GESTRA
GESTRA Steam Systems
NRG 16-19
NRG 16-27
NRG 16-28
VKE 16-1
VKE 26
Installation Instructions 818725-01
Measuring electrode NRG 16-19
Measuring electrode NRG 16-27
Measuring electrode NRG 16-28
Test set VKE 16-1
Test set VKE 26
1
Contents
Page
Important Notes
Usage for the intended purpose ..............................................................................................................4
Safety note ............................................................................................................................................. 4
Danger ...................................................................................................................................................4
PED (Pressure Equipment Directive) ........................................................................................................4
ATEX (Atmosphère Explosible) .................................................................................................................4
Explanatory Notes
Scope of supply ......................................................................................................................................5
Description ............................................................................................................................................. 5
Function .................................................................................................................................................5
Technical Data
NRG 16-19, NRG 16-27, NRG 16-28 .......................................................................................................
Corrosion resistance ...............................................................................................................................6
Test chamber VKE 16 ..............................................................................................................................
Test chamber VKE 26 ..............................................................................................................................7
Name plate / marking ............................................................................................................................. 8
Dimensions of NRG 16-19, NRG 16-27, NRG 16-28 ................................................................................
Dimensions of test chamber VKE 16 ......................................................................................................10
Dimensions of test chamber VKE 26 .....................................................................................................11
Dimensions of NRG 16-28 for Rhombusline steam traps ......................................................................
Installation
NRG 16-19, NRG 16-27, NRG 16-28 .....................................................................................................12
Attention ............................................................................................................................................... 12
Tools .....................................................................................................................................................12
Examples of installation NRG 16-19, NRG 16-27, NRG 16-28 ................................................................13
11
6
7
9
2
Contents – continued –
Page
Wiring
Connecting cables for measuring electrodes ......................................................................................... 14
Wiring ...................................................................................................................................................14
Tools .....................................................................................................................................................14
Measuring electrodes NRG 16-27, NRG 16-28 pin assignment ..............................................................15
Commissioning
Checking wiring ....................................................................................................................................16
Applying mains voltage ......................................................................................................................... 16
Maintenance
Danger .................................................................................................................................................16
Maintenance interval ............................................................................................................................16
Decommissioning
Disposal................................................................................................................................................17
3
Important Notes
Usage for the intended purpose
Use the electrodes NRG 16-19, NRG 16-27 and NRG 16-28 in conjunction with a suitable detector
(e. g. test station NRA 1-3) only for monitoring steam traps for banking-up of condensate and loss of
live steam.
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 personnel who – through
adequate training – have achieved a recognised level of competence.
Danger
When loosening the measuring electrode steam or hot water might escape.
This presents the danger of severe scalding. It is therefore essential not to remove the
electrode unless the boiler pressure is verified to be zero.
The electrode is hot during operation. This presents the danger of severe burns to hands
and arms. Installation and maintenance work should only be carried out when the system
is cold.
PED (Pressure Equipment Directive)
The equipment fulfils the requirements of the Pressure Equipment Directive (PED) 97/23/EC.
Applicable with fluids of group 2.
ATEX (Atmosphère Explosible)
According to the European Directive 94/9/EC the equipment must not be used in explosion-risk areas.
4
Explanatory Notes
Scope of supply
NRG 16-19
1 Measuring electrode NRG 16-19
1 Joint ring D 17 x 21 to DIN 7603 (made from 1.4301), form A, bright annealed
1 Installation manual
NRG 16-27
1 Measuring electrode NRG 16-27
1 Joint ring D 17 x 21 to DIN 7603 (made from 1.4301), form D, bright annealed
1 Installation manual
NRG 16-28
1 Measuring electrode NRG 16-28
1 Joint ring D 24 x 29 to DIN 7603 (made from 1.4301), form A, bright annealed
1 Installation manual
Description
The measuring electrode fitted in the steam trap or in a separate test chamber monitors the steam trap
for banking-up of condensate and loss of live steam.
The measuring electrodes NRG 16-27, NRG 16-28 feature an additional temperature sensor for
detecting the condensate temperature.
The test station NRA 1-3 is designed for the connection of up to max. 16 measuring electrodes.
Function
The following electrodes can be used for monitoring steam traps:
n Measuring electrodes NRG 16-27, NRG 16-28 for detecting loss of live steam (electrode exposed)
and banking-up of condensate (by measuring the temperature of the condensate) or
n Measuring electrode NRG 16-19 for detecting banking-up of condensate or loss of live steam
(electrode exposed or immerged).
The measuring electrode NRG 16-27, NRG 16-28 works according to the conductivity measurement
principle and signals electrode exposed or immerged. The equipment is also equipped with a temperature sensing element PT 1000 for measuring the temperature of the condensate. The measuring
electrode is installed either directly inside the steam trap to be monitored or in the separate test
chamber VKE 16 mounted upstream of the steam trap.
