Flowserve LRR1-40 User Manual
GESTRA Steam Systems
LRR 1-40
Installation Instructions 818527-00
TDS Control Unit LRR 1- 40
Contents
Page
Important Notes
Usa ge for the intended purpose.......................................................................................6
Safety note.......................................................................................................................6
ATEX (Atmosphères Expl osibles)....................................................................................7
Danger note.....................................................................................................................7
Explan atory Notes
Scope of supply .......................................... .....................................................................7
Description.......................................................................................................................8
Function...........................................................................................................................9
Technical data................................................................................................................10
Name plate.....................................................................................................................13
Installation
Control unit LRR 1-40....................................................................................................13
Tools ..............................................................................................................................13
Wiring
Bus cable.......................................................................................................................14
Change baud rate ........ ..................................................................................................15
Wir e terminal strip....................................... ...................................................................15
Wir ing diagram LRR 1-40..............................................................................................16
Wir ing diagram for CAN bus ..........................................................................................17
Tools ..............................................................................................................................18
Basic Settings
CAN bus.........................................................................................................................19
NodeID...........................................................................................................................19
Factory setting ...............................................................................................................20
Commissioning
Start ...............................................................................................................................21
Performance of the continuous blowd o wn valve............................................................21
2
Conte nts
Page
Operation
Normal operation ...........................................................................................................22
Continuous boiler blowdown..........................................................................................22
Intermittent boiler blowdown..........................................................................................22
Stand-by operation ........... .............................................................................................23
24 hr purging pulse.................................................................................... ....................23
MAX limit / MIN limit.......................................................................................................24
MAX limit / MIN limit=Automati c intermittent boiler blowdown ......................................24
Performance test ...........................................................................................................25
Please note when using the equipment as conductivity limiter......................................25
Performance test for relays 1 and 4...............................................................................26
System Faults
Causes...........................................................................................................................27
Test................................................................................................................................27
Systematic malfunction analysis....................................................................................28
Fault finding list for troubleshooting system faults..................................... ....................29
Action against high frequency interference....................................................................30
Replace controller..........................................................................................................31
Malfunctions
Fault finding list for troubleshooting ...............................................................................32
Annex
Factory setting of n ode IDs............................................................................................33
Establishi ng / changing node ID ....................................................................................33
Table Node ID........ ........... .......... .......... ........... .......... ........... .......... ........... .......... ..........34
Change factory setting...................................................................................................34
Declaration of conformity...............................................................................................35
Examples of installation.................................................................................................3 6
3
Functional Elements
1
2
3
4
Fig. 1
5 6 7
Test
8
10
9
Fig. 2
1
LNN
1
2
A
+-C
CS
LH
123456789101112131415
B
2716 17 18 19 20 21 22 23 24 25 26 28 29 30
MAX
12
P
Test
F
E
D
C
4
Key
1
LED 1 (MAX)
2
LED 2 (Valve closed)
3
LED 3 (Valve open)
4
LED 4 (MIN)
5
Program button for switching between oper ating and parameterising mode
6
Increase button
7
Decrease button
8
Enter button / test mode
9
Green LED "Power"
Red LED "Status CAN bus"
10
A
Upper termina l strip
B
Lower termina l strip
C
Fixing screws (cross recess head screws M4)
D
Code switch
E
Casing
F
Supporting rail type TH 35, EN 60715
5
Important Notes
Usage for the intended purpose
Use blowdown controller LRR 1-40 only in conjunction with conductivity electrode
LRG 16-40 and an operating & display unit type URB or SPECTORcontrol for detecting
and monitoring electrical conductivity in liquids.
Note that the application of the control unit LRR 1-40 for conductivity limiting purposes or
cont inuous boiler blowdown is only permissible if it is us ed in conjunction with the
conductivity elec trode LRG 16-40 and an operating & display unit type URB or
SPECTORcontrol.
To guarantee a trouble-free operation observe the requi rements made on water quality
as specified in the pertinent TRD and EN regulations.
Any type of use differing from the usage described a bove must be considered as
improper. The resulting risk will have to be borne by the user alone. The manu facturer
hereby expressly r ejects any claims for any damage resul ting from improper usage.
Safety note
The equipment must only be installed and c ommissioned 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.
For installation, removal, commissioning, operation and maintenance, every person who
works with the equipment must have read and understood the complete installation
manual. Furthermore, respon sibilities must have been defined clearly and
unambi guously and must be adhered to.
