Flowserve NRGS 11-1 User Manual

NRGS 11-1
NRGS 16-1
NRGS 16-1 S

Installation Instructions 810393-02

Level Electrode NRGS 11-1
Level Electrode NRGS 16-1
Level Electrode NRGS 16-1S



1

Contents

Page

Important Notes

Usage for the intended purpose................................................................................... 7

Safety Note .................................................................................................................... 7

Danger ........................................................................................................................... 7

Explanatory Notes

Scope of supply ............................................................................................................. 8

System description........................................................................................................ 8

Function......................................................................................................................... 8

Designs ......................................................................................................................... 8

Technical data ......................................................................................................... 9, 10

Installation

NRGS 11-1, NRGS 16-1 ............................................................................................. 10

NRGS 16-1 S (marine applications) ..................................................................... 10, 11

Table ‘Functions’ ......................................................................................................... 11

Examples of installation .............................................................................................. 19

Wiring

Wiring diagram NRGS 11-1, NRGS 16-1, NRGS 16-1 S ........................................... 12

Fill control ....................................................................................................................13

Discharge control ........................................................................................................ 13

Standard Setting

Factory setting ............................................................................................................. 14

Switch selection of measuring range ......................................................................... 14

Commissioning

Warning ....................................................................................................................... 15

Check wiring ............................................................................................................... 15

Check correlation of switching functions ................................................................... 15

Apply mains voltage ................................................................................................... 15

Annex

Warning ....................................................................................................................... 16

Fault finding list ........................................................................................................... 16

Declaraction of conformity .......................................................................................... 18

2

Dimensions

NRGS 16-1: 338

NRGS 11-1: 240

173

140

338

62436, 936, 1436

173

140

∅ 42

500, 1000, 1500

Fig. 1

Fig. 2

3

Parts Drawings

50

A

B

D

C

Fig. 4

∅ 40

≥14

1" BSP, DIN 228

N8

65 –70

N10

0.5

Fig. 5Fig. 3

4

Parts Drawings

Fig. 6

E

F

L

Fig. 7

G

234

1

K

J

I

H

5

5

Key

1

LED “Low-level alarm”

2

LED “Pump ON”

3

LED “Pump OFF”

4

LED “High-level alarm”

5

Code switch “Measuring range”

A

Electrode thread 1" BSP, DIN 228

B

Seating surface

C

Joint ring (of stainless steel 1.4301) D 33 x39 to DIN 7603

D

Flange DN 50, PN 40 to DIN 2635

E

Housing screws M4

F

Cable entry PG 9 / PG 16

G

Housing cover

H

Terminal strip

I

PE connection

J

Terminal strip ‘Test’

K

Thermal fuse T

L

Plug

6

max

102 ° C

Important Notes

Usage for the intended purpose

Use compact system for level monitoring type NRGS 11-1, NRGS 16-1,
NRGS 16-1 S only for level indication in electrically conductive liquids.

Safety Note

Installation must only be performed by qualified staff.
Qualified staff are those persons who – through adequate training in electrical

engineering, the use and application of safety equipment in accordance with
regulations concerning electrical safety systems, and first aid & accident
prevention – have achieved a recognised level of competence appropriate
to the installation and commissioning of this device.

Danger

When loosening the electrode live steam or hot water might escape. This
presents the danger of severe injury. It is therefore essential not to
dismantle the electrode unless the boiler pressure is verified to be zero.

The terminal strip of the NRGS 11-1, NRGS 16-1, NRGS 16-1 S is live
during operation. This presents the danger of electric shock. Cut off
power supply before fixing or removing the housing cover.

7

Explanatory Notes

Scope of Supply

NRGS 11-1

1 Compact system type NRGS 11-1, PN 6
1 Joint ring (of stainless steel 1.4301) D 33x 39 to DIN 7603
1 Installation manual

NRGS 16-1

1 Compact system type NRGS 16-1, PN 40
1 Joint ring (of stainless steel 1.4301) D 33x 39 to DIN 7603
1 Installation manual

NRGS 16-1S

1 Compact system type NRGS 16-1 S (flanged design for marine application)
1 Flange DN 50, PN 40, DIN 2635
1 Installation manual

System Description

The compact system NRGS 11-1, NRGS 16-1, NRGS 16-1 S works according to
the conductivity measurement principle.

