Flowserve NRGS 16-2 User Manual

NRGS 16-2

Installation Instructions 810212- 00

Level electrode NRGS 16-2

A Siebe Group Product

1

Dimensions

173

140

337.5500, 1000, 1500

2

Fig. 1

NRGS 16- 2

AA

A

AA

BB

B

BB

CC

C

CC

≥14

50

65–70

Fig. 2 Fig. 3

∅ 40

1" BSP DIN 228

N8

N10

0.5

3

NRGS 16- 2

MAX 70°C

MAX 95%

FF

EE

DD

D

DD

F

E

FF

EE

HH

H

HH

GG

II

G

I

GG

II

JJ

J

JJ

Fig. 4

PP

P

PP

OO

O

OO

NN

N

NN

MM

M

MM

LL

L

LL

KK

K

KK

Fig. 5

4

Legend

AA

A

AA

Electrode thread 1" BSP, DIN 228

BB

B

BB

Seating surface

CC

C

CC

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

DD

D

DD

Housing screws M4

EE

E

EE

Cable entry PG 9/PG 16

FF

F

FF

Housing cover

GG

G

GG

LED “Low level alar m”

HH

H

HH

LED “Low level alar m”

II

I

II

LED “Pump ON”

JJ

J

JJ

DIP switch “Measuring range”

KK

K

KK

Button ‘Test’

LL

L

LL

Terminal strip

MM

M

MM

PE connection

NN

N

NN

Terminal strip ‘Test’

OO

O

OO

Thermal fuse T

PP

P

Screw

PP

102 °C

max

5

Contents

Page

Important Notes

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

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

Warning...........................................................................................................................7

Explanatory Notes

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

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

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

Design ............................................................................................................................. 8

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

Installation

NRGS 16-2..............................................................................................................10, 11

Table Functions ............................................................................................................. 11

Examples of installation ................................................................................................17

Wiring

NRGS 16-2 ................................................................................................................... 12

Standard Setting

Factory setting ..............................................................................................................13

Switch selection of measuring range ............................................................................13

Commissioning

Warning.........................................................................................................................14

Wiring check .................................................................................................................14

Application of mains voltage .........................................................................................14

Checking of switching functions ....................................................................................14

Checking of low level alarm ..........................................................................................14

Annex

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

Fault finding list .............................................................................................................15

Declaraction of conformity ............................................................................................16

6

Important Notes

Safety Note

Use compact system for level monitoring type NRGS 16-2 only for level indication.
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.

Warning

The terminal strip of the NRGS 16-2 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 16-2

1 Compact system type NRGS 16-2
1 Joint ring (of stainless steel 1.4301) D 33x39 DIN 7603
1 Installation Instruction

System Description

The compact system NRGS 16-2 works according to the conductivity measurement
principle. With the NRGS 16-2 a maximum of 3 levels can be signalled in conductive
liquids:

■

Low level alarm, pump ON, pump OFF with one normally open contact

The NRGS 16-2 has a level switch integrated in the electrode case for the controlling
of all functions. An external switching device is not required.
The NRGS 16-2 has two electrode rods for the detection of low water level. The
signalling of the low-level alarm is effected via two separate switching channels.

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 rod
submerged/exposed or switchpoint reached/not reached. Before installation, the
length of the electrode rod must be adapted to the switching levels, e. g. for
max./min. alarm, controlling of a valve or pump.

Design
NRGS 16-2:

Screwed design 1" BSP, DIN ISO 228. Fig. 1

8

Technical Data
Type Approval N°

.

TÜV

WR/WB . 97-392

Max. service pressure

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

224 V +/– 10%, 50/60 Hz (option)

Power consumption

5 V A

Fuse

Thermal fuse T

= 102°C

max

Sensitivity

Range 1: 10
Range 2: 0.5

µ

S/cm

µ

S/cm

Electrode voltage

10 V

ss

Output

2 volt-free relay contacts. 1 volt-free normally open contact.
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

9

Technical Data - continued
Indicators and adjustors

2 red LEDs for signalling “Low water”,
1 green LED for signalling “Pump ON”,
1 four-pole DIP switch for changing sensitivity,
1 button “TEST” for functional checking of low level alarm

Cable entry

Cable gland with integral cable clamp
1x PG 19
1x PG 16

Protection

IP 65 to DIN 40050

Max. admissible ambient temperature

70°C (158 °F)

Weight

approx. 1.8 kg

Installation

NRGS 16-2

1. Determine required measur ing lengths of electrode rods and enter data in table1

Fig. 2.

