Flowserve NRS 1-42 User Manual

NRS 1-42

Installation Instructions 810373-03

Level Switch Type NRS 1-42



1

Contents

Page

Important Notes

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

Safety note ......................................................................................................................7

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

Explanatory Notes

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

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

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

Technical data .................................................................................................................9

Installation

NRS 1-42 ....................................................................................................................... 10

Example of installation ..................................................................................................27

Wiring

Wiring diagram ................................................................................................3, 4, 10, 11

Basic Adjustment

CAN bus ........................................................................................................................ 12

Node ID .........................................................................................................................12

Factory setting...............................................................................................................12

Adjust sensitivity ...........................................................................................................13

Operation

On-off control ................................................................................................................ 14

Switchpoint 1 ................................................................................................................. 14

Switchpoint 2 ................................................................................................................. 14

Switchpoint 3 ................................................................................................................. 14

Switchpoint 4 ................................................................................................................. 14

Alarm ............................................................................................................................. 15

High-level (

Low-level (MIN) alarm ..................................................................................................... 15

Relay test high level / low level.......................................................................................15

System Malfunctions

Systematic analysis of malfunctions 1 – 3 ............................................................. 16–20

Malfunctions

Fault-finding list for troubleshooting ........................................................................21, 22

Annex

Factory set default node IDs .........................................................................................23

Assigning/changing node IDs .................................................................................23, 24

Declaration of conformity .............................................................................................. 25

2

MAX) alarm ...................................................................................................15

Wiring Diagram

Twisted pair cable

Twisted pair cable

Fig. 1

Relay Relay Relay Relay

1234

Fill/

MAX MIN

discharge
control

Terminating resistor

ΩΩ

120

Ω

ΩΩ

Control terminal
URB 1

CEP

1)

Level switch
NRS 1-42

Power supply CAN data line

Terminating resistor
120 Ω

1)

CEP = central earthing point

Fig. 2

Controller
. . .

Level electrodes
NRG 16-42

Terminating resistor
120 Ω

Electrodes
...

3

Wiring Diagram

Discharge control – Pump OFF at low level

Twisted pair cable

Twisted pair cable

Terminating resistor 120

Fig. 3
Fill control – Pump OFF at high level

ΩΩ

Ω

ΩΩ

Pump contactor

Fig. 4

4

Twisted pair cable

Twisted pair cable

Terminating resistor 120

Pump contactor

ΩΩ

Ω

ΩΩ

Parts Drawing

1

Fig. 5

7 6 5 4 3 2

A

A

B

Fig. 6

5

Key

1

Indicator LEDs

Discharge control Fill control

LED 1 – switchpoint 1

LED 2 – switchpoint 2

LED 3 – switchpoint 3

LED 4 – switchpoint 4

2

LED “Bus status”

3

LED “Power”

4

Enter button / test mode

5

Decrease button

6

Increase button

7

Program button

8

Code switch, 10 poles

A

Terminal strip

B

Screws for terminal strip

High-level alarm High-level alarm

Pump ON Pump OFF

PUMP OFF Pump ON

Low-level alarm Low-level alarm

6

Important Notes

Usage for the intended purpose

Use level switch NRS 1-42 in conjunction with level electrode NRG 16-42 only for
level signalling in liquid and electrically conductive fluids.

Safety note

The equipment must only be installed 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.

Warning

The terminal strip of the NRS 1-42 is live during operation. This presents
the danger of electric shock. Cut off power supply before fixing or
removing the cover.

7

Explanatory Notes

Scope of supply

NRS 1-42

1 Level switch type NRS 1-42 (plug-in unit in plastic case with terminals)
1 Terminating resistor 120 Ω
1 Installation manual

System description

Use level switch type NRS 1-42 together with level electrode type NRG 16-42 for
level monitoring. The level switch has the following functions:

■

Four levels with one switchpoint each.

■

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

The level data are transferred from the electrode NRG 16-42 to the level switch via a
CAN bus.

Function

At regular intervals the level electrode NRG 16-42 sends a data telegram to the level
switch NRS 1-42. The data transfer is effected by means of a CAN bus according to
DIN ISO 11898. The transferred measuring data are then evaluated and assigned to
the manually adjusted switchpoints. To guarantee the correct functioning and safety
of the system the data transmitting cycle of the level switch is constantly monitored
by the level switch. When the CAN bus line is interrupted the level switch sends a
visual signal to indicate a malfunction and the relays 1 and 4 will be instantaneously
de-energized (fail-safe position).