With the NRGS 11-1, NRGS 16-1, NRGS 16-1 S a maximum of 4 levels can be
signalled in conductive liquids:

■

4 levels with one switchpoint each

■

High-level alarm, low-level alarm, pump ON, pump OFF with one
switchpoint each

The NRGS 1...-1(S) has a switching controller integrated in the electrode case for
the control of all functions. External switchgear is therefore not required.

Function

The conductivity of the liquid is used to signal the liquid level. Some liquids are
conductive, which means that they allow an electric current to flow through
them. For the safe functioning of this device a minimum conductivity of the liquid
to be measured is required.
The conductivity measurement method can detect two conditions: electrode tip
submerged or exposed, meaning switchpoint reached or not reached. Before
installation, the length of the electrode tip must be cut to the required switching
levels, e.g. for high-level/low-level alarm, controlling of a valve or pump.

Designs

NRGS 11-1, NRGS 16 -1:
Screwed design 1" BSP, DIN ISO 228. Fig. 1

NRGS 16-1S:

Flanged design for marine applications DN 50, PN 40, DIN 2635. Fig. 2

8

Explanatory Notes – continued –

Technical Data

Type Approval N°

NRGS 11-1: TÜV · WRB · 01-388
NRGS 16-1: TÜV · WRB · 01-388
NRGS 16-1 S: GL 99250-96 HH
LR 98/20075
RINA No ELE/30298/1

Max. service pressure

NRGS 11-1: 6 barg at 159°C
NRGS 16-1: 32 bar g at 238°C
NRGS 16-1S: 32 bar g at 238°C

Connections

Screwed 1" BSP, DIN ISO 228
Flanged DN 50, PN 40, DIN 2635

Materials

Case: Die cast aluminium 3.2161 (G AlSi8Cu3)
Stem: S. S. 1.4571 (CrNiMoTi 17 12 2)
Flange: Forged steel 1.0460 (C 22.8)
Measuring electrodes: S. S. 1.4571 (CrNiMoTi 17 12 2)
Electrode insulation: PTFE
Spacer disc: PTFE

Lengths supplied

1500 mm

1000 mm
1500 mm

Mains supply

230 V +/- 10 %, 50/60 Hz
115 V +/- 10 %, 50/60 Hz

124 V +/- 10%, 50/60 Hz (option)

Power consumption

5 VA

Fuse

Thermal fuse T

Sensitivity

Range 1: 10 µS/cm
Range 2: 0.5 µS/cm

Electrode voltage

10 V

ss

Output

4 volt-free relay contacts.
Max. contact rating with a switchting voltage of 24 V, 115 V and 230 V a. c.:
ohmic 4 A, inductive 0.75 A at cos ϕ 0.5. Max contact rating with a switching
voltage of 24 V d. c.: 4 A
Contact material: silver, hard-gold plated

= 102 °C

max

9

Explanatory Notes – continued –

Technical Data – continued –

Energizing/deenergizing delay

3 sec., factory set

Indicators and adjustors

4 red LEDs for signalling “electrode submerged”, “output relay energized”
1 four-pole code switch for changing sensitivity

Cable entry

Cable gland with integral cable clamp
2 x PG 9 (M 16)
1 x PG 16 (M20)

Protection

IP 65 to DIN EN 60529

Max. admissible ambient temperature

70 °C

Weight

NRGS 11-1: approx. 1.4 kg
NRGS 16-1: approx. 1.8 kg
NRGS 16-1S: approx. 2.5 kg

Installation

NRGS 11-1, NRGS 16-1, NRGS 16 -1S

1. Determine required measuring lengths of electrode tips and enter data in table Fig. 3.

2. Cut electrode tips 1 , 2 , 3 and 4 accordingly.

3. Deburr faces of electrode tips.

4. Strip off 50 mm of PTFE insulation from the ends of electrode tips.

NRGS 11-1, NRGS 16-1

5. Check seating surfaces of threads or flange provided on vessel or boiler

standpipe. Fig. 5

6. Place joint ring onto seating surface of electrode Fig. 3. Use only joint ring

C

B

(of stainless steel 1.4301) D 33 x 39 to DIN 7603 supplied with electrode.

7. Apply a light smear of silicone grease (e.g. Molykote

®

111 ) to electrode thread .

