Flowserve NRG 16-50 User Manual

GESTRA Steam Systems
NRG 16-50 NRG 17-50 NRG 19-50 NRG 111-50
Installation Instructions 818954-01
Level Electrodes NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50
English
1
2
Contents
Page
Application
Usage for the intended purpose ..............................................................................................................4
Function .................................................................................................................................................4
Directives and Standards
Pressure Equipment Directive (PED) 97/23/EC ........................................................................................
Functional Safety acc. to IEC 61508 ........................................................................................................
VdTÜV Bulletin "Wasserstand 100" (= Water Level 100) ..........................................................................
ATEX (Atmosphère Explosible) ................................................................................................................. 5
Technical Data
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 ..................................................................................
Corrosion resistance ............................................................................................................................... 7
Sizing .....................................................................................................................................................7
Name plate / marking .............................................................................................................................8
Dimensions NRG 16-50, NRG 17-50, NRG 19-50 ....................................................................................
Dimensions NRG 111-50 ......................................................................................................................10
Functional Elements
NRG 16-50, NRG 17-50, NRG 19-50 ..................................................................................................... 11
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 four-pole connector ............................................11,12
NRG 16-50F, NRG 17-50F, NRG 19-50F, NRG 111-50F aluminium terminal box ..................................... 13
Key .......................................................................................................................................................14
Important Notes
Safety note ...........................................................................................................................................15
Scope of supply .................................................................................................................................... 15
Installation
5 5 5
6
9
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50, step 1 ..................................................................... 16
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50, step 2 ..................................................................... 16
NRG 16-50F, NRG 17-50F, NRG 19-50F, additional information ..............................................................16
Tools .....................................................................................................................................................17
Examples of installation
NRG 16-50, NRG 17-50, NRG 19-50 ..................................................................................................... 18
NRG 111-50 .........................................................................................................................................19
Key .......................................................................................................................................................20
Contents – continued –
Page
Electrical Connection
Connection of level electrode ................................................................................................................ 21
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50, with four-pole connector .........................................
NRG 16-50F, NRG 17-50F, NRG 19-50F, NRG 111-50F, with aluminium terminal box .............................
Wiring diagram ..................................................................................................................................... 22
Key .......................................................................................................................................................23
Tools .....................................................................................................................................................23
Commissioning, fault indication and remedy
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 ................................................................................23
Decommissioning
Disposal................................................................................................................................................23
21 21
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4
Application
Usage for the intended purpose
The level electrodes NRG 16-50, NRG 17-50, NRG 19-50 and NRG 111-50 are used in conjunction with level switch NRS 1-50 as water level limiters for steam boiler plants and (pressurised) hot water installations. Water level limiters switch off the heating when the water level falls below the set minimum level (low water).
Function
When the water level falls below the low level, the level electrode is exposed and a low level alarm is triggered in the level switch NRS 1-50. This switchpoint “Low water level (LW)” is determined by the length of the electrode tip.
The self-monitoring function ensures that an alarm will also be triggered if the electrode insulation is contaminated or has developed a leak or if there is a malfunction in the electrical connection.
The level electrode is installed inside steam boilers, vessels or inlet lines of hot-water systems. The protective tube mounted on site (see section Examples of Installation (pages 18, 19) ensures correct functioning.
One level electrode NRG 1...-50 can be installed together with one GESTRA level electrode, one level switch or transmitter for water level control and high level alarm in one single protection tube or level pot.
If the level electrode is installed in an isolatable level pot outside the boiler, make sure that the connecting lines are rinsed regularly. In addition, the logic unit SRL is required to monitor the purging times and the purging sequence.
If the connecting lines for steam ≥ 40 mm and water ≥ 100mm, the installation is considered to be internal. In this case the rinsing processes do not have to be monitored.
Directives and Standards
Pressure Equipment Directive (PED) 97/23/EC
Water level limiters are safety accessories as defined in the Pressure Equipment Directive (PED). The level electrode NRG 1...-50 in conjunction with level switch NRS 1-50 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.
