Page 1
GESTRA Steam Systems
NRS 1-40.1
Installation Instructions 818548-00
Control Unit NRS 1-40.1
Page 2
Contents
Page
Important Notes
Usage for the intended purpose...............................................................................................................4
Safety note..............................................................................................................................................4
Classification pursuant to article 1 of the Pressure Equipment Directive (PED) .........................................4
ATEX (Atmosphère Explosible) .................................................................................................................4
Explanatory Notes
Scope of supply.......................................................................................................................................5
System description..................................................................................................................................5
Function..................................................................................................................................................7
Technical Data
NRS 1-40.1.............................................................................................................................................8
Name plate / Marking..............................................................................................................................9
Dimensions ...........................................................................................................................................10
Installation
Control unit NRS 1-40.1 ........................................................................................................................11
Change settings ....................................................................................................................................11
Mount control unit.................................................................................................................................11
Tools.....................................................................................................................................................11
Functional Elements
Key .......................................................................................................................................................12
Wiring
Bus cable, cable length and size ...........................................................................................................13
Change baud rate..................................................................................................................................13
Wire terminal strip.................................................................................................................................13
Wiring diagram for control unit NRS 1-40.1 ...........................................................................................14
Wiring diagram for CAN bus system - example - ...................................................................................15
Tools.....................................................................................................................................................16
Basic Settings
Factory settings.....................................................................................................................................16
Commissioning
Change configuration ............................................................................................................................17
2
Page 3
Contents
Page
Start, Operation, Alarm and Test
NRS 1-40.1 .......................................................................................................................................... 19
System Malfunctions
Causes ................................................................................................................................................. 21
Systematic fault finding procedure for system malfunctions.................................................................. 22
Fault finding list for troubleshooting system malfunctions: Limiters 1–4 ............................................... 24
Fault finding list for troubleshooting system malfunctions: Control Unit ................................................. 25
Action against high frequency interference ........................................................................................... 25
Replace control unit.............................................................................................................................. 26
Check installation and performance
Check switchpoints............................................................................................................................... 26
Malfunctions
Fault finding list for level electrode NRG 1.-40 / control unit NRS 1-40.1............................................... 27
Fault finding list for level electrode NRG 1.-41.1 / control unit NRS 1-40.1............................................ 28
Fault finding list for temperature transmitter TRV 5-40 / control unit NRS 1-40.1 .................................. 28
Emergency Operation
Emergency operation of water level limiting system LW ........................................................................ 29
Annex
CAN bus ............................................................................................................................................... 30
Factory set node IDs ............................................................................................................................. 30
Node ID ................................................................................................................................................ 31
Change node ID .................................................................................................................................... 31
Table Node ID ....................................................................................................................................... 32
Decommissioning................................................................................................................................. 32
Disposal ............................................................................................................................................... 33
Declaration of Conformity ..................................................................................................................... 33
3
Page 4
Important Notes
Usage for the intended purpose
The control unit NRS 1-40.1 must only be used in conjunction with the associated sensors for monitoring
water level and temperature limits.
The equipment can be used as
■
Low -level limiter (min. water-level alarm) or as low-level limiting system in conjunction with level electrode NRG 1x-40,
■
as high level alarm in conjunction with level electrode NRG 1x-41.1 and
■
as safety temperature controller/limiter in conjunction with temperature transmitter type TRV 5-40.
A combination of these functions is possible.
Any type of use differing from the usage described above must be considered as improper. The resulting
risk will have to be borne by the user alone. The manufacturer hereby expressly rejects any claims for any
damage resulting from improper usage.
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 staff who - through adequate training - have
achieved a recognised level of competence.
Danger
The terminal strips of the control unit NRS 1-40.1
are
live during operation.
This presents the risk of severe cases of electric shock!
Always cut off power supply to the equipment before mounting, removing or connecting
the terminal strips!
Classification pursuant to article 1 of the Pressure Equipment Directive (PED)
Category IV
Designation Safety accessory
CE marking CE 0525
ATEX (Atmosphère Explosible)
According to the European Directive 94/9/EC the equipment must not be used in potentially explosive areas.
4
Page 5
Explanatory Notes
Scope of supply
NRS 1-40.1
1 Control unit NRS 1-40.1
1 Terminating resistor 120Ω
1 Installation manual
System description
The control unit NRS 1-40.1 has four limiting functions for monitoring the MIN/MAX water levels (low/high
level alarms) and MAX temperature in steam and (pressurised) hot water plants in accordance with TRD
and EN 12952 and EN 12953.
The level electrodes type NRG 1x-40, NRG 1x-41.1 and the temperature transmitter type TRV 5-40 detect
the current water level and temperature and their readings are sent as a data telegram to the CAN bus.
The CANopen protocol is used for the data transfer via CAN bus.
Only one limiting system with one control unit NRS 1-40.1 may be used per CAN bus network.