8. Screw level electrode into threads or flange provided on vessel or boiler standpipe
and tighten with a 41 mm open-end spanner. The torque required is 140 Nm
when cold.

Molykote® 111 is a registered trademark of DOW Corning Corp., Midland Michigan, USA

10

A

Installation – continued –

NRGS 16-1S

9. Check seating surfaces and place flat gasket on connection standpipe.

0. Place blind flange with bore together with level electrode onto connection

1

standpipe and fix with bolts. Tighten bolts in diagonally opposite pairs. Fig. 4

Table 1

D

Function

Function

e. g. First low-level alarm
e. g. Feed pump ON
e. g. Fee pump OFF

e. g. High level alarm

Attention

■

The seating surfaces of the threads or flange provided on the vessel or
boiler standpipe must be accurately machined. Fig. 5

■

Do not bend electrode tip when mounting.

■

Do not lag electrode body.

Note

■

For the approval of the boiler standpipe with connecting flange the
relevant local and national regulations must be considered.

■

See four examples of installation on page 19.

Tools

■

Open-end spanner 41 mm A. F. to DIN 894

■

Bolt cutter

■

Hacksaw

■

Flat file, medium cut

Electrode tip

1
2
3
4

Please enter length and function.

Length [mm]

11

Wiring

NRGS 11-1, NRGS 16 -1, NRGS 16-1S

2

Use multi-core flexible cable with min. conductor size 1.5 mm

1. Unscrew screws , remove housing cover Fig. 6

2. Unscrew union nuts of cable entry .

E

F

G

The electrode terminal can be turned through +/– 180°.

3. Slacken plug with 17 mm open-end spanner but do not remove. Fig. 7

L

4. Turn electrode terminal into desired direction (+/- 180°).

5. Tighten plug slightly.

6. Remove terminal strip from board.

L

H

7. Connect terminal strip according to wiring diagram, connect PE connection .

8. Plug in terminal strip.

9. Install housing cover , fasten screws and install cable entry .

G

E

Wiring diagram

for wiring.

I

F

12

Mains

Fig. 8

Wiring – continued –

Fill Control

Discharge Control

LW

Mains

Fig. 9

Mains

Attention

■

Fuse supply cables with T 250 mA.

■

The connection of the switchpoints 2 and 3 must be provided on site
(pump contactor, auxiliary relay)!

Tools

■

Screwdriver for cross head screws, size 1

■

Screwdriver for slotted screws, size 2.5; completely insulated according
to VDE 0680

■

Open-end spanner 17 mm A. F. to DIN 894

Fig. 10

13

Standard setting

Factory setting

The compact system is delivered with the following factory settings:

■

Measuring range ≥ 10 µS/cm

Switch selection of measuring range

The measuring range can be switch selected between ≥ 0.5 µS/cm and ≥ 10 µS/cm
by means of code switch :

1. Unscrew screws at the electrode terminal, remove cover , Fig. 6

DIP switch 1– 4 OFF Measuring range

DIP switch 1 – 4 ON Measuring range

2. Replace cover and fasten screws .

G

5

E

G

≥ 0.5 µS/cm.

≥ 10 µS/cm.

E

Attention

■

Do not damage the electronic components when setting the code
switch.

Tools

■

Screwdriver for cross head screws, size 1

■

Screwdriver for slotted screws, size 2.5; completely insulated according
to VDE 0680

14

Commissioning

Warning

The terminal strip of the NRGS 11-1, NRGS 16-1, NRGS 16-1 S is live
during operation.
This presents the danger of electric shock.
Cut off power supply before removing or replacing housing cover.

Check wiring

1. Check whether the system has been wired according to wiring diagram Fig. 8.

2. Check whether mains supply corresponds to the wiring carried out on the
equipment.

Check correlation of switching functions

1. Check whether the designated switchpoints – i.e. switch functions – have been
correlated with the individual electrode rods. See table "Functions", page 11.

Apply mains voltage

1. Switch on mains supply and check the correct functioning of the equipment at
the corresponding switchpoints. LEDs , , and are provided for visual

4321

check of switchpoints. Fig. 7

Remove housing cover to check LEDs , , and . See “Wiring”

G

1 2 3 4

15

Annex

Warning

The terminal strip of the NRGS 11-1, NRGS 16-1, NRGS 16-1 S is live
during operation.
This presents the danger of electric shock.
Cut off power supply before fixing or removing the housing cover.