Functional Safety acc. to IEC 61508
The level electrodes NRG 1...-50 / NRG 16-36 are certified acc. to IEC 61508 only if used in combination with level switch NRS 1-50. This standard describes the functional safety of safety-related electrical/electronic/programmable electronic systems.
The equipment combination NRG 1...-50 or NRG 16-36 + NRS 1-50 corresponds to a type B subsystem with Safety Integrity Level (SIL) 3.
VdTÜV Bulletin “Wasserstand 100” (= Water Level 100)
The level electrodes NRG 1-50, NRG 1...-11 and NRG 16-36 in conjunction with the level switch NRS 1-50 are type approved according to the VdTÜV Bulletin “Water Level 100”.
The VdTÜV Bulletin “Wasserstand (=Water Level) 100” specifies the requirements made on water level control and limiting equipment for boilers.
ATEX (Atmosphère Explosible)
The level electrodes NRG 1...-50, NRG 1...-11 and NRG 16-36 are simple items 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 does not bear an Ex marking. The suitability of the Zener barriers is certified in a separate document.
Note that the requirements of the IEC 61508 are not met if the NRG 1...-50, NRG 1...-11, NRG 16-36 + Zener barriers + NRS 1-50 are interconnected!
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Technical Data
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50
Service pressure
NRG 16-50: PN 40, 32 bar at 238 °C NRG 17-50: PN 63, 60 bar at 275 °C NRG 19-50: PN 160, 100 bar at 311 °C NRG 111-50: PN 320, 183 bar at 357 °C
Mechanial connection
Screwed ¾" to EN ISO 228-1 (NRG 16-50, NRG 17-50, NRG 19-50) Screwed 1" to EN ISO 228-1 (NRG 111-50)
Materials
Sheath: 1.4301, X5 CrNi18-10 Screw-in body: 1.4571, X6CrNiMoTi17-12-2 (NRG 16-50, NRG 17-50, NRG 19-50) Screw-in body: 1.4529, X1NiCrMoCuN25-20-7 (NRG 111-50) Measuring electrode: 1.4571, X6CrNiMoTi17-12-2 (NRG 16-50, NRG 17-50, NRG 19-50) Measuring electrode: 1.4122, X39CrMo17-1 (NRG 111-50) Electrode tip: 1.4401, X5CrNiMo17-12-2 Electrode insulation: Gylon
®
(NRG 16-50, NRG 17-50, NRG 19-50) Electrode insulation: Special ceramic (NRG 111-50) NRG 1...-50: Four-pole connector: polyamid (PA) NRG 1...-50F: Terminal box 3.2161 G AlSi8Cu3
Lengths supplied
500 mm, 1000 mm, 1500 mm, 2000 mm, 2500 mm, 3000 mm ph value
Max. admissible: 10 (NRG 111-50)
Electrical connection
NRG 1...-50:
Four-pole connector, cable glands M 16
NRG 1...-50F: Terminal box made from aluminium, cable gland M 20
Protection
IP 65 to EN 60529
Max. admissible ambient temperature
70°C
Weight
Approx. 1.2 kg (without extension) (NRG 16-50, NRG 17-50, NRG 19-50) Approx. 2.1 kg (without extension) (NRG 16-50F, NRG 17-50F, NRG 19-50F) Approx. 1.8 kg (without extension) (NRG 111-50) Approx. 2.7 kg (without extension) (NRG 111-50F)
Approvals
EC Prototype approval PED Pressure Equipment Directive 97/23/EC, EN 12952-11, EN 12953-09: Requirements made on limiting equipment for boilers.
Functional Safety SIL 3 IEC 61508: Functional safety of safety-related electrical/electronic/programmable electronic systems
TÜV type approval VdTÜV Bulletin “Wasserstand 100” (= Water Level 100): Requirements made on water level limiting & control equipment.