5
Page 6
Explanatory Notes
– continued –
System description
– continued –
By connecting the level electrodes and the temperature transmitter with the control unit the following combinations of functions are possible:
Control unit NRS 1-40.1
Function 1 Function 2 Function 3 Function 4
Low-level limiter
(LW alarm)
Level electrode
NRG 1x-40
Low-level limiter
(LW alarm) 1
Level electrode
NRG 1x-40
Low-level limiter
(LW alarm) 1
Level electrode
NRG 1x-40
Low-level limiter
(LW alarm) 2
Level electrode
NRG 1x-40
Low-level limiter
(LW alarm) 2
Level electrode
NRG 1x-40
High level limiter
(HW alarm)
Level electrode
NRG 1x-41.1
Low-level limiter
(LW alarm) 1
Level electrode
NRG 1x-40
Low-level limiter
(LW alarm) 1
Level electrode
NRG 1x-40
Low-level limiter
(LW alarm) 1
Level electrode
NRG 1x-40
Safety temperature
controller/limiter
Temperature
transmitter TRV 5-40
Safety temperature
controller/limiter
Temperature
transmitter TRV 5-40
Low-level limiter
(LW alarm) 2
Level electrode
NRG 1x-40
Safety temperature
controller/limiter
Temperature
transmitter TRV 5-40
Low-level limiter
(LW alarm) 2
Level electrode
NRG 1x-40
Safety temperature
controller/limiter
Temperature
transmitter TRV 5-40
High level limiter
(HW alarm)
Level electrode
NRG 1x-41.1
Safety temperature
controller/limiter
Temperature
transmitter TRV 5-40
Safety temperature
controller/limiter
Temperature
transmitter TRV 5-40
Safety temperature
controller/limiter
Temperature
transmitter TRV 5-40
Safety temperature
controller/limiter
Temperature
transmitter TRV 5-40
6
Page 7
Explanatory Notes
– continued –
Function
At regular intervals the control unit NRS 1-40.1 evaluates the data telegram coming from the level electrodes NRG 1x-40, NRG 1x-41.1 and the temperature transmitter TRV 5-40. This data telegram contains:
■
An alarm when the electrode NRG 1x-40 emerges and/or when the electrode insulation
is defective,
■
An alarm when the electrode NRG 1x-41.1 enters into the water and/or when the electrode insulation
is defective,
■
An alarm when the adjusted cut-off temperature is exceeded (temperature transmitter TRV 5-40),
■
The result of the self-checking routine (detection of measured value),
■
The temperature in the electrode terminal box and the casing of the temperature transmitter.
When a level or temperature alarm is raised the safety circuit is interrupted after the de-energizing delay.
The control unit does not lock automatically. This function must be implemented in the following circuit.
The safety circuit will be interrupted instantaneously with the following malfunction alarms:
■
Malfunction in the level electrodes (self-checking negative, temperature in terminal box too high),
■
Malfunction in the temperature transmitter (self-checking negative, temperature in casing too high),
■
Malfunction in the control unit (self-checking negative),
■
Communication malfunction.
The self-testing routine checks the safety functions of the controller, the level electrodes and the temperature transmitter. This self-test is carried out every 3 seconds in the controller and every 10 seconds in all
other pieces of equipment.
An additional self-testing routine checks every 6 hours the de-energizing of the output relays in the controller.
Malfunction messages are updated during each self-checking routine. If there is no malfunction the messages will be deleted automatically and the safety circuit is closed again. However, if the malfunction still
persists, the malfunction message will remain.
Alarm and malfunction messages are indicated by LEDs, and the signal output is instantaneously energized.
7
Page 8
Technical Data
NRS 1-40.1
Type approval no.
TÜV. SWB/SHWS. 03 –413
EG BAF-MUC 03 07 103881 004
Input/output
Interface for CAN bus to ISO 11898 CANopen
Output voltage supply for sensors
18–36V DC, short-circuit protected
Output safety circuit
2 volt-free relay contacts, locally connected in series.
Contact material AgNi 0.15.
Max. contact rating with a switching voltage of 24V AC/ DC, 115V AC and 230V AC: resistive / inductive 4A.
Provide contactors with RC combinations according to manufacturer's specification to ensure interference
suppression.
Signal output
1 Photo MOS output for external signalling, alarm signal instantaneous, malfunction signal timed.
24-230 V AC /DC, max. current rating 100mA, NO contact.
Factory setting of de-energizing delay of output relay
3 seconds,
other time delays (15, 25, etc.) on request
Indicators and adjustors
4 Pushbuttons for operation / "TEST",
4 LEDs for alarm and malfunctions messages,
1 LED "Power",
1 LED bus status, controller malfunction message
1 Ten-pole code switch for setting node ID and baud rate.
1 Six-pole code switch for system configuration
Internal self-checking routine
Every 3 seconds
Periodic testing of output relay contacts
Every 6 hours
Mains supply
230V + 10 /- 15%, 50-60 Hz or
115V + 10 /- 15%, 50-60 Hz
Power consumption
10 VA,
Protection
Casing: IP 40 to EN 60529
Terminal strip: IP 20 to EN 60529
Admissible ambient temperature
0- 55°C
8
Page 9
Technical Data
g
A
– continued –
NRS 1-40.1
– continued –
Casing
Casing material: Base: black polycarbonate; front panel: grey polycarbonate,
Cross section of connector: 1 x4.0 mm² solid or
1x2.5 mm² stranded wire with sleeve to DIN 46228 or
2x1.4mm² stranded wire with sleeve to DIN 46228
Terminal strips separately detachable
Fixing of casing: Mounting clip on supporting rail TH 35, EN 60715.
Weight
Approx. 0.8kg
Name plate / Marking
Steuergerät
control device
appareille de commande
C
+
H
87
L
N
Alarm
extern
24-230 V
100 mA
IP 40 (IP20) 50 / 60 Hz 10 VA 230 V
larm
3sec.
LNN
1
Sicherheitsstromkreis
protection circuit
circuit de securite
Safety note
Characteristics
CAN bus
Wiring diagram
Betriebsanleitun
beachten
See installation
instructions
Voir instructions de
montage
IN / OUT: CAN-Bus
18-36 V DC
S
-
C
L
12345 161718 2529
S
24V
CAN-BUS
DC
Equipment designation
Node ID
Mains supply /
protection
Pressure/temperature
range
Type approval no.
Manufacturer
Fig. 1
GESTRA AG
Münchener Str. 77
D-28215 Bremen
250 V ~ T 2,5 A
VS.-Nr.:XX
Mat.Nr.:
Xxxxxx
Spare part specification
Fuse
CE marking
0525
9
Page 10
Technical Data
Dimensions
– continued –
2716 17 18 19 20 21 22 23 24 25 26 28 29 30
GESTRA
GESTRA
NRS 1-40
NRS 1-40.1
100
73
Fig. 2
TEST
123456789101112131415
17 1 8 19 20 21 22 23 249251026
LNN
1
1
1
2716
GESTRA
GESTRA
NRS 1-40
NRS 1-40.1
8
MAX 55°C
%
MAX 95%
IP 20
10
Fig. 3
20
-C CS
LH
1
2345678
+
TEST
11 12281329143015
20
Page 11
Installation
Control unit NRS 1-40.1
Note
When changing the default factory settings (see page 16 and 17) the following steps:
■
Change baud rate,
■
Change configuration (see section “Commissioning“) and
■
Change node ID (see section “Annex“)
must be carried out before mounting the equipment. Make sure that the terminal strips
are unplugged before performing the work in a single operation.
Change settings
1. Unplug the upper and lower terminal strips . (see Fig.4)
A
2. The terminal strip can be unplugged after undoing the right and the left fixing screws .
3. Set code switch and as required.
4. Re-insert terminal strips and fasten the fixing screws .
D E
A B C
B
C
Mount control unit
The control unit NRS 1-40.1 is clipped onto a support rail type TH 35, EN 60715 in the control cabinet.
G
(see Fig.4)
Tools
■
Screwdriver (5.5/100)
11
Page 12
Functional Elements
LNN
1
1
2
2716 17 18 19 20 21 22 23 24 25 26 28 29 30
MAX
GESTRA
GESTRA
NRS 1-40
1
P
NRS 1-40.1
G
Tes t
A
-
123456789101112131415
CCS
LH
+
E
D
F
B
C
Fig. 4
The code switches are accessible after removing the lower terminal strip. The terminal strips can be unplugged after undoing the right and the left fixing screws.
Key
A
Upper terminal strip
12
B
Lower terminal strip
C
Fixing screws (cross recess head screws M4)
D
Code switch for setting node ID and baud rate.
E
Code switch for system configuration
F
Casing
G
Supporting rail type TH 35, EN 60715
Page 13
Wiring
Bus cable, cable length and size
Note that screened multi-core twisted-pair control cable is required as Bus line, e. g. UNITRONIC® BUS
CAN 2 x 2 x...mm² or RE-2YCYV-fl 2x2x ...mm².
The cable length dictates the baud rate (data transfer rate) between the bus nodes, and the total power
consumption of the sensor dictates the conductor size.
S 8 S 9 S 10 Baud rate Cable length
Number of pairs
and conductor size [mm²]
OFF ON OFF 250 kBit/s 125 m 2x2x0.34
Factory setting
ON ON OFF 125 kBit/s 250 m 2x2 x0.5
OFF OFF ON 100 kBit/s 335 m 2x2 x0.75
ON OFF ON 50 kBit/s 500 m available on demand (depends
on bus configuration)
OFF ON ON 20 kBit/s 1000 m
ON ON ON 10 kBit/s 1000 m
The baud rate is set via code switch Fig.4 (S8 to S10). Default factory setting of control unit NRS 1-40.1:
D
baud rate 250 kBit/s (cable length up to 125m). For longer cable lengths reduce baud rate accordingly.
Make sure that all bus nodes feature the same settings.
Change baud rate
With lower terminal strip unplugged:
Set the baud rate via code switches S8 to S10 as specified in the table in section Bus cable, cable length
D
and size by using a thin blade screwdriver.
Re-insert terminal strip and fasten the fixing screws .
B C
Wire terminal strip
Wire terminal strips in accordance with the wiring diagram.
Connect screens only to terminal 3.
Note
The max. baud rates and cable lengths indicated above are based on empirical values obtained by GESTRA. In certain cases it may be necessary to reduce the baud rate in order to
ensure trouble-free operation.
13
Page 14
Wiring
– continued –
Wiring diagram for control unit NRS 1-40.1
Wire link with same potential
Safety circuit / supply
S
24V DC
Twisted pair cables
LN
Safety circuit - uninterrupted -
N
L
MIN
2716 17 18 19 2 0 21 22 23 2 4 25 26 28 29 30
LNN
-C CS
123456789101112131415
1
LH
+
GESTRA
GESTRA
NRS 1-40
NRS 1-40.1
NL
Further equipment in
the safety circuit
Attention:
NRS 1-40.1 is the
first device in the
safety circuit.
Do not connect terminals 26, 27, 28, 30.
Photo-MOS output
24V-230V AC/DC, 100mA
Instantaneous alarm signal
Timed malfunction signal
14
Twisted pair cables
Fig. 5
Attention
When using the control unit NRS 1-40.1 for more than two limiting functions the CAN bus
must be supplied with 24V DC by a safety power supply unit (e. g. Siemens SITOP Power 05).