Additional functions, such as (de-)energizing delay times of the output relays
(1 to 25 seconds), can be adjusted with the control terminal and display unit
URB 1.

8

Technical data

Type approval n°

TÜV · WR 98-399

Input/ Output

Interface for CAN bus to DIN ISO 11898 CANopen

Output – voltage supply for electrode

Power supply 24 V DC, short-circuit protected
4 volt-free relay contacts.
Max. contact rating with switching voltages of 24 V AC, 115 V AC and
230 V AC: 4 A resistive, 0.75 A inductive at cos ϕ 0.5
Max. contact rating with a switching voltage of 24 V DC: 4 A.
Contact material: silver, hard-gold plated

Interference suppression

Provide contactor with an external RC combination (100 Ω / 47 nF)

Relay de-energizing delay

Output “

MIN”, “MAX” 3 s

Indicators and adjustors

4 pushbuttons for parameterisation/"TEST"
1 red LED for switchpoint “
1 red LED for switchpoint “

HIGH LEVEL” (MAX)
LOW LEVEL” (MIN)

2 green LEDs for switchpoints “pump ON” and “pump OFF”
1 green LED “
1 red LED “

POWER”

BUS FAU LT”

1 ten-pole code switch, 7 poles for node ID and 3 poles for baud rate settings

Sensitivity

Range 1: ≥ 10 µS/cm
Range 2: ≥ 0.5 µS/cm

Supply voltage

230 V ± 10%, 50/60 Hz
115 V ± 10%, 50/60 Hz (option)

Power consumption

10 VA

Protection

Case: IP 40 to DIN ISO 60529
Terminal strip: IP 20 to DIN ISO 60529

Admissible ambient temperature

0 °C to 55 °C

Enclosure material

Front panel: polycarbonate, grey
Case: polycarbonate, black

Weight

Approx. 0.8 kg

9

Installation

NRS 1-42

Installation on mounting rail

1. Clip level switch onto mounting rail 35x 15 mm
(DIN EN 50022).

2. Align level switch, fig. 11, fig. 12

Tool

■

Screwdriver (5.5/100)

Wiring

Note that screened multi-core twisted-pair control cable is required, e. g. UNITRONIC
BUS CAN 2 x 2 x ... 2 or RE-2YCYV-fl 2 x 2 x ... 2.

The baud rate (data transfer rate) dictates the cable length between the bus nodes and
the total power consumption of the measuring sensors dictates the conductor size.

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FFO NO FFO s/tiBk052 m521

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NONOFFOs/tiBk521m0525.0x2x2

FFOFFONOs/tiBk001m53357.0x2x2

NOFFONOs/tiBk05m005

FFONONOs/tiBk02m0001

NONONOs/tiBk01m0001

sriapforebmuN

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The baud rate is set via a code switch. Reduce baud rate if cable is longer than
specified in the table. Make sure that all bus nodes have the same settings.

To protect the switching contacts fuse circuit with 2.5 A (anti-surge fuse) or according
to TRD regulations (1.0 A for 72 hrs operation).

When a max. cable length of 1000 m is desired, make sure to modify the baud
rate accordingly. Refer to pages 23 and 24 for more details.

Wiring diagram

See wiring diagrams on page 3 and 4.

®

UNITRONIC® is a registered trademark of LAPP Kabelwerke GmbH, Stuttgart

10

Wiring – continued –

Attention

■

Wire equipment in series. Star-type wiring is not permitted.

■

Interlink screens of control cables such that electrical continuity is
ensured and connect them once to the central earthing point (CEP).

■

To protect the switching contacts fuse circuit with T 2.5 A or
according to TRD regulations.

■

If more than one system component is connected to a CAN bus network
provide the first and last equipment with a terminating resistor of 120 Ω.

Fig. 2

■

The CAN bus network must not be interrupted while operating.
Any interruption will result in HIGH/LOW level alarm!

If the level controller must be replaced, remove terminal
strip Fig. 6.

Before removing the CAN-bus line from the terminal strip disconnect all
relevant system components.

Note

■

Connect screen only to terminal 3, ensuring electrical continuity and
connect it once to the central earthing point (CEP).

■

The loop resistance must be under 10Ω.

■

The rated voltage is stated on the name plate.

■

When switching off inductive loads, voltage spikes are produced that
may impair the operation of control and measuring systems. Inductive
loads should therefore be provided with commercial arc suppressor
RC combinations, e.