2. Cut electrode rods 1 , 2 , 3 and 4 accordingly.
The electrode rods 1 and 2 (low level limiter) must have the same length.

3. Deburr faces of electrode tips.

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

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

Fig. 3

CC

C

6. Place joint ring onto seating surface of electrode Fig. 2. Use only joint ring

CC

(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. DOW Corning 111 Compound)

AA

A

to electrode thread .

AA

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.

BB

B

BB

10

Installation - continued

Table 1

Function

Low-level alarm
Low-level alarm
e.g. Pump ON

e.g. Pump OFF

Attention

■

The seating surfaces of the threads or flange provided on the vessel or
boiler standpipe must be accurately machined. Fig. 3

■

Do not bend electrode rod 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 17.

Tools

■

Open-end spanner 41 mm A.F.

■

Bolt cutter

■

Hacksaw

■

Flat file, medium cut

Function

Electrode rod

1
2
3
4

Length [mm]

11

Wiring

NRGS 16-2

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

FF

F

DD

D

1. Unscrew screws , remove housing cover Fig. 4

2. Unscrew union nuts of cable entry .

DD

EE

E

EE

FF

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

PP

P

3. Loosen screw with 17 mm open-end spanner but do not remove. Fig. 5

PP

4. Tur n electrode ter minal into desired direction (+/– 180°).

PP

P

5. Tighten screw slightly.

6. Remove terminal strip from board.

PP

LL

L

LL

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

8. Plug in terminal strip.

FF

F

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

FF

DD

D

DD

Wiring diagram

2

for wiring.

MM

M

MM

Mains

Fig. 6

Attention

■

Fuse supply cables with T 250 mA.

Tools

■

Screwdriver for cross head (“Phillips”) screws, size 1

■

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

■

Open-end spanner 17 mm A.F.

12

Standard setting

Factory setting

The compact system is delivered with the following factor y settings:

■

Measuring range ≥ 10µS/cm

Switch selection of measuring range

The measuring range can be switch selected between ≥ 0.5

JJ

J

by means of DIP switch :

1. Unscrew screws at the electrode terminal, remove cover , Fig. 6
DIP switch 1– 4 OFF Measuring range ≥ 0.5

DIP switch 1– 4 ON Measuring range ≥ 10

2.Replace cover and fasten screws

JJ

DD

D

DD

µ

µ

FF

F

FF

DD

D

DD

S/cm

S/cm

µ

S/cm and ≥ 10 µS/cm

FF

F

FF

Attention

■

Do not damage the electronic components when operating DIP switch.

Tools

■

Screwdriver for cross head (“Phillips”) screws, size 1

■

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

13

Commissioning

Warning

The terminal strip of the NRGS 16-2 is live during operation.
This presents the danger of electric shock.
Cut off power supply before removing or replacing housing cover.

Wiring check

1. Check whether the system NRGS 16-2 has been wired according to wiring
diagram Fig. 6.

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

Application of mains voltage

1. Switch on mains supply and check the correct functioning of the equipment at the

GG

HH

II

G

H

I

GG

HH

corresponding switchpoints. LEDs , , are provided for visual check of

II

switchpoints. Fig. 5

II

GG

I

FF

F

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

FF

G

HH

II

GG

H

HH

Check correlation of switching functions

1. Check the switching function “Low level alarm” of the electrode rods and .

11

1

11

22

2

22

For this test the level in the vessel must fall below the low level mark.
The low-level alarm must then be activated by the level switch.

2. Check the switching function “Pump ON” and “Pump OFF”. See table 1.

Check low-level alarm

KK

K

The function of the low-level alarm can be simulated by pushing the button “TEST” .