The power supply unit must be in accordance with DIN VDE 0106 (safety separation) and
fused with an overcurrent protective device to EN 61010-1 / VDE 0411.
The CAN bus supply must not be connected to terminals 1 and 5.
CAN bus
Terminating resistor
120Ω
Page 15
Wiring
– continued –
Wiring diagram for CAN bus system - example -
Central
earthing point
CEP
Operating device
NRS 1-40.1
Level electrode
NRG 1x-40
Level electrode
NRG 1x-40
Voltage supply CAN data line
Level electrode
NRG 1x-41.1
Temperature
transmitter
TRV 5-40
Terminating resistor
120Ω
Fig.6
Attention
■
■
■
■
Terminating resistor
120Ω
Wire equipment in series. Star-type wiring is not permitted!
Link screens of bus cables such that electrical continuity is ensured and connect them
once to the central earthing point (CEP).
Because of the self-checking routine of the output contacts the control unit NRS 1-40.1
must always be the first equipment in the safety circuit, which means that terminal 25
must be permanently connected to L of the safety circuit.
Terminal N1 (18) must be permanently connected to the zero potential (N) of the safety
circuit. Non-compliance will cause malfunctions, in particular if the control unit and the
safety circuit are supplied with different voltage potentials (e. g. control unit 230 V / safety
circuit 24 V). Provided that the electric potentials are equal, a wire link can be attached
to terminals 17 and 18.
■
To protect the switching contacts provide the circuit with a T 2.5A or 1.0A fuse (TRD 604,
72 hrs. operation).
■
If two or more system components are connected in a CAN bus system, provide the first
and the last device with a terminating resistor of 120Ω (terminal CL/CH).
■
Only one control unit NRS 1-40.1 may be used per CAN bus network.
■
The CAN bus system must not be interrupted during operation.
In the event of an interruption a malfunction alarm is raised.
15
Page 16
Wiring
– continued –
Wiring diagram for CAN bus system - example -
Note
■
Connect screen only to the respective terminals and to the central earthing point (CEP).
■
The rated voltage is indicated on the name plate.
■
When switching off inductive loads, voltage spikes are produced that may impair the operation of control and measuring systems. Connected contactors must therefore be provided with suppressors such as RC combinations.
■
In the event of an alarm the signal output (terminal 7 and 8) is instantaneously closed.
■
In the event of a malfunction the signal output (terminals 7 and 8) is opened and closed
in a clock-pulse controlled way in order to ensure an optical differentiation between an
alarm and a malfunction signal. If required you can wire terminals 7 and 8 with an external signal lamp.
Tools
– continued –
■
Screwdriver for slotted screws, size 2.5, completely insulated according to VDE 0680-1
■
Screwdriver for cross head screws, size 2
Basic Settings
Factory settings
Control unit NRS 1-40.1
The control unit features the following factory set default values:
■
Node ID: 1
■
Baud rate: 250 kBit/s (125m cable length)
■
De-energizing delay: 3 sec.
■
Configuration: Operation with two level electrodes NRG 1x-40, one level electrode NRG 1x-41.1 and
one temperature transmitter TRV 5-40.
16
Page 17
Commissioning
Danger
The terminal strips of the control unit NRS 1-40.1 are live during operation.
This presents the risk of severe cases of electric shock!
Always cut off power supply to the equipment before mounting, removing or connecting
A
the terminal strips , !
Change configuration
The control unit NRS 1-40.1 features four limiting functions for monitoring water level and temperature.
The level electrodes NRG 1x-40, NRG 1x-41.1 and the temperature transmitter TRV 5-40 can be connected
to the control unit.
For the operation in question the required number of limiting functions of the control unit NRS 1-40.1 has
to be ascertained.
With lower terminal strip unplugged:
Set the baud rate via code switch Fig.4 (S1 to S6) as specified in the table by using a thin blade screwdriver.
Re-insert terminal strip and fasten the fixing screws .
B C
B
E
Since the components are easier to access before the the equipment is mounted you should change the
configuration before carrying out the installation.
17
Page 18
Commissioning
– continued –
Change configuration
ON
123 546
Toggle switch, white
Code switch Limiting function
E
E
– continued –
S1 S2 S3 S4 S5 S6 1 2 3 4
OFF OFF ON ON ON ON
ON ON ON ON ON ON
ON ON OFF OFF ON ON
ON ON OFF OFF OFF OFF
Water level
LW1
Water level
LW1
Water level
LW1
Water level
LW1
Water level
LW2
Water level
LW2
Water level
LW2
High level
HW
High level
HW
Temperature
MAX
ON ON OFF OFF ON ON
ON ON OFF OFF OFF OFF
OFF OFF ON ON ON ON
ON ON ON ON ON ON
Note
When determining the limiting functions 1–4 please take also the installation instructions of
the level electrodes NRG 1x-40, NRG 1x-41.1 and the temperature transmitter TRV 5-40 into
account.
Factory setting
Water level
LW1
Water level
LW1
Temperature
MAX1
Temperature
MAX1
Temperature
MAX1
Water level
LW2
Temperature
MAX2
Temperature
MAX2
Temperature
MAX1
Temperature
MAX2
18
Page 19
Start, Operation, Alarm and Test
NRS 1-40.1
L1
Signal
LED
L2
L3
L4
GESTRA
GESTRA
NRS 1-40
NR S 1-40 .1
TEST
Malfunction alarm control unit
and bus status LED
Mains supply LED
Fig. 7
Control keys
Assignment of signal LED / key / equipment
LED 1 / Key 1: Limiter 1 (e. g. level electrode NRG 1x-40, low level LW)
LED 2 / Key 2: Limiter 2 (e. g. level electrode NRG 1x-40, low level LW)
LED 3 / Key 3: Limiter 3 (e. g. level electrode NRG 1x-41.1, high level HW)
LED 4 / Key 4: Limiter 4 (e. g. temperature transmitter TRV 5-40, MAX temperature)
Start
Apply mains voltage.
