatic self-test cyclically monitors the safety and function of the temperature sensor and the
measured value acquisition.
The data are transferred to the URS 6x safety control unit as a data telegram via the CANopen protocol
using a CAN bus to ISO 11898.
These data telegrams contain the following information:
■ Actual temperature
■ Sensor alarm if the set “AL.Hi” limit is exceeded
■ Malfunction indications in the event of faults in the electronic unit
■ Excessive temperature in the transmitter terminal box
Behaviour in the event of alarms
The alarm state is displayed on the TRV 5-60 and transferred to the URS6x safety control unit via CAN
bus. After the delay time, the safety control unit switches off the connected safety circuit. The safety
control unit does not lock independently during this process.
The safety circuit is interrupted without a delay if the following fault indications occur:
■ Fault in sensors (negative self-test, excessively high temperature in transmitter terminal box)
■ Communication failure
Behaviour in the event of faults
The cyclical self-tests monitor the safety functions of the equipment in the sensors. Fault indications are
updated with each self-test. If there are no faults, the display automatically goes blank. Alarms and fault
indications are transferred to the control unit via the CANopen protocol.
Simulating the alarm state *
The triggering of an alarm can be simulated by:
■ Pressing the rotary knob on the TRV 5-60
or
■ Pressing the relevant button on the URS 60 or URS 61 safety control unit
or
■ Using the URB 60
The equipment will then behave as if a normal alarm had been triggered.
* The tables on pages 32 - 33 clearly show the relationship between the equipment
status, the display and the alarm LEDS.

14 TRV 5-60 - Installation & Operating Manual - 819633-01
Technical data
Supply voltage
■ 24V DC ±20%
Power consumption
■ Max. 7 W
Current input
■ Max. 0.3 A
Internal fuse
■ T2A
Safety cutout at excessive temperature
■ Cutout occurs when an excessive temperature of 75 °C is measured in the electrode tip
Input/output
■ Interface for CAN bus to ISO 11898, CANopen, insulated
■ M12 CAN bus connector, 5-pole; A-coded
■ M12 CAN bus coupling, 5-pole; A-coded
Measuring range and adjustable AL.Hi limit in °C (cutout temperature)
■ Measuring range: 0 °C to 700 °C
■ Minimum limit: 20 °C
■ Maximum limit: 650 °C
■ Reset hysteresis: -2 K
Indicators and controls
■ 1 x 4-digit green 7-segment display for showing actual values and status information
■ 1 x red LED for displaying the alarm or malfunction status
■ 1 x green LED for displaying normal operation
■ 1 x rotary knob IP65 with button for menu navigation and test function
Protection class
■ III Safety Extra Low Voltage
IP rating to EN 60529
■ IP 65

15TRV 5-60 - Installation & Operating Manual - 819633-01
Technical data
Admissible ambient conditions
■ Ambient temperature: 0 °C – 70 °C
■ Storage temperature: - 40 °C – 80 °C
■ Transport temperature: - 40 °C – 80 °C
■ Air humidity: 10% – 95%, non-condensing
Terminal box
■ Terminal box material: Cast aluminium, powder-coated
■ Terminal box attachment: Using the supplied mounting bracket
Terminals and cable entries
■ 1 x 3-pole spring-loaded terminal for connecting a Pt100 temperature sensor
■ Cross-section: 0.2 to 1.5 mm2
■ 1 x M16 cable gland with integrated strain relief for cable diameters 5 to 9 mm
Weight
■ Approx. 1.0 kg
Factory settings
The TRV 5-60 temperature transmitter is delivered ex-works with the following settings.
Parameter Display in menu Unit Parameter values
Limiter ID Id 0004
Baud rate bd.rt kbit/s 0050
Alarm limit AL.Hi °C 0025
Password PW - - - oFF
Fig. 5

16 TRV 5-60 - Installation & Operating Manual - 819633-01
Example name plate/Identification
The date of production (quarter and year) is stamped on the screw-in body.
Fig. 6
A
A
Betriebsanleitung beachten!
See installation instruction!
Vor dem Öffnen des Deckels
Gerät freischalten!
Before removing cover
isolate from power supplies!
Tamb = °C (°F)T
bar (psi)
°C (°F)
L/H=
Pmax
Tmax
Tamb
GESTRA AG
Münchener Str.77
28215 Bremen
Made in Germany
1 Safety note
2 Equipment designation
3 Equipment function
4 Nominal pressure rating
5 Connection thread
6 Material of screw-in body
7 IP rating
8 Operating data (maximum pressure and temperature)
9 Supply voltage
0Power consumption
!Installed length in mm
"Measuring range in ppm
§Measuring range in µS/cm
$ Data interface
%Safety integrity level
&Type-approval number
/Conformity marking
(Disposal information
)Manufacturer
=Protection class
aMaterial number-serial number
bSet limit (TMax)
1
2
3
4 5 6 7
8
9 0
!
&
(
)
a
/
=
$
%
"§
b