■

In spite of correct wiring H. F. interference caused by the installation may
lead to system breakdowns and malfunction messages. If necessary
refer to the “Fault finding list for troubleshooting” on page 21.

A

g. 0.1 µF/100 Ω.

Tool

■ Screwdriver for slotted screws, size 2.5, completely insulated according to

VDE 0680.

11

Basic Adjustments

CAN Bus

All level and conductivity controllers and associated electrodes are interconnected by
means of a CAN bus using the CANopen protocol. Every item of equipment features
an electronic address (node ID). The four-core bus cable serves as power supply and
data highway for high-speed data exchange.
The CAN address (node ID) can be set between 1 and 123.

The NRS 1-42 is configured at our works and ready for service with other GESTRA
system components without having to set the node ID.

If several systems of the same kind are to communicate in one CAN bus
network, be sure to assign one node ID for each individual system component.
Refer to pages 23 and 24 for more details.

Node-ID

Factory setting

The level switch features the following factory set default values:

■

Baud rate: 250 kb/s

■

Sensitivity: 10 µS/cm

■

Node ID: 020

■

Relay with energizing delay switchpoint 1: 0s

■

Relay with energizing delay switchpoint 4: 0s

■

Relay with de-energizing delay switchpoint 1: 3s

■

Relay with de-energizing delay switchpoint 4: 3s

12

Basic Adjustments – continued –

Adjust sensitivity 0.5 µS/cm

Press button briefly.
Sensitivity range 1 (10 µS/cm, factory-set

default value) is activated.
Use button and to switch between

sensitivity range 10 µS/cm and 0.5 µS/
cm.

LED illuminated

briefly

LED Power

Press button briefly.
Sensitivity 0.5 µS/cm is selected.

Press button briefly.

Note:

When in program mode in the event of a
system malfunction the LED “Bus status”
and/or the LED “Power” flash rapidly.
Quit program mode and analyse system
malfunction (see pages 16 – 18).

Press button twice briefly.
Sensitivity range 0.5 µS/cm is saved.
The four indicator LEDs signal the

present operating mode.

LED illuminated

LED flashes

LEDs indicate present operating mode

LEDs flash slowly

LEDs flash slowly

briefly

briefly

twice briefly

13

Operation

ON-OFF Control

The setpoint range of the liquid level is

LEDs indicate present operating mode

reached when electrode tips 3 and 4 are
submerged and electrode tips 1 and 2 are
exposed.

Note: All LEDs go out once the setpoint is
reached.

Switchpoint 1

Switchpoint 1 reached

■

Time delay activated, LED 1 flashing

■

Time delay elapsed, LED 1 permanently illuminated, relay 1 de-energized

Level below switchpoint 1

■

LED 1 goes out, relay 1 energized

Switchpoint 2

Switchpoint 2 reached

■

Time delay activated, LED 2 flashing

■

Time delay elapsed, LED 2 permantently illuminated, relay 2 energized

Level below switchpoint 2

■

LED 2 goes out, relay 2 de-energized

Switchpoint 3

LED “Power”

Level below switchpoint 3

■

Time delay activated, LED 3 flashing

■

Time delay elapsed, LED 3 permantently illuminated, relay 3 energized

Switchpoint 3 reached

■

LED 3 goes out, relay 3 de-energized

Switchpoint 4

Level below switchpoint 4

■

Time delay activated, LED 4 flashing

■

Time delay elapsed, LED 4 permanently illuminated, relay 4 de-energized

Switchpoint 4 reached

■

LED 4 goes out, relay 4 energized

14

Operation – continued –

Alarm

There are two alarm conditions:

■ High-level (MAX) alarm

■ Low-level (MIN) alarm

High-Level (MAX) Alarm

LED 1 flashes rapidly.
LED 1 remains permanently illuminated

after the de-energizing delay.

Low-Level (MIN) Alarm

LED 4 flashes rapidly.
LED 4 remains permanently illuminated

after the de-energizing delay.

Relay Test MIN/MAX

illuminatedflashes

flashes illuminated

Press button briefly.
The test mode is activated for 5 seconds.

Hold down button .
LED 4 goes out.
A low-level (

MIN) alarm is simulated for

switchpoint 4.

Hold down button .
LED 1 goes out.
A high-level (

MAX) alarm is simulated for

switchpoint 1.