Type approval no. TÜV · SWB / SHWS · XX-XXX (see name plate)
Gylon® is a registered trademark of Garlock Sealing Technologies, Palmyra NY, USA
Technical Data – continued –
Corrosion resistance
If the equipment is used for the intended purpose, its safety is not impaired by corrosion.
Sizing
The body is not designed for pulsating loads. Welds and flanges are designed to withstand dynamic loading (bending and alternative stress). The dimensional allowances and anti-corrosive additives reflect the latest state of the technical art.
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8
Technical Data – continued –
Name plate / marking
Equipment designation Safety note
Disposal note Pressure rating, thread type,
material number, type approval number CE marking
Fig. 1
Manufacturer
Serial number
Safety note
Equipment designation Pressure rating, thread type, material
number
Pressure/temperature rating
CE Marking, type approval
Fig. 2
Disposal note
Manufacturer
Serial number
Fig. 3
Technical Data – continued –
GESTRASt eamSystem s
GESTRA
Dimensions NRG 16-50, NRG 17-50, NRG 19-50
175
140
¾", DIN EN ISO 228-1
b = 70
338
¾", DIN EN ISO 228-1
100
≤ 3000 100 272
≤ 3000
Fig. 4
NRG 16-50, NRG 17-50, NRG 19-50 with four-pole connector
Fig. 5
NRG 16-50F, NRG 17-50F, NRG 19-50F with aluminium terminal box
9
10
GESTRAStea mSystems
GESTRA
Technical Data – continued –
Dimensions NRG 111-50
175
140
136≤ 3000 334
1", DIN EN ISO 228-1
30
b = 70
400
1", DIN EN ISO 228-1
136
30
≤ 3000
Fig. 6
NRG 111-50
Fig. 7
NRG 111-50F
Functional Elements
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50
Fig. 8
1
2
3
4
6
Fig. 9
8
7
5
30
110
14
Fig. 10
NRG 16-50 NRG 17-50 NRG 19-50
Fig. 11
NRG 111-50
Fig. 12
58
33/40
¾", DIN EN ISO 228-1
1", DIN EN ISO 228-1
N 8
0,5
N 10
11
12
Functional Elements – continued –
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 four-pole connector
9
0
a
b c
d
e
f
Fig. 13
Functional Elements – continued –
GESTRA Steam Systems
GESTRA
KK
H
1 2 3 4 5 6
1
2
3
4
5
NRG 16-50F, NRG 17-50F, NRG 19-50F, NRG 111-50F aluminium terminal box
gi h
Fig. 14
k
j
Fig. 15
13
14
Design / Functional Elements – continued –
Key
1 Measuring electrode 2 Bore 3 Spring 4 Electrode tip 5 NRG 1...-50: Joint ring 27 x 32, form D, DIN 7603, 1.4301, bright annealed
NRG 111-50: Joint ring 33 x 39, form D, DIN 7603, 1.4301, bright annealed
6 Seating surface 7 Electrode thread 8 Thermal insulation, provided on site, d = 20 mm (outside of thermal insulation of steam boiler) 9 Screw M 4 0 Cover a Upper part of the terminal box b Connecting plate c Insulating plate d Contact plate of level electrode e Cable strain relief f Cable gland M 16 (PG 9) g Housing screws M 4 h Cable gland M 20 x 1.5 i Housing cover j Nut k Terminal strip
Important Notes
Safety note
Water level limiters are safety devices and 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.
Danger
When loosening the 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 electrode unless the boiler pressure is verified to be 0 bar.
The electrode becomes hot during operation. Risk of severe burns to hands and arms. Before carrying out installation and maintenance work make sure that the steam trap is cold.
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.
Note
For outdoor installations please use level electrode NRG 1...-50 F. Level electrodes with this suffix (F) feature a terminal box made from aluminium.