KK

Fig. 5

The low-level alarm must then be activated.

14

Annex

Warning

The terminal strip of the NRGS 16-2 is live during operation.
This presents the danger of electric shock.
Cut off power supply before removing or replacing housing cover.

Fault finding list
Switchpoint “Pump ON” has been exceeded – no function

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

Fault: The thermal fuse has failed.
Remedy: In case of defective thermal fuse the mains voltage has not been

connected to terminal : Replace defective thermal fuse
(Order No. 051629).
The ambient temperature must not exceed 70 °C.

Switchpoint “Pump OFF” has been exceeded – no function

Fault: The electric conductivity is too low.
Remedy: Switch DIP switch to ≥ 0.5 µS/cm.

Fault: The electrode housing does not have earth connection to the boiler.
Remedy: Clean seating surfaces and insert metal joint r ing (of stainless steel 1.4301)

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

Fault: Electronic board is defective.
Remedy: Replace board (Order No. 391423).

NN

N

NN

JJ

J

JJ

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

Fault: The electrode rods have ear th contact.
Remedy: Change installation position.

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

Fault: The isolating valves of the external measur ing pot (optional) are closed.
Remedy: Open isolating valves.

Switchpoint has been reached – incorrect function

Fault: The switching function has not been correctly allocated. Electrode rods

have been cut to the wrong size.

Remedy: Identify electrode supply wire and reconnect accordingly.

15

Annex - continued

Declaration of conformity

We hereby declare that the equipment NRGS 16-2 conforms to the following European
guidelines:

■

LV guideline 73/23/EWG version 93/68/EWG

■

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

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, 28th April 1997

GESTRA GmbH

Dr. Anno Krautwald

Dr. Christian Politt

Legend

11

Flange PN 40, DN 50 (2"), DIN 2527

1

11

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

22

For the approval of the boiler standpipe with connecting flange the relevant

2

22

regulations must be considered.
Vent hole

33

3

33
44

High water (HW)

4

44

Electrode rod d = 5 mm

55

5

55

Protection tube DN 80

66

6

66

Protection tube DN 100

77

7

77

Electrode distance ≥ 14 mm

88

8

88

Electrode distance ≥ 40 mm

99

9

99

11

00

1

0

Low water (LW)

11

00

11

11

1

1

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

11

11

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

11

22

1

2

11

22

16

Examples of installation

44

4

44

88

8

88

≤ 90°

∅20

1"BSP

DN 50

≥10

11

1

11
22

2

22

∅ 20

33

3

33

20

55

5

55
66

6

66

11

00

1

0

11

00

11

11

1

1

11

11

Fig. 7 Fig. 8

¾"BSP

1"BSP

11

1

11

DN 20

22

2

22

≤ 1500

≤ 90°

∅20

1"BSP

DN 50

44

4

44

88

8

88

≥ 10

1"BSP

11

1

11
22

2

22

20
∅

33

3

33

20

55

5

55
66

6

66

11

00

1

0

11

00

11

11

1

1

11

11

11

11

1

1

11

11

11

1

11
22

2

22

≤ 20

44

4

44

DN 100

24.5 24.5

99

9

99
33

3

33

20

∅20

44

4

44

≤ 3000

ME

55

5

55
77

7

77
88

8

88

11

00

1

0

11

00

DN 20

11

22

1

2

11

22

≤ 20

55

5

55

11

00

1

0

11

00

≤ 90°

∅20

Fig. 9

Fig. 10

DN 20

17

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Luis Cabrera, 86-88

Tel. [phone]

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Fax [phone]

®

®

GESTRA GmbH

Postfach 10 54 60

Siebe Instrument & Valve Division

D-28054 Bremen

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D-28215 Bremen

Hemmstraße 130
D-28215 Bremen

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Fax[phone]

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E-mail

[e-mail]

Internet www.gestra.de

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A Unit of Flowserve Corporation

A Siebe Group Company

810212-00/1297c · ©1997 GESTRA GmbH · Bremen · Printed in Germany

18