LEDs illuminated

briefly

Indicator LED 4 goes out

Indicator LED 1 goes out

15

System Malfunctions

There are four system malfunctions that might occur in the level switch and the level
electrode:

■ Max. admissible temperature in electrode terminal box exceeded

■ No or faulty communication between controller and electrode

■ Fault in CAN bus

■ Failure of 24 V power supply unit built in level switch NRS 1-42

Danger

The terminal strip of the NRS 1-42 is live during operation.
This presents the danger of electric shock.
Cut off power supply before mounting or removing the equipment.

16

System Malfunctions – continued –

Systematic Malfunction Analysis

The sources of malfunctions occurring 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 sensing units of
bus nodes.

Level electrode
Conductivity electrode
Pressure sensor
Temperature sensor

Check

Use fault-finding
list to correct
fault(s).

Final test:
have all faults
been eliminated?

System
Malfunction

Use fault-finding list
to identify the
fault(s).

Cut off power supply
to the equipment.

Step 2

Plug in terminal strip
of the bus nodes, e. g.

NRS ...

and

NRG ... (sensor)

Step 3

Apply mains voltage
to bus nodes, e. g.

NRS ...

and

NRG ...

Check next system

System O.K.

Detach terminal
strips between
bus nodes e. g.

NRS ...

and

NRG ...

17

System Malfunctions – continued –

Danger

The terminal strip of the NRS 1-42 is live during operation.
This presents the danger of electric shock.
Cut off power supply before mounting or removing the equipment.

System Malfunction 1

The four indicator LEDs flash slowly.

MAX/MIN alarm

Fault:
Remedy:

The max. admissible temperature in the electrode terminal box is exceeded.
Insulate electrode flange to protect the equipment against heat radiation.

LEDs flash slowly

As soon as the temperature drops below the max. admissible limit the equipment
automatically returns to normal operation.

System Malfunction 2

The four LEDs flash rapidly.

MAX/MIN alarm

Fault:
Remedy:

The CAN bus line between the nodes is interrupted.
Check wiring and terminals. Restart system.

LEDs flash rapidly

Fault:
Remedy

18

Incorrect node ID settings.

:

Set correct node ID(s), referring to sections “Basic Adjustment” and “Annex”.
Disconnect the system from its power supply. After 5 sec. connect

power and restart system.

System Malfunctions – continued –

System Malfunction 3
The four indicator LEDs flash slowly.

LED flashes slowly

Fault:

The plausibility test shows that the low level electrode ends above high
level.

Remedy:

Check electrode tips and, if necessary, correct the assignment of the
connectors on the preamplifier board of the electrode.

System Malfunction 4
LED “Bus status” flashes slowly.

Fault:
Remedy:

Malfunction in CAN bus.
Restart system.

LED “Bus status” flashes slowly

MAX/MIN alarm

Fault

: Data transfer in CAN bus interrupted.

Remedy:

The bus cables have to be correctly connected according to the wiring
diagram (observe polarity!). Make sure that all end-of-line nodes are
provided with 120 Ω terminating resistors. Disconnect the system from its
power supply. After 5 sec. connect power and restart system.

LED flashes slowly

LED flashes slowly

Fault:
Remedy:

Fault:

Remedy:

The baud rate of one or more nodes is not set correctly.
Check baud rate settings of all bus nodes. The baud rates must be
identical. Refer to section “Annex” for more details. Disconnect the system
from its power supply. After 5 sec. connect power and restart system.

The overall length of the bus cable does not correspond to the selected
baud rate.
Change baud rate settings of all nodes according to the ratings indicated
in section “Annex”. Disconnect the system from its power supply. After 5
sec. connect power and restart system.

19

System Malfunctions – continued –

System Malfunction 5

LED “Power” flashes slowly.

LED flashes slowly

Fault:

Remedy:

Fault:
Remedy:

The power supply unit (PSU) is overloaded. The power supply unit may
be misused for other components.

Check load of power supply unit. Be sure to use the PSU only for the
voltage supply of network components.

Disconnect the system from its power supply. After 5 sec. connect power
and restart system.

Power supply unit fails to function.
Replace PSU.

20

Malfunctions

Danger

The terminal strip of the NRS 1-42 is live during operation.
This presents the danger of electric shock.
Cut off power supply before mounting or removing the equipment.