Scope of supply
NRG 16-50
1 Level electrode NRG 16-50, PN 40 1 Joint ring 27 x 32, Form D, DIN 7603, 1.4301, bright annealed 1 Installation manual
NRG 17-50
1 Level electrode NRG 17-50, PN 63 1 Joint ring 27 x 32, Form D, DIN 7603, 1.4301, bright annealed 1 Installation manual
NRG 19-50 1 Level electrode NRG 19-50, PN 160 1 Joint ring 27 x 32, Form D, DIN 7603, 1.4301, bright annealed 1 Installation manual
NRG 111-50 1 Level electrode NRG 111-50, PN 320 1 Joint ring 33 x 39, Form D, DIN 7603, 1.4301, bright annealed 1 Installation manual
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16
Installation
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50, step 1
1. Screw electrode tip
2. Carefully determine required measuring length of electrode.
3. Mark length of electrode tip
4. Unscrew electrode tip
5. After visual inspection screw electrode tip
electrode tip 4 so that its end completely enters the small hole 2.
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50, step 2
6. Check seating surfaces.
7. Place joint ring
8. Apply a light smear of silicone grease (e. g. WINIX
9. Screw level electrode into threads or flange provided on vessel and tighten with a 41 mm open-end
spanner. The torque required when cold is 160 Nm.
NRG 16-50 F, NRG 17-50 F, NRG 19-50 F, additional information
If one level electrode NRG 1...-50 is installed together with one level electrode, one level switch or transmitter (with aluminium terminal box) in a single protection tube or level pot, please observe the following:
1. Mount the first level electrode as specified in the pertinent installation manual. When installing level electrode NRG 1...-50 F, please observe the following instructions:
1. Unscrew screws
towards this cover..
2. Remove cable lugs from terminal lugs.
3. Loosen nut
4. Screw in level electrode as described in items 6 – 9.
5. Turn terminal box into desired position (+/–180°).
The terminal box can now be turned through +/– 180°.
6. Tighten nut
7. Plug cable lugs onto terminal lugs.
8. Mount housing cover
4 into measuring electrode 1. Fig. 8
4.
4 from measuring electrode 1 and cut tip.
4 into measuring electrode 1. Slide spring 3 along
Fig. 12
5 onto seating surface 6 of the electrode. Fig. 9
®
2150) to electrode thread 7.
g and remove housing cover i. Fig. 14. The arrow on the name plate points
Fig. 15
j with a 19 mm spanner, but do not remove! Fig. 15
j with a torque of 25 Nm.
i and tighten screws g.
WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt
Installation – continued –
Note
n One level electrode NRG 1...-50 can be installed together with one GESTRA level
electrode, one level switch or transmitter for water level control and high level alarm in one single protection tube or level pot (inside diameter 100 mm). electrode NRG 1...-50 is installed inside the vessel, it must be at least 40 mm away from the upper vent hole.
n The installation of two water-level limiting electrodes NRG 1...-50 in one single
standpipe is not allowed.
n For the approval of the boiler standpipe the relevant regulations must be considered. n Refer to pages 18 – 19 for typical installation examples. n The angle of inclination of the electrode must not exceed 45°, with the length of the
electrode rod being limited to 1000 mm.
n For outdoor installations please use level electrode NRG 1...-50 F. Level electrodes with
this suffix (F) feature a terminal box made from aluminium.
Attention
n The seating surfaces of the standpipe or the flange provided on the vessel must be
accurately machined, see
n If the level electrode NRG 111-50 is to be installed in a flanged standpipe DN 50 use
only the GESTRA PN 160 hat flange .
n Do not bend electrode tip when mounting. n Use only the joint rings supplied with the electrode.
NRG 16-50, NRG 17-50, NRG 19-50: 27 x 32, form D, DIN 7603, 1.4301 NRG 111-50: 33 x 39, form D, DIN 7603, 1.4301
n Do not lag electrode body above the hexgonal section! n Do not insulate electrode thread with hemp or PTFE tape! n Do not apply conductive paste or grease to the electrode thread! n Make sure that the air distance between the electrode rod and earth (flange, vessel
wall) is not less than 14 mm.
n Observe the minimum distances for the installation of the electrode!