LED "Power" is illuminated Mains voltage applied
LED 1– 4 are flashing System is being started and tested.
Output contacts are open. Signalling output is
closing (lamp test).
Operation
Limiters 1– 4 indicate
no alarm
LED 1– 4
are not illuminated
Output contacts are closed,
signalling output is open.
Limiters 1– 4,
one or more limiters
indicate an alarm
During operation:
Press key 1, 2, 3 or 4 and
hold it down until the end of
the test, limiters must react
as if there was an alarm.
Alarm
One or more of the LEDs
1, 2, 3, 4 are flashing
rapidly
One or more of the LEDs
1, 2, 3, 4 are illuminated
Test - Limiters 1 – 4
LED 1, 2, 3 or 4
is flashing rapidly
LED 1, 2, 3 or 4
is illuminated
De-energizing initiated,
signalling output is closed instantaneously.
De-energizing period has elapsed, output
contacts are open, signalling output closed.
Alarm simulated in limiter 1 - 4.
de-energizing initiated,
signalling output is closed instantaneously.
De-energizing period has elapsed, output
contacts are open, signalling output closed.
Test finished.
19
Page 20
Start, Operation, Alarm and Test
– continued –
NRS 1-40.1
– continued –
Note
■
In the event of an alarm the control unit NRS 1-40.1 does not lock automatically.
If a lock function is required by the installation it must be provided in the follow-up
circuitry (safety circuit). This circuit must meet the requirements of DIN VDE 0116
(EN 50156).
20
Page 21
System Malfunctions
Causes
Malfunctions occur if CAN bus components have been mounted or configured incorrectly or if electronic
component parts are defective, or in the event of excessive heat in the equipment or electrical interference
in the supply system.
Further malfunctions are:
■
Faulty communication within the CAN-Bus system
■
Overloading of the 24V power supply unit in the controller
Note
Before carrying out the systematic fault finding procedure please check:
Wiring:
Is the wiring in accordance with the wiring diagram?
Is the polarity of the bus line always correct?
Is the bus line of each of the end nodes provided with a 120Ω resistor?
Configuration of level electrode NRG 1x - 40 (low water level LW):
Are the wire links (device 1 or 2) set correctly?
Does the position of the wire link tally with the node ID?
Configuration of the temperature transmitter TRV 5-40
Is the transmitter correctly adjusted as device 1, 2, 3 or 4?
Node ID:
Are the node IDs set correctly?
Note that a node ID must only be used for one item of equipment!
Baud rate:
Is the length of the cable in accordance with the adjusted baud rate?
Is the baud rate the same for all devices?
Danger
The terminal strips of the control unit NRS 1-40.1 are live during operation.
This presents the risk of severe cases of electric shock!
Always
the terminal strips! When the CAN bus is interrupted during operation an alarm will be raised.
cut off power supply
to the equipment before mounting, removing or connecting
21
Page 22
System Malfunctions
– continued –
Systematic fault finding procedure for system malfunctions
The sources of malfunctions occuring in CAN bus systems operating with several bus-based stations must
be analysed systematically since faulty components or incorrect settings can give rise to negative interactions with intact bus devices in the CAN bus system. These unwanted interactions can cause error messages in fully functional bus devices, which will make fault detection even more difficult.
We recommend the following systematic fault finding procedure:
Step 1 (Start)
Detach
terminal strips
in all Bus sensors.
Level electrode
Conductivity electrode
Pressure sensor
Temperature sensor
etc.
Check
Use fault-finding
list to identify
the fault(s)!
Final test
Have all faults
been eliminated?
System Fault
Use fault-finding
list to identify
the malfunction.
Cut off power supply
to the equipment !
Step 2
Plug in terminal strip
of the sensor
of the system
e. g. NRS ...
and
NRG... (electrodes)
Step 3
Apply mains voltage
to bus devices
of the system
e. g. NRS ...
and
NRG...
Check next system
System O.K.
Detach
terminal strips
between bus devices
of the system
e. g. NRS...
and
NRG...
22
Page 23
System Malfunctions
– continued –
Systematic fault finding procedure for system malfunctions
GESTRA
GESTRA
NRS 1-40
NRS 1-40 .1
TES T
Fig. 8
Signal
LED
L1
L2
L3
L4
Control keys
– continued –
Malfunction alarm control unit
and bus status LED
Mains supply LED
Assignment of signal LED / key / equipment:
LED 1 / Key 1: Limiter 1 (e. g. level electrode NRG 1x-40, low level LW)
LED 2 / Key 2: Limiter 2 (e. g. level electrode NRG 1x-40, low level LW)
LED 3 / Key 3: Limiter 3 (e. g. level electrode NRG 1x-41.1, high level HW)
LED 4 / Key 4: Limiter 4 (e. g. temperature transmitter TRV 5-40, MAX temperature)
Indication of system malfunctions in limiters 1 – 4
Limiters 1– 4,
one or more limiters
have a malfunction
LED 1, 2, 3, 4,
one or more LEDs
are flashing slowly
Output contacts open instantaneously.