Usage of the equipment for the intended purpose includes compliance with the rules and
notes in these installation instructions for installation, removal, commissioning, operation
and mai ntenance.
The operating company must ensure that, whenev er the equipment is being operated, it
is in perfect condition.
Working methods that jeopardise safety must not be used!
6
Important Notes – conti nued –
ATEX (Atmosphères Explosibles)
According to the European Directive 94/9/EC the equipment must not be used in
potentially explosive areas.
Danger note
Danger
The term inal strip of the control equipment is live during operation. This
presents the danger of electric shock!
Cut of f pow er supp l y before attaching or detaching the terminal strip of the
control e quipment!
Explanatory Notes
Scope of supply
LRR 1-40
1 Control unit LRR 1-40 (plug-in unit in plastic case)
1 Terminating resistor 120Ω
1 Installation manual
7
Explanatory Notes – continued –
Desc r ip tio n
As the boil er water evaporates, 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
manufactu rer, foaming and priming occurs as the density of the boiler water increases,
resulting in a carry-over of solids with vapour into steam lines and super heaters. As a
consequence, the operational safety is impaired and severe damage to boiler and tubes
may occur.
In addition, excess phosphate (due to phosphate treatment) or concentrated residual
hardness particles form accumulated sludge that deposits on heating surfaces and on the
bottom of the steam boiler. The insulating layer formed by these deposits can cause the
boiler metal to become overheated, resulting in a dangerou s situation since the metal is
now subjected to design pressure at an elevated temperature.
The TDS control unit LRR 1-40 in conjunction with the conductivity electrode LRG 16-40
and the operating & display unit type URB or SPECTORcontrol ensure efficient boi ler
blowdown.
The quality of the boiler water is monitored with the aid of:
■ Conductivity control / limitation,
■ Continuous boiler blowdown control,
■ Automatic intermittent blowdown control.
The TDS controller LRR 1-40 can be used in combination with the conductivity electrode
LRG 16-40 and an operating & display unit type URB or SPECTORcontrol for TDS
control (c onductivity limitation) and continuous boiler blowdown in steam boilers and
(pressuris ed) hot-water plants.
The data exchange between the control unit LRR 1-40, the conductivi ty electrode
LRG 16-40 and the operating device as well as further equipment is effected via CAN bus
according to ISO 11898, using the CANopen protocol.
8
Expl an ato ry No tes – co ntinue d –
Function
The conductivity electrode LRG 1-40 sends at regular intervals data telegrams via CAN
bus to the control unit LRR 1-40.
The data telegram of the conductivity electrode LRG 16-40 contains the following data:
■ Conductivity reading (actual value X), based on 25°C
■ Temperatur e of boiler water,
■ Alarm: Internal cable monitoring signals malfunction(s),
■ Alarm: Temperature sensor for boiler water is defective,
■ Alarm: Excessively high temperature in terminal box.
All transmitted process data are continuously evaluated by the control unit and assigned
to the control range and the respective switch points.
If the associated conductivity electrode interrupts the data transmitting cycle, an alarm
message is given and a visual signal is indicated by the display of the operating device.
Use operati ng device URB or SPECTORcontrol to configure, parameterize, operate and
show the available parameters of the conductivity electrode. The control unit LRR 1-40
can only test the ener gizing/de-energizing of the relays for the limit values.
The control unit features the following functions:
■ Use as 2-position controller for the control of a conti nuous blowdown valve,
■ Use as 3-position proportional stepping controller for the control of a continu ous
blowdown valve with feedback potentiometer,
■ Triggering of daily purgin g pulse (24h) to actuate the continuous blowdown valve,
■ De-activation of control function during stand-by operation of steam boiler,
■ Alarm signal in the event of a malfunction in the conductivity electrode,
■ Max. limit alarm for conductivity limiting,
■ Min. limit alarm or
■ Automatic blowdown c ontrol with timed actuation of the intermittent blowdown valve,
■ Analog actual value output (4-20mA) for external conductivity indication (optional).
9
Expl an ato ry No tes – co ntinue d –
Technical data
Type approval no.
TÜV.WÜL.02-007
EG BAF-MUC 02 05 103881 003
Input/Output
Interface for CAN bus to ISO 11898 CANopen.
Inputs
CAN bus interface with power supply 18-36V D C, short circuit protected.