Fault finding list

Level has exceeded switchpoint “High Water” – no function

Fault:
Remedy:

Fault:
Remedy:

Fault:
Remedy:

Fault:
Remedy:

Fault:
Remedy:

Mains voltage has not been applied.
Apply mains voltage. Wire equipment according to the wiring diagram.

The thermal fuse has been triggered.
In case of defective thermal fuse the mains voltage has not been
connected to terminal : Replace defective thermal fuse
(stock code 051 629).
The ambient temperature must not exceed 70 °C.

The electric conductivity is too low.
Set code switch to ≥ 0.5 µS/cm.

The electrode housing does not have earth connection to the boiler.
Clean seating surfaces and insert metal joint ring (of stainless steel

1.4301) 33 x 39 to DIN 7603.
Do not insulate compact system with hemp or PTFE tape!

Electronic board is defective.
Replace board (stock code 391 422).

J

5

Level has fallen below switchpoint “Low Water” – no function

Fault:
Remedy:

Fault:
Remedy:

Fault:
Remedy:

Switchpoint has been reached – incorrect function

Fault:

Remedy:

If faults occur that are not listed above or cannot be corrected, please contact our
service centre or authorized agency in your country.

16

The electrode tips have earth contact.
Change installation position.

The vent hole in the protection tube does not exist, is obstructed or flooded.
Check protection tube and, if necessary, provide vent hole.

The isolating valves of the external measuring pot (optional) are closed.
Open isolating valves.

The switching function has not been correctly allocated. Electrode tips
have been cut to the wrong size.
Identify electrode supply wire and reconnect accordingly.

For your notes

17

Annex – continued –

Declaration of Conformity

We hereby declare that the equipment NRGS 11-1, NRGS 16-1 and NRGS 16-1 S
conform to the following Euopean guidelines:

■

LVD 73/23/eec version 93/68/eec

■

EMC guideline 89/336/eec version 93/68/eec

which are based on the following harmonised standards:

■

LV standard EN 60947-5-1: 1991

■

EMC standard EN 50 081-2, EN 50 082-2

This declaration is no longer valid if modifications are made to the equipment
without consultation with us.

Bremen, 4th September 2002

GESTRA GmbH

Head of the Design Dept.

Uwe Bledschun

(Academically qualified engineer)

Quality Assurance Manager

Lars Bohl

(Academically qualified engineer)

Key

1

Flange PN 40, DN 150 (2"), DIN 2527
Flange PN 40, DN 100 (4"), DIN 2527

2

For the approval of the boiler standpipe with connecting flange the relevant
regulations must be considered.

3

Vent hole

4

High water (HW)

5

Electrode tip d = 5 mm

6

Protection tube DN 80

7

Protection tube DN 100

8

Electrode distance

9

Electrode distance

10

Low water (LW)

≥ 14 mm

≥ 40 mm

11

Reducer K-88.9x 3.2 – 42.4 x 2.6 W to DIN 2616, part 2

12

Reducer K-114.3x 3.6 – 48.3 x 2.9 W to DIN, 2616 part 2

18

Examples of installation

1" BSP

1

DN 50

4

2

∅ 20

3

20

5

6

8

≥ 10

≤ 90°

∅ 20

10
11

Fig. 11 Fig. 12

1" BSP ¾" BSP

DN 20

1
2

≤ 1500

≤ 90°

∅ 20

1" BSP

DN 50

4

1
2

20
∅

3

20

5

6

8

10

≥ 10

1" BSP

11

11

1
2

≤ 20

4

DN 100

24.5 24.5

9
3

20

∅ 20

4

≤ 90°

∅ 20

Fig. 13

≤ 3000

ME

5

5

7
8

10

DN 20

12

Fig. 14

10

≤ 20

DN 20

19

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Tel. [phone]
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E-mail: [e-mail]

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Tel. [phone]
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E-mail: [e-mail]

®

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Telefon [phone], Telefax [phone]
E-Mail [e-mail], Internet www.gestra.de

A Unit of Flowserve Corporation

810393-02/304cm · © 1998 GESTRA GmbH · Bremen · Printed in Germany

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