Signalling output is operating in the switching
mode.
Limiters 1– 4,
one or more limiters
have a malfunction.
LED 1, 2, 3, 4,
one or more LEDs are
flashing slowly
Malfunction
in control unit
Analysis of system malfunctions in limiters 1 – 4
Press and
hold down
corre-
LED 1 is flashing
slowly
Faulty communication between
limiter and controller,
HF interference
sponding
key
(key 1, 2,
3 or 4)
LED 2 and 3 are
flashing slowly
LED 3 is flashing
Excessively high temperature in the
terminal box of the electrode or the
temperature transmitter
Sensor defective.
slowly
Analysis of system malfunctions in the controller
LED bus status
is flashing slowly
LED bus status
is illuminated
Faulty communication within the CAN bus system.
HF interference
Control unit defective.
Output contacts open instantaneously.
Signalling output is operating in the switching
mode.
LED Power is
flashing slowly
Bus supply voltage below 18V.
23
Page 24
System Malfunctions
Fault finding list for troubleshooting system malfunctions: Limiters 1 – 4
Depending on the indication of the malfunction press and hold down key 1 or 2 or 3 or 4.
LED 1 is flashing slowly
– continued –
Fault:
Remedy:
Fault:
Remedy:
LEDs 2 and 3 are flashing slowly
Fault:
Remedy:
LED 3 is flashing slowly
The
limiter
nicate.
Check 24V bus supply, wiring, configuration of the low level electrodes (wire links), node ID,
baud rate setting and terminating resistor. If modifications have to be made, switch off mains
voltage and switch it on again after about 5seconds.
The
limiter
There is a source of interference in the surrounding area. To suppress interferences provide
contactors and actuators with RC combinations in accordance with the specifications of the
manufacturer. Take action against high frequency interference.
The temperature in the terminal box of the level electrode or the temperature transmitter exceeds the max. limit.
Check installation of electrode and insulate electrode flange against thermal radiation. Check
place of installation of the temperature transmitter.
(level electrode / temperature transmitter) and
and the
controller
the control unit
cannot communicate. The fault occurs at long intervals.
cannot commu-
Fault:
Remedy:
Fault:
Remedy:
One or more of the self-checking routines detected a malfunction, which means that the
electronic insert of the level electrode or the temperature transmitter is defective.
Replace electronic insert.
The temperature sensor is defective (parting of a cable, short circuit).
Check temperature sensor and supply cables (see Installation Instructions TRV 5-40),
replace measuring element of the temperature sensor.
24
Page 25
System Malfunctions
Fault finding list for troubleshooting system malfunctions: Control Unit
LED bus status is flashing slowly
– continued –
Fault:
Remedy:
Fault:
Remedy:
LED bus status is illuminated
Fault:
Remedy:
Faulty communication in the CAN bus system.
Check 24 V bus supply, wiring, configuration of the limiter, node ID and baud rate
settings as well as terminating resistors. If modifications have to be made, switch off mains
voltage and switch it on again after about 5 seconds.
No or faulty communication with limiters. The fault occurs at long intervals.
There is a source of interference in the surrounding area. To suppress interferences provide
contactors and actuators with RC combinations in accordance with the specifications of the
manufacturer. Take action against high frequency interference.
The control unit must be defective because one or more of the self-checking routines detected a malfunction, e. g. faulty output relay in the control unit, no or clock-pulse controlled
voltage applied across terminal 25.
Switch off mains voltage and switch it on again after about 5 seconds (the equipment restarts). The control unit must be replaced if after a maximum of 1 minute a malfunction is
indicated again.
LED Power is flashing slowly
Fault:
Remedy:
Fault:
Remedy:
Action against high frequency interference
All connected inductive loads such as contactors and actuators must be provided with RC combinations in
accordance with the specifications of the manufacturer.
Should sporadic failures occur in installations susceptible to faults (e. g. malfunctions due to out-of-phase
switching operations) we recommend the following actions in order to suppress interferences:
HF interference suppression of voltage supply by means of ferrite rings and
HF interference suppression of CAN bus line by means of hinged-shell ferrite rings.
Bus supply voltage below 18 V DC. The power supply unit of the controller is overloaded.
Mount and connect a safety power supply unit (e. g. Siemens SITOP Power 05).
Bus supply voltage below 18 V DC. Faulty wiring (short circuit).
Check wiring. Switch off mains voltage and switch it on again after about 1 second (the
equipment restarts).
25
Page 26
System Malfunctions
Replace control unit
1.
Cut off power supply
to the equipment!
– continued –
2. Remove terminal strips , . For this purpose turn the right and left fixing screws in direction of
A B C
the arrow until the terminal strip can be removed.
3. Undo the fixing slide in order to snap out the controller and take it off the supporting rail .
G
When ordering spare parts please state the serial number indicated on the name plate.
Check installation and performance
Check switchpoints
In order to check the switchpoints "Level below low water level (LW)" or "Level above high water level
(HW)" the water level must be lowered or - as the case may be - the boiler must be filled.
The switchpoint "MAX temperature" can also only be checked by increasing the temperature accordingly.
All devices must respond as if there were an alarm.
Check switchpoints after commissiong or replacing the level electrode, temperature sensor or temperature
transmitter.