Faulty steam traps cause either banking-up of condensate or loss of live steam. Both conditions will be
detected by the measuring electrode and indicated and evaluated by the test station NRA 1-3.
The measuring electrode NRG 16-19 works according to the conductivity measurement principle, too.
Depending on the installation the electrode detects either loss of live steam or banking-up of condensate. The readings are then evaluated by the test station NRA 1-3 or by the level switch NRS 1-2.
5
Technical Data
NRG 16-19, NRG 16-27, NRG 16-28
Service pressure
PN 40, max. 32 barg at 238°C
Connection
NRG 16-19, NRG 16-27: screwed
NRG 16-28: screwed M 24 x 1.5
Materials
NRG 16-19
Screw-in type enclosure
Spacer disk
Electrode rod
Insulating disk
NRG 16-27, NRG 16-28
Screw-in type enclosure
Electrode rod
Insulation of electrode rod
Sensitivity of response
> 1 μS/cm at 25°C
Electrode voltage
12 V
Wiring
NRG 16-19: Connecting line made from PTFE, 2 m long, 2 x 1.5 mm
NRG 16-27, NRG 16-28: M 12 sensor connector, 5 poles, A coded
Protection
IP 65 to DIN EN 60529
Ambient temperature at terminal box
Max. 80°C
Weight
Approx. 0.3 kg
3
/8" to ISO 228-1
2
Corrosion resistance
When used for its intended purpose the safe functioning of the electrode will not be impaired by
corrosion.
Gylon® is a registered trademark of Garlock GmbH, Neuss
6
Technical Data – continued –
Test chamber VKE 16
Designs
Electrode connection in flow direction to the left or to the right. Please state when ordering.
Pressure / temperature ratings
Service pressure barg 40 28.4 23.3 23.1
Related temperature °C 20 250 385 400
Materials
Enclosure 1.0619
Flanges 1.0460
Connections
Flanges: DIN, PN 40
Screwed sockets: BSP and NPT thread
Nominal sizes: DN 15, 20, 25, ½", ¾", 1"
Available on request: DN 40, 50; 1½", 2"
Connection of electrode
Screwed 3/8" to ISO 228-1
Test chamber VKE 26
Pressure / temperature ratings
Service pressure barg 40 28.4 23.3 23.1
Related temperature °C 20 250 385 400
Materials
Flanges 1.0460
Connections
Threaded standpipe: 3/8" BSP
Air-balance pipe: 3/8" BSP
Connection of electrode
Screwed 3/8" to ISO 228-1
7
Technical Data – continued –
Name plate / marking
Fig. 1 Equipment designation on hexagon part of electrode
Equipment designation
Manufacturer
Specification of
end connection
Protection
Equipment designation
Manufacturer
Fig. 2
8
Specification of
end connection
Protection
Technical Data – continued –
Dimensions of NRG 16-19, NRG 16-27, NRG 16-28
approx. 80
approx. 32
Connector
Joint ring
32 mm
A. F.
Fig. 3 NRG 16-19
approx. 130
approx. 45
Fig. 4 NRG 16-27
Connector
Joint ring
32 mm
A. F.
3/8" to ISO 228-1
Measuring
electrode
3/8" to ISO 228-1
Connector
Joint ring
approx. 130
M 24 x 1.5
approx. 45
Measuring tube
NRG 16-28
9
Technical Data – continued –
Dimensions of test chamber VKE 16
L
∅ g
∅ D
∅ k
2
H
1
H
Horizontal installation
Fig. 5
Dimensions
Nominal size
mm 15 20 25 40 50 15 20 25 40 50
Inch ½ ¾ 1 1½ 2 ½ ¾ 1 1½ 2
L 150 150 160
Length
Space required
for servicing
Height
A
~130 (NRG 16-27)
S
H
1
H
2
D 95 105 115
b 16 18 18
Flange dimensions
k 65 75 85
g 45 58 68
i 14 14 14
Number of holes 4 4 4
Flanged to DIN Screwed sockets
~80 (NRG 16-19)
~40 (NRG 16-19)
~50 (NRG 16-27)
~93
b
on request
A
S
(left) right
∅ i
Designs
95
~80 (NRG 16-19)
~130 (NRG 16-27)
~40 (NRG 16-19)
~50 (NRG 16-27)
~118
on request
10
Technical Data – continued –
Dimensions of test chamber VKE 26
3
/8" Air-balance
line
70
3
10
/8" to
DIN ISO 228-1
Fig. 6
48
35 mm
Space required
for servicing
75
31
43
56
Dimensions of NRG 16-28 for Rhombusline steam traps
50 mm
Space required
for servicing
Fig. 7
Electrode NRG 16-28
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Installation
NRG 16-19, NRG 16-27, NRG 16-28
The measuring electrode NRG 16-28 can be directly screwed into Rhombusline steam traps. For this
purpose unscrew the sealing plug and remove the strainer (see Fig. 7).