Fig. 18. If the
Fig. 17, 21
Fig. 12 .
Fig. 11
Fig. 11, Fig. 16-22
Tools
n Open-end spanner A. F. 13, DIN 3110, ISO 3318 n Open-end spanner A. F. 19, DIN 3110, ISO 3318 n Open-end spanner A. F. 41, DIN 3110, ISO 3318 n Scriber n Hacksaw n Flat file, medium cut, DIN 7261, form A
17
18
4
Examples of installation
NRG 16-50, NRG 17-50, NRG 19-50
¾"
l
DN 50
s o
m
20
n
20
p q
t
90°
20
Fig. 16 Protection tube (provided on site) if electrode
is used as internal water-level limiter
¾"
10
u
¾"
l m
45°
14
14
14
max. 1000
20
Fig. 17 Inclined installation, e. g. in ascending inlet
lines of hot-water installations or vessels
¾"
l
DN 20
20
o
p r
s o
n
DN 100
24,5 24,5
20
20
o
t
90°
20
Fig. 18 Protection tube (provided on site) if electrode
is used as internal water level-limter com­bined with water level control or high water level alarm
10
u
3000
DN 20
Centre distance
10
Fig. 19 Level pot if electrode is used as external
water-level limiter
p
t
DN 20
Examples of Installation – continued –
NRG 111-50
1"
l
DN 80
o
m
20
n
20
p q
s
10
90°
20
Fig. 20 Protection tube (provided on site) if elec-
trode is used as internal water-level limiter
t
u
45°
14
14
14
max. 1000
20
Fig. 21 Inclined installation, e. g. in steam
boilers
1"
l
DN 20
DN 80
Centre distance DN 20
DN 20
Fig. 22 Level pot if electrode is used as
external water-level limiter
19
20
Examples of Installation – continued –
Key21Connection of level electrode
l Flange PN 40, PN 63, PN 160, DN 50, DIN 2501-1 (for one electrode)
Flange PN 40, PN 63, PN 160, DN 100, DIN 2501-1 (for two electrodes) Flange PN 250, DN 80, DIN 2501-1 (NRG 111-50)
m For the approval of the boiler standpipe with connecting flange the relevant regulations
must be considered.
n Vent hole Provide vent hole as close to the boiler wall as possible! o High water HW p Electrode rod d = 8 mm q Protection tube DN 80 (in France according to AFAQ DN 100) r Protection tube DN 100 s Electrode distance 14 mm (air gap and creepage distance) t Low water LW u Reducer DIN 2616-2, K-88.9 x 3.2 - 42.4 x 2.6 W
Electrical Connection
To connect the level electrode(s) use screened multi-core control cable with a min. conductor size
0.5 mm2, e.g. LiYCY 4 x 0.5 mm2 . Max. length 100 m with an electrical conductivity of the boiler water > 10 μS/cm at 25 °C.
Max. length 30 m with an electrical conductivity of the boiler water < 10 μS/cm at 25 °C. Wire terminal strip in accordance with the wiring diagram. Fig. 21.
Connect screens only to terminals 5 and 13 of the level switch NRS 1-50.
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50, with four-pole connector
1. Undo screw 9. Fig. 13
2. Remove upper part contact plate d.
3. Remove cover
4. Press connecting plate
The upper part of the terminal box can be turned in steps of 90°.
5. Detach cable gland
6. Run cable through cable gland connecting plate b in accordance with wiring diagram. Fig. 23
7. Press connecting plate
8. Fix cable with cable clamp
9. Re-attach cover
10. Put upper part of the terminal box onto the level electrode and fix it with screw
a of the terminal box from the level electrode but leave insulating plate c on
0. b out of upper part of the terminal box a.
f and cable clamp e from upper part of the terminal box a.
f and upper part of the terminal box a and wire terminals of the
b into the upper part of the terminal box and align cable.
e and cable gland f.
0 and insert screw 9.
9.
NRG 16-50 F, NRG 17-50 F, NRG 19-50 F, NRG 111-50 F, with aluminium terminal box
1. Unscrew screws
2. Undo cable gland
3. Remove terminal strip
4. Connect terminal strip according to the wiring diagram.
5. Attach terminal strip.
6. Tighten the cable gland in order to seal the cable entry. Use the supplied sealing plug to seal off the unused cable entry and tighten the cable gland.
7. Mount housing cover
g and remove housing cover i. Fig. 14
h. Pull cable through cable entry.
k from circuit board.
Fig. 25
i and tighten screws g.
22
Electrical Connection – continued –
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
NRG 1...-50 NRG 1...-50
1 1
2 2
3 3
Wiring diagram
U
1-2
U
-2
U
-1
Fig. 23
Fig. 24 Wiring of level electrode
with four-pole connector
U
1-2
U
-2
U
-1
+ -
v
w
Fig. 25 Wiring of level electrode with aluminium terminal box
+ -
v
w
Terminal strip NRS 1-50
Electrical Connection – continued –
Key
v Stand-by input 1 / 2, 24 V DC, for connecting the logic unit SRL w Level electrode NRG 1...-50
Tools
n Screwdriver for cross head screws, size 1 n Screwdriver for slotted screws, size 2.5, completely insulated according to DIN VDE 0680-1 n Open-end spanner A.F. 18 (19) mm
Commissioning, fault indication and remedy
For additional information on commissiong procedures and troubleshooting refer to the installation manual of the level switch NRS 1-50.
Decommissioning
Danger
Risk of severe burns and scalds to the whole body! Before installing the level electrode make sure that the vessel or the external pot are depressurised (0 bar) and cooled down to room temperature (20 °C).
Disposal
Dismantle the level electrode and separate the waste materials, using the specifications in the table “Materials” as a reference. For the disposal of the equipment observe the pertinent legal regulations concerning waste disposal.
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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Agencies all over the world:
www.gestra.de
GESTRA
España
GESTRA ESPAÑOLA S.A.
Luis Cabrera, 86-88 E-28002 Madrid Tel. 0034 91 / 5 15 20 32 Fax 0034 91 / 4 13 67 47; 5 15 20 36 E-mail: aromero@flowserve.com
Great Britain
Flowserve GB Limited
Abex Road Newbury, Berkshire RG14 5EY Tel. 0044 16 35 / 46 99 90 Fax 0044 16 35 / 3 60 34 E-mail: gestraukinfo@flowserve.com
Italia
Flowserve S.p.A.
Flow Control Division Via Prealpi, 30 l-20032 Cormano (MI) Tel. 0039 02 / 66 32 51 Fax 0039 02 / 66 32 55 60 E-mail: infoitaly@flowserve.com
Polska
GESTRA POLONIA Spolka z.o.o.
Ul. Schuberta 104 PL - 80-172 Gdansk Tel. 0048 58 / 3 06 10 - 02 0048 58 / 3 06 10 - 10 Fax 0048 58 / 3 06 33 00 E-mail: gestra@gestra.pl
Portugal
Flowserve Portuguesa, Lda.
Av. Dr. Antunes Guimarães, 1159 Porto 4100-082 Tel. 00351 22 / 6 19 87 70 Fax 00351 22 / 6 10 75 75 E-mail: jtavares@flowserve.com
USA
Flowserve GESTRA U.S.
2341 Ampere Drive Louisville, KY 40299 Tel. 001 502 / 267-2205 FaxL 001 502 / 266-5397 E-mail: FCD-Gestra-USA@flowserve.com
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen Münchener Str. 77, D-28215 Bremen Telephone 0049 (0) 421 35 03 - 0 Fax 0049 (0) 421 35 03 -393 E-Mail gestra.ag@flowserve.com Internet www.gestra.de
818954-01/12-2009cm (808807-02) · GESTRA AG · Bremen · Printed in Germany
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