26
Page 27
Malfunctions
Fault finding list for level electrode NRG 1.-40 / control unit NRS 1-40.1
Water level below switchpoint "Low water (LW)" - no low level alarm
Fault:
Remedy:
Fault:
Remedy:
Fault:
Remedy:
Water level not yet below switchpoint "Low water (LW)" - but a low level alarm is raised
Fault:
Remedy:
Fault:
Remedy:
LED "Power" and LEDs 1 - 4 are not illuminated.
Apply mains voltage, wire equipment in accordance with wiring diagram.
The electrode rod(s) is/are too long.
Cut electrode rod(s) to the length dictated by the switchpoint LW.
If the electrode is installed inside the boiler: The vent hole in the protection tube does not exist
or is obstructed.
Check installation of level electrode. Make sure that the level in the protection tube corresponds to the actual water level.
The electrode rod(s) is/are too short.
Replace electrode rod(s) and cut electrode rod(s) to the length dictated by the switchpoint LW.
The earth connection to the vessel is interrupted.
Clean seating surfaces and screw in the electrode together with the supplied joint ring
∅
27x32 DIN 7603. Do not insulate the electrode with hemp or PTFE tape!
Fault:
Remedy:
The insulation of the level electrode is faulty.
Replace level electrode.
27
Page 28
Malfunctions
Fault finding list for level electrode NRG 1.-41.1 / control unit NRS 1-40.1
Switchpoint "High water (HW)" exceeded - no high level alarm
– continued –
Fault:
Remedy:
Fault:
Remedy:
Fault:
Remedy:
Fault:
Remedy:
Switchpoint "High water (HW)" not yet exceeded - but a high level alarm is raised
Fault:
LED "Power" and LEDs 1 - 4 are not illuminated.
Apply mains voltage, wire equipment in accordance with wiring diagram.
The electrode rod is too short.
Replace electrode rod and cut electrode rod to the length dictated by the switchpoint HW.
If the electrode is installed inside the boiler: The vent hole in the protection tube does not exist
or is obstructed.
Check installation of level electrode. Make sure that the level in the protection tube corresponds to the actual water level.
The earth connection to the vessel is interrupted.
Clean seating surfaces and screw in the electrode together with the supplied joint ring
∅
27x32 DIN 7603. Do not insulate the electrode with hemp or PTFE tape!
The electrode rod is too long.
Remedy:
Fault:
Remedy:
Fault finding list for temperature transmitter TRV 5-40 / control unit NRS 1-40.1
Switchpoint "MAX temperature" not yet exceeded - but a MAX temperature alarm is raised
Fault:
Remedy:
Cut electrode rod to the length dictated by the switchpoint HW.
The insulation of the level electrode is faulty.
Replace level electrode.
The temperature sensor is defective.
Check whether the temperature sensor (Pt 100) gives correct readings (basic values of meas-
uring resistors to DIN 43760 for Pt 100). In case of incorrect readings replace the measuring
element of the temperature sensor.
If faults occur that are not listed above or cannot be corrected, please
contact our service centre or authorized agency in your country.
28
Page 29
Emergency Operation
Emergency operation of water level limiting system LW
Provided that the control unit works with two level electrodes NRG 1x-40 (water level limiting system), if
one level electrode fails to operate the installation can continue to operate in emergency mode with
level electrode under constant supervision according to TRD 401 and EN 12952 and EN 12953.
The following settings are required:
1. Set the wire link to the left in order to configure the working level electrode as device 1 and set the node
ID to "2" (see
"Emergency Operation" in the installation manual of NRG 1x-40
).
one
2. Control unit:
Cut off power supply
and unplug the lower terminal strip .
3. The terminal strip can be unplugged after undoing the right and the left fixing screws .
4. Set switch S1 of the code switch Fig.4 to ON and S2 to S7 to
D
OFF
B
C
. The control unit NRS 1-40.1 has
now the node ID 1.
5. Set switches S1 and S2 of the code switch Fig.4 to
6. Re-insert terminal strip and fasten the fixing screws .
B C
E
OFF
.
Attention
■
Enter beginning of emergency operation in the boiler log.
■
An installation operating in emergency mode has to be constantly supervised!
■
Immediately replace faulty level electrode.
■
Enter end of emergency operation in the boiler log.
29
Page 30
Annex
CAN bus
All devices (level, conductivity, temperature) are interconnected via CAN bus. The CANopen protocol is
used for the data exchange between the equipment groups. All devices have an electronic address - the
node ID. The four-core bus cable serves as power supply and data highway for high-speed data exchange.
The CAN address (nodeID) can be set between 1 and 123.
The control unit NRS 1-40.1 has already been configured at our works for operation with other GESTRA
components and can be used straight away without having to set the node ID.
Factory set node IDs
Control equipment
NRS 1-40.1 ID:001
Sensors
NRG 16-40 ID:002
NRG 16-40 ID:003
NRG 16-41.1 ID:004
NRS 1-42 ID:020
NRS 2-40 ID:039
NRR 2-40 ID:040
LRR 1-40 ID:050
TRV 5-40 ID:005
NRG 16-42 ID:021
NRG 26-40 ID:041
LRG 16-40 ID:051
Individual node IDs must be set manually in the respective equipment.
Please observe the pertinent installation instructions.
30
Page 31
Annex
– continued –
Node ID
Should it be necessary to establish other node IDs please take the interdependence of the equipment into
consideration and assign the node IDs for the individual group components according to the following
table:
Control unit
NRS 1-40.1
Sensor 1 e. g.
level electrode
NRG 1.-40
as device 1
Sensor 2 e. g.
level electrode
NRG 1.-40
as device 2
Sensor 3 e. g.
level electrode
NRG 1.-41.1
X X+1 X+2 X+3 X+4
1 2 3* 4 5
Factory setting
Reserved area
Note
The node ID 3* of the second level electrode NRG 1.-40 must be set on site since the equipment features 2 as default factory setting.
Sensor 4 e. g.
Temperature
transmitter
TRV 5-40
Change node ID
With lower terminal strip unplugged:
Set the node ID via code switches Fig.4 (S1 to S 7) a specified in the above table "Node ID" by using a
D
thin blade screwdriver.
Re-insert terminal strip and fasten the fixing screws . Enter the adjusted node ID on the name plate.
B C
Danger
The terminal strips of the control unit NRS 1-40.1 are live during operation.
This presents the risk of severe cases of electric shock!
Always
cut off power supply
to the equipment before mounting, removing or connecting
the terminal strips!
Attention
A node ID must only be used for one piece of equipment in the CAN bus system.
The node ID 0 is not permissible.
31
Page 32
Annex
– continued –
Tab le Node ID
In a CAN bus system a maximum of 123 nodes (devices) can be administered. Each node has its own address (node ID). This address can be set via a 10-pole code switch Fig.4.
D
ON
123 54678910
Toggle switch, white
D
ON
12354 678910
Toggle switch, white
Node ID 1 Node ID 71
S1
ON
1S1
ON
S2 OFF 2 S2 OFF 2
S3 OFF 4 S3
S4 OFF 8 S4
ON
ON
S5 OFF 16 S5 OFF 16
S6 OFF 32 S6 OFF 32
S7 OFF 64 S7
ON
(Factory setting) (Example)
S8 S9 S10 Baud rate Cable length
D
1
4
8
64
OFF ON OFF 250 kBit/s 125 m
Factory setting
ON ON OFF 125 kBit/s 250 m
OFF OFF ON 100 kBit/s 335 m
ON OFF ON 50 kBit/s 500 m
OFF ON ON 20 kBit/s 1000 m
ON ON ON 10 kBit/s 1000 m
Decommissioning
A
First unplug the terminal strips , . For this purpose turn the right and left fixing screws in direction
B C
of the arrow until the terminal strip can be removed.
Undo the fixing slide in order to snap out the controller and take it off the supporting rail.
32
Page 33
Annex
– continued –
Disposal
Dismantle the control unit and separate the waste materials, using the specifications in the table "Materials" as a reference. Electronic component parts such as the circuit board must be disposed of separately!
For the disposal of the control unit observe the pertinent legal regulations concerning waste disposal.
Declaration of Conformity
We hereby declare that the control unit
■
LV guideline 73/23/eec version 93/68/eec
■
EMC guideline 89/336/eec version 93/68/eec
■
Pressure Equipment Directive (PED) 97/23/EC of 29 May 1997
NRS 1-40.1
conforms to the following European guidelines:
Applied conformity assessment procedure: Annex III, Module B and D, verified by the
Notified Body 0525.
This declaration is no longer valid if modifications are made to the equipment without consultation with us.
Bremen, 7th April 2005
GESTRA AG
i. V. i. V.
Dipl.-Ing. Uwe Bledschun
Leiter Konstruktion / Head of Design Dept.
Qualitätsbeauftragter / Quality Assuranc e Representative
Dipl.-Ing. Lars Bohl
33
Page 34
www.gestra.de
España
GESTRA ESPAÑOLA S.A.
Luis Cabrera, 86-88
E-28002 Madrid
Tel. 00 34 91 / 51 52 032
Fax 00 34 91 / 41 36 747; 51 52 036
E-mail: aromero@flowserve.com
Great Britain
Flowserve Flow Control (UK) Ltd.
Burrel Road, Haywards Heath
West Sussex RH 16 1TL
Tel. 00 44 14 44 / 31 44 00
Fax 00 44 14 44 / 31 45 57
E-mail: gestraukinfo@flowserve.com
Italia
Flowserve S.p.A.
Flow Control Division
Via Prealpi, 30
I-20032 Cormano (MI)
Tel. 00 39 02 / 66 32 51
Fax 00 39 02 / 66 32 55 60
E-mail: infoitaly@flowserve.com
Poland
GESTRA POLONIA Spolka z.o.o.
UI. Schuberta 104
PL - 80-172 Gdansk
Tel. 00 48 58 /306 10-02 od 10
Fax 00 48 58 /306 33 00
E-mail: gestra@gestra.pl
Portugal
Flowserve Portuguesa, Lda.
Av. Dr. Antunes Guimarães, 1159
Porto 4100-082
Tel. 0 03 51 22 / 6 19 87 70
Fax 0 03 51 22 / 6 10 75 75
E-mail: jtavares@flowserve.com
USA
Flowserve DALCO Steam Products
2601 Grassland Drive
Louisville, KY 40299
Tel. 00 15 02 / 4 95 01 54, 4 95 17 88
Fax 00 15 02 / 4 95 16 08
E-mail: dgoodwin@flowserve.com
GESTRA AG
Postfach 10 54 60, D- 28054 Bremen
Münchener Str. 77, D -28215 Bremen
Telefon +49 (0) 421 35 03-0
Telefax +49 (0) 421 35 03-393
E-Mail gestra.ag@flowserve.com
Internet www.gestra.de
818548-00/605agt ©2005 GESTRA AG Bremen Printed in Germany
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