The steam traps can be installed in horizontal pipes or in vertical pipes with downward flow.
The measuring electrodes NRG 16-19, NRG 16-27 are to be screwed into the test chambers VKE 16,
VKE 26:
1. Check sealing surfaces of the steam trap and the test chamber.
2. Put joint ring onto the seating surface of the electrode. Use only the joint ring supplied with the
electrode.
3. Apply a light smear of grease (e. g. Molykote
®
111) to the thread.
4. Screw the measuring electrode into the steam trap or test chamber and tighten it, using an
open-end spanner 32 mm A. F.
The torques required for tightening when cold are:
NRG 16-19: 60 Nm,
NRG 16-27: 60 Nm,
NRG 16-28: 210 Nm.
Attention
n The seating surfaces of the steam trap or the test chamber must be accurately
machined.
n Do not insulate the electrode thread with hemp or PTFE tape.
n Observe the specified torques for tightening.
Tools
n Open-end spanner, 32 mm A. F.
Molykote® 111 is a registered trademark of DOW Corning Corp., Midland Michigan, USA
12
Installation – continued –
Examples of installation NRG 16-19, NRG 16-27, NRG 16-28
VKE 26 with NRG 16-19
Any type of steam trap, e. g. UNA 16
Electrode NRG 16-19
Test station NRA 1-3
Alarm
VKE 16
Electrode NRG 16-27
Electrode NRG 16-28
Fig. 8
Installation temperature,
optional
Any type of steam trap, e. g. BK 45, MK 45,
UNA 14/16, UNA 23-26, or other makes
Installation temperature,
optional
RHOMBUSline steam traps, e. g.
BK 45, MK 45-1, MK 45-2
Test station NRA 1-3
Alarm
Test station NRA 1-3
Alarm
13
Wiring
Connecting cables for measuring electrodes
NRG 16-19
The measuring electrode comes with a 2 m long connecting cable and can be directly connected
to the test station NRA 1-3. To extend the cable use screened two-core cable, e. g. Ölflex 110 CH,
manufactured by LAPP, 2 x 0.5 mm2. Max. cable length between measuring electrode and test station
NRA 1-3: 50 m.
NRG 16-27, NRG 16-28
Use screened five-core cable, e. g. Ölflex 110 CH, manufactured by LAPP, 5 x 0.5 mm
length between measuring electrode and test station NRA 1-3: 50 m. Please connect the screen to the
measuring electrode.
Pre-assembled connecting cables (with connector) of various lengths available as accessories.
Wiring
Connect the cables to the terminal strips of the test station according to the wiring diagram.
Tools
n Screwdriver for cross recess head screws, size 1 and 2
n Screwdriver for slotted screws, size 2.5, completely insulated to VDE 0680.
2
. Max. cable
14
Wiring – continued –
Measuring electrodes NRG 16-27, NRG 16-28 pin assignment
Test station NRA 1-3
Level switch NRS 1-2
Intermediate distributor may be fitted on site
Chassis (blue)
Approx. 2 m PTFE cable
Fig. 9
Fig. 10
Electrode NRG 16-19
1 Measuring electrode
2 Temperature sensor
3 Temperature sensor
4 Temperature sensor
5 Chassis
3 2 1 54
Coupler
15
Commissioning
Checking wiring
Before commissioning please check:
Are the measuring electrodes /temperature sensors wired in accordance with the wiring diagram?
Applying mains voltage
Apply mains voltage to the test station.
Maintenance
Danger
When loosening the measuring electrode steam or hot water might escape.
This presents the danger of severe scaling. It is therefore essential not to remove the
electrode unless the boiler pressure is verified to be zero.
The electrode is hot during operation. This presents the danger of severe burns to hands
and arms. Installation and maintenance work should only be carried out when the system
is cold.
Maintenance interval
We recommend to remove the measuring electrodes every 6 months and clean them with a wet cloth.
If faults occur that are not listed above or cannot be corrected, please contact our service centre or
authorized agency in your country.
16
Decommissioning
Disposal
Remove the measuring electrode NRG 16-19, NRG 16-27, NRG 16-28 and separate the waste
materials, using the material specification as a reference. Electronic components (circuit boards) must
be disposed of properly.
For the disposal of the measuring electrode observe the pertinent legal regulations concerning waste.
17
For your notes:
18
For your notes:
19
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GESTRA
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Telephone +49 (0) 421 35 03-0
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818725-01/907cm · 2006 GESTRA AG · Bremen · Printed in Germany
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