Analog control input for indicating valve position via feedback potentiometer 1000Ω,
angle of rotation 320°, supply voltage 5V DC.
Voltage input 18-36V AC (50/60 Hz) or DC for external com mand:
Control OFF, valve CLOSED, intermittent blowdown OFF. With DC protected against
polarity reversal.
Outputs
Four volt-free relay contacts.
Max. contact rating with a s witching voltage of 24V AC/DC, 115V AC and 230V AC:
resistive / inductive 4A.
Contact material AgNi 0.15.
Current output 4-20mA as actual va lue output, max. load 750Ω (optional).
Conductivity measuring range with actual value output 4-20mA
Beginning of measuring range End of measuring range
ppm* µS/cm * mA ppm* µS/cm * mA
10 20 20
50 100 20
100 200 20
250 500 20
0.25 0.5 4
500 1000 20
1000 2000 20
3000 6000 20
6000 12000 20
* based at 25°C
10
Note
The electrical conductivity is measured in µS/cm. For ppm (parts per million)
use the f ollowing conversion:
1µS/cm = 0.5ppm.
Expl an ato ry No tes – co ntinue d –
Technical data - c ontinued -
Indicators and adjustors
Four pushbuttons as operating elements.
Four LED s for indicating the operating modes.
One green LED for power suppl y.
One red LE D for sta tus indication of CAN bus.
One 10-pole code switch for setting node ID and baud rate.
Setpoint W
Adjustable within the measuring range between the adjusted MIN/ MAX limi ts.
Control range (configuration as proportional controller)
Beginning: 0.5 x setpoi nt W up to 1.5 x setpoint W
Dead band (con figuration as proporti onal controller)
Based on setpoint W:
Setpoint W below 2000 µS/cm (1000 ppm) DB = 3%
Setpoint W above 2000 µS /cm (1000 ppm) DB = 1%
Switching hysteresis of controller output (configuration as 2-position controller)
Adjustabl e between 1 and 25% of the adjus ted setpoint.
Operating position of the continuous blowdown valve
Adjustabl e as a function of the continuous blowdown valve.
Proportion al band Xp
From 1 to 150% relative to setpoint W (configuration as proportional controller),
adjustable, 0% (configuration as 2-position contr oller).
MIN/MAX limits
Measuring range up to 200 µS/cm (100 ppm):
MIN limit adjustable between 0.5 µS/cm (0.25 ppm ) and MAX limit
- 2 µS/cm (1 ppm),
MAX limit adjustable between 200 µS/cm (100 ppm) and MIN limi t
+2 µS/cm (1 ppm).
Other measuring ranges:
MIN limit adjustable between 0.5 µS/cm (0.25 ppm) and MAX limit
-20 µS/cm (10 ppm),
MAX limit adjustable between end of measuring range and MIN limit
+20µS/cm (10ppm).
MIN/MAX limits,
Switching hystereses
MIN limit: +1% of the adjusted MIN limit,
MAX limit: -1% of the adjusted MAX limit.
11
Expl an ato ry No tes – co ntinue d –
Technical data - continued -
24 hr purging pulse
Forced opening of the continuous blowdown valve every 24 hours, adjustable.
Automatic intermittent blowdown
Interval time (duration of break): 1-120 hours, adjustable in steps of one hour.
Duration of pulse: 1-60 se conds, adjustable in steps of one second.
Mains supply
230V +10 / -15%, 50-60 Hz
115V +10 / -15%, 50-60 Hz (optional)
24V +10 / -15%, 50-60 Hz (optional)
Power consumption
10V A
Protection
Casing: IP 40 to EN 60529,
Terminal strip IP 20 to EN 60529.
Admissi ble ambien t temperatur e
0-55°C
Casing
Design: Case made of insulating material, with pl ug-in terminals
Casing material: Base: black polycarbonate; front panel: grey polycarbonate,
Number of terminals: 30
Cross section of connector: 1x4.0 mm2 solid or
1x 2.5 mm2 stranded wire with sleeve to DIN 46228 or
2x1.4mm2 stranded wire with sleeve to DIN 46228,
Fixing of conductor: Plus/ Minus terminal screw M 3.5,
Term inals with s elf-lifting wire protection.
Terminal strip: Separately detachable,
Fixing of casing: Mounting clip on supporting rail TH 35, EN 60715.
Weight
Approx. 0.8 kg
12
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