17TRV 5-60 - Installation & Operating Manual - 819633-01
OK
+
-
Functional elements
A Terminal box
B Cover screws M4 x 16 mm
C Operating panel with 4-digit LCD, alarm LEDs and rotary knob, see page 31
D M12 CAN bus socket, 5-pole, A-coded
E M12 CAN bus connector, 5-pole, A-coded
F M16 cable gland (connecting cable of TRG 5-6x temperature sensor)
G M12 x 40 mm (size 18), screw for mounting bracket
H Mounting bracket
A B
C
F
G
D
E
H
Fig. 7

18 TRV 5-60 - Installation & Operating Manual - 819633-01
Dimensions (with mounting bracket)
Fig. 8
OK
+
-
Fig. 9
Mounting bracket with drill template
43
23
6.6
10
55
80
All dimensions in mm
M12M16M12
All dimensions in mm
200
172
140
6

19TRV 5-60 - Installation & Operating Manual - 819633-01
Preparing for installation
The TRV 5-60 temperature transmitter is designed for mounting on a wall or panel.
It must be mounted on a sufficiently flat and stable surface (wall or steel girder, etc.).
■ The mounting bracket is preassembled at the factory. 4 hexagon socket head bolts M6 x 30 mm,
4 nuts M6 and 8 washers M6 are supplied, see page 4.
If the equipment is to be installed outdoors, outside the protection of a building, environ-
mental influences may adversely affect function.
■ Pay attention to the admissible ambient conditions in the technical data,
see page 15.
■ Do not operate the equipment if the temperature is below freezing.
◆ At temperatures below freezing, use a suitable heat source (e.g. control cabinet
heater, etc.).
■ Connect all plant parts to a central earthing point to prevent equalisation currents.
■ Use a cover to protect the equipment from direct sunlight, condensation and
heavy rain.
■ Use UV-resistant cable ducts for routing the connecting cable.
■ Take further measures to protect the equipment from harmful environmental influences
such as lightning, insects and animals, and salty air.
You will need the following tools:
■ Allen key, 5 mm
■ Box wrench, 10 mm
Installing the temperature transmitter
1. Switch off voltage to the plant.
2. Then check that the plant is not carrying live voltage.
3. Determine the desired installation position and mark the four drill holes.
You can manually rotate the mounting bracket to the desired position if necessary.
4. Drill the required mounting holes.
5. Next, install the temperature transmitter.

20 TRV 5-60 - Installation & Operating Manual - 819633-01
Connecting a TRG 5-6x temperature sensor
Connecting cable, cable type/cross-section and admissible cable length
■ Use a three-core, shielded cable, e.g. Ölflex®110CH from Lapp, 3 x 1.0 mm2, to connect the TRG 5-6x
temperature sensor.
■ The length of the cable between the temperature sensor and temperature transmitter must not
exceed 25 m.
Only lay the shield on the TRG 5-6x temperature sensor.
Please read the information about this in the Installation & Operating Manual of the TRG 5-6x
temperature sensor.
Safe and secure cable routing helps to prevent malfunctions. Please note the following recom-
mendations:
■ Keep cables away from heat sources
■ Use protective tubes if necessary
■ Do not route signal lines parallel to power lines
You will need the following tools
■ Phillips screwdriver PH2
■ Stripping tool
Connecting the temperature sensor
1. Using a Phillips screwdriver, open the back of the terminal box.
2. Strip off cable sheathing to approx. 60 mm and remove the shield from the cable. The shield may only
be laid on the temperature sensor.
3. Undo the cable gland Fand pull the temperature sensor cable and through the gland, taking care not
to forget the seal.
4. Strip the cores to approx. 7 mm.
5. Connect the cores as shown in the wiring diagram, see page 21.
6. Tighten the cable gland Fsecurely to ensure it is adequately sealed.
7. Finally, screw the rear panel of the terminal box firmly back on, making sure the seal is correctly
seated.