Fault finding list for troubleshooting

Device fails to work – indication of malfunction

Fault:

Remedy:

Device fails to work – no function

Fault:
Remedy:

Switchpoints reached / level below switchpoints – no function

Fault:
Remedy:

Fault:
Remedy:

In spite of correct wiring and commissioning of the equipment an
interference signal is indicated.
The interference signal is caused by H. F. interferences coming from the
installation. For interference suppression of the voltage supply we supply
ferrite rings, stock code 147253. The 230 V supply lines should be
looped through the ferrite ring five to ten times. If several controllers are
used in the system, they can be fed from the interference suppressed
supply lines. For the interference suppression of the bus line we supply
hinged-shell ferrite rings, stock code 147254. The hinged-shell ferrite
rings are clamped onto the bus line close to the terminal strip of the
controller.
Restart the system after installation.

LED “Power” does not light up.
Turn on the power. Connect the equipment in accordance with the wiring

diagram.

The electric conductivity is too low.
Set sensitivity to

The electrode body does not have earth connection to the vessel.
Clean seating surfaces and insert metal joint ring (of stainless steel 1.4301)

D 33 x 39 to DIN 7603.
Do not insulate the level electrode with hemp or PTFE tape!

≥≥

≥ 0.5 µS/cm.

≥≥

Fault:
Remedy:

Fault:

Remedy:

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 item) are
closed.

Open isolating valves.

21

Malfunctions – continued –

Fault finding list for troubleshooting – continued –

Switchpoints reached / level below switchpoints – 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.

The switching function has not been correctly allocated.
Electrode rods have been cut to the wrong size.

Identify electrode supply wires and reconnect the circuit board in the
terminal box accordingly.

22

Annex

Danger

The terminal strip of the NRS 1-42 is live during operation.
This presents the danger of electric shock.
Cut off power supply before mounting or removing the equipment.

Factory set default values of node IDs

Switching

Level electrode

controller

The individual node IDs must be manually adjusted on the equipment.
Please observe the installation instructions of the device in question.

Assigning / changing node ID

If several systems of the same kind are to communicate in one CAN bus network, be
sure to assign one node ID for each individual system component (e. g. controller).

Detach terminal strips in order to change the code switch settings .

Attention

■ Do not assign the same node ID twice within the CAN bus network.

A 8

Fig. 7

23

Annex – continued –

Node ID

OFF

S1

OFFS2

S3

ON

OFFS4

S5

ON

OFFS6
OFFS7

Fig. 8 (Factory setting)

S8

OFF

ON

OFF

S9 S0

ON

ON

OFF

ON

OFF 1000 m

ON
ONON

Fig. 10 (Factory setting: 250 kBits/s)

1
2
4

8
16
32
64

OFF

OFF

ON
ON
ON
ON

20

Baud rate

250 kBit/s

125 kBit/s
100 kBit/s

50 kBit/sOFF
20 kBit/s
50 kBit/s

S1
S2
S3

S7

Fig. 9 (Example)

Cable length

Node ID

OFF

ON
ON

OFFS4
OFFS5
OFFS6

ON

125 m

250 m
335 m
500 m

1000 m

70

1
2
4

8
16
32
64

24

Annex – continued –

Declaration of conformity

We hereby declare that the equipment NRS 1-42 conforms to the following Euopean
guidelines:

■

LV guideline 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 DIN EN 50178

■

EMC standard DIN EN 50 081-2, DIN EN 610 00-6-2

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

Head of the Design Dept.

Uwe Bledschun

(Academically qualified engineer)

Bremen, 23

GESTRA GmbH

rd

July 2002

Quality Assurance Manager

Lars Bohl

(Academically qualified engineer)

25

Key

Terminal strips

A

Supporting rail 35 x15 to DIN EN 50022

C

26

Example of Installation

Fig. 11

100

73

118

Fig. 12

20 20

27

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West Sussex RH 16 1TL
Tel. [phone] / 31 44 00
Fax [phone] / 31 45 57
E-mail: [e-mail]

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E-28002 Madrid
Tel. [phone]
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E-mail: [e-mail]

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Tel. [phone]
Fax 00 39 02 / 66 32 55 60
E-mail: [e-mail]

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Av. Dr. Antunes Guimarães, 1159
Porto 4100-082
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

®

GESTRA GmbH

Postfach 10 54 60, D-28054 Bremen, Münchener Str. 77, D-28215 Bremen
Telefon [phone] - 0, Telefax [phone]
E-Mail [e-mail], Internet www.gestra.de

A Unit of Flowserve Corporation

810373-02/304cm · © 2000 GESTRA GmbH · Bremen · Printed in Germany

28