Flowserve NRS 2-40 User Manual

NRS 2-40

Installation Instructions 810371-02

Level Switch Type NRS 2-40



1

Contents

Page

Important Notes

Usage to the intended purpose .......................................................................................7

Safety note / Danger.......................................................................................................7

Explanatory Notes

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

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

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

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

Installation

NRS 2-40 ...................................................................................................................... 10

Example of installation ................................................................................................. 29

Wiring

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

Basic Adjustment

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

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

First / second control equipment ..................................................................................12

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

Commissioning

NRS 2-40 ...................................................................................................................... 14

Control range ................................................................................................................ 14

Establish control range............................................................................................15, 16

Establish switchpoints within adjusted control range ....................................................16

Establish switchpoints ........................................................................................... 16 – 19

Operation

Normal operation ..........................................................................................................19

Alarm ............................................................................................................................. 19

High-level alarm ............................................................................................................19

Low-level alarm ............................................................................................................. 19

Relay test high/low (

System Malfunctions

Systematic fault finding procedure ................................................................................21

Analysis of system malfunctions 1 – 4 ....................................................................22–24

Operation Malfunctions

Fault-finding list for troubleshooting ........................................................................ 25, 26

Annex

Factory set default node IDs .........................................................................................27

Assigning / changing node IDs ................................................................................27, 28

Declaration of conformity .............................................................................................. 29

2

MAX/MIN) level .................................................................................20

Wiring Diagram

Relay Relay Relay Relay

1234

Fill/

MAX

discharge
control

MIN

Seite

Paired cable

Paired cable

Fig. 1

Control terminal
URB 1

*) CEP = central earthing point

Level switch
NRS 2-40

CEP*)

Power supply CAN data line

Terminating resistor
120 Ω

Fig. 2

Controller
. . .

Potentiometer

Terminating resistor

ΩΩ

120

Ω

ΩΩ

Level electrodes
NRG 26-40

Terminating resistor
120 Ω

optional output
for actual value
4-20 mA

Electrodes
...

3

Wiring Diagram

Discharge control –

Pump OFF at low level (MIN)

Pump contactor

Paired cable

Paired cable

Fig. 3

Potentiometer

Terminating resistor

ΩΩ

120

Ω

ΩΩ

Fill control – Pump OFF at high level (MAX)

Paired cable

Paired cable

Fig. 4

Potentiometer

Terminating resistor

ΩΩ

120

Ω

ΩΩ

optional output
for actual value
4-20 mA

Pump contactor

optional output
for actual value
4-20 mA

4

Parts Drawing

1

Fig. 5

A

A B

3567

4

2

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 2-40 in conjunction with level electrode NRG 26-40 only for
liquid level monitoring and control.

Safety notes

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.

Danger

The terminal strip of the NRS 2-40 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 2-40

1 Level switch type NRS 2-40 (plug-in unit in plastic case with box terminals)
1 Terminating resistor 120 Ω
1 Operating manual

Description

Use level switch type NRS 2-40 in combination with level electrode type
NRG 26-40 for level monitoring. The level switch has the following functions:

■

Four liquid levels with one switchpoint each.

■

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

■

Continuous level monitoring within control band defined by two preset limits.

■

Actual-value output 4-20 mA (optional)

■

Contact multiplication by connecting in parallel a second level switch NRS 2-40
without optional actual value output.

The level data are transmitted via CAN-bus from the electrode NRG 26-40 to the level
switch.

Function

At regular intervals the level electrode type NRG 26-40 sends a data telegram to the
level switch NRS 2-40. 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 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 (alarm
position).

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

8

Technical data

Type approval no.

NRS 2-40: TÜV · WR · 98-399

Input / Output

Interface for CAN bus to DIN ISO 11898 using CANopen

Output – voltage supply for electrodes

Power supply 24 V DC, short-circuit protected
Analogue output 4– 20 mA, load 500 Ω for display of actual value (optional).
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 / 47nF)

Relay de-energizing delay

Output “MIN”, “MAX” 3 s

Indicators and adjustors

1 red LED for switchpoint “High level” (MAX)
1 red LED for switchpoint “Low level” (MIN)
2 green LEDs for switchpoints “PUMP ON” and “PUM OFF”
1 green LED “Power”
1 red LED “Bus fault”
1 ten-pole code switch for node ID and baud rate settings
4 pushbuttons

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 2-40

Installation on mounting rail

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

2. Align level switch, fig. 14, fig. 15

Tool

■

Screwdriver (5.5/100)

Wiring

Note that screened multi-core twisted-pair control cable is required, e. g.
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and the total power consumption of the measuring sensors dictates the conductor
size.

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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 page 27 and 28 for more details.

Wiring diagram

See wiring diagrams on pages 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 (1.0 A for 72 hrs.).

■

If two or more system components are connected in a CAN bus network,
the first and last equipment have to be provided with a terminating
resistor of 120 Ω. Fig. 2

■

The CAN bus network must not be interrupted while operating.
Any interruption will result in

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 designated terminals.

■

The loop resistance must be under 10 Ω.

■

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.

■

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 pages 25
and 26.

HIGH/LOW level alarm!

A

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 2-40 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 27 and 28 for more details.

Node ID

First and second control equipment

It is possible to operate the level switch NRS 2-40 together with a second level
switch NRS 2-40 when 8 instead of only 4 switchpoints are required.
The second level switch is termed “second control equipment” and must be
ordered separately.

The NRS 2-40 can also be operated together with the level controller NRR 2-40
as “second control equipment”.

The standard equipment NRS 2-40 is termed “first control equipment 1”.
Be sure to assign different node IDs for NRS 2-40 (first control equipment),

additional NRS 2-40 (second control equipment) and NRR 2-40 (controller)!

The name plate of the NRS 2-40 is marked “Control equipment 1” or
“Control equipment 2”.

12

Basic Adjustments – continued –

Factory setting

The level switch features the following factory set default values:

■

Baud rate: 250 kb/s

■

Control equipment: 1

■

Node ID: 039

■

Control equipment: 2

■

Node ID: 040

■

Switchpoint 1: 80%

■

Switchpoint 2: 60%

■

Switchpoint 3: 40%

■

Switchpoint 4: 20%

80%
60 %
40%
20%

■

Relay with energizing delay switchpoint 1: 1s

■

Relay with energizing delay switchpoint 2: 1s

■

Relay with energizing delay switchpoint 3: 1s

■

Relay with energizing delay switchpoint 4: 1s

■

Relay with de-energizing delay switchpoint 1: 3s

■

Relay with de-energizing delay switchpoint 2: 1s

■

Relay with de-energizing delay switchpoint 3: 1s

■

Relay with de-energizing delay switchpoint 4: 3s

100 %

Fig. 7

13

Commissioning

NRS 2-40

Apply power to the unit.
The four indicator LEDs flash rapidly.

The LED “Power” lights up.
The system test cycle takes about 2 sec.

Control Range

1

Desired control range [mm]

2

Max. control range

Establish the control range
for your level monitoring

1

37

application.

2

Fig. 8

26

Indicator LEDs flash rapidly

LED “Power” illuminated

NRG 26-40

1

Lower control
range limit

14

Commissioning – continued –

Establish control range

Press button for 3 sec.
Lower the liquid level in the vessel until the

lower limit of the control range is reached.

1

Use button if you want to establish the
upper limit of the desired control range first.

If two control devices are used only one
has to be adjusted.

Press button briefly.

Note:

In the event of a system malfunction,
the LED(s) “Bus status” and/or “Power”
will be flashing rapidly when in
program mode. Quit program mode
and analyse the system malfunction
(see pages 22 – 24).

Press button briefly.
The lower limit of the control range is

now saved.

LEDs illuminated LEDs flash slowly

3 sec.

LEDs flash LEDs flash slowly

briefly

LEDs illuminated LEDs flash slowly

LED “Power”

briefly

Press button briefly.
Raise liquid level until the upper limit of

the desired control range is reached.

1

Press button briefly.

LEDs illuminated LEDs flash slowly

briefly

LEDs flash LEDs flash slowly

briefly

15

Commissioning – continued –

Establish control range – continued –

Press button twice briefly.
The upper limit of the desired control

range is now saved.
The NRS 2-40 is back in operating

mode.

Establish switchpoints within the adjusted control range

1

Switchpoint 1

2

Switchpoint 2

3

Switchpoint 3

4

Switchpoint 4

5

Adjusted control range

1
2
3
4

NRG 26-40

5

twice briefly

Fig. 9

Establish switchpoints

Press button briefly.
Raise or lower the liquid level in the

vessel until the desired value is reached.
Use button if you want to establish a

different switchpoint first.

16

LED illuminated LEDs flash slowly

briefly

Commissioning – continued –

Establish control range – continued –

Press button briefly.
Lower or raise liquid level until

switchpoint 4 within the adjusted control
range is reached.

Note:

In the event of a system malfunction the
LED(s) “Bus status” and/or “Power” will
be flashing rapidly.

Press button briefly.
Switchpoint 4 is now saved.

Press button briefly.
Switchpoint 3 is now active.

LED illuminated LEDs flash slowly

briefly

LED illuminated LEDs flash slowly

briefly

LED illuminated LEDs flash slowly

briefly

Press button briefly.
Raise liquid level until switchpoint 3

within the adjusted control range is
reached.

Press button briefly.
Switchpoint 3 is now saved.

LED flashes LEDs flash slowly

briefly

LED illuminated LEDs flash slowly

briefly

17

Commissioning – continued –

Establish control range – continued –

Press button briefly.
Switchpoint 2 is now active.

Press button briefly.
Raise liquid level until switchpoint 2

within the adjusted control range is
reached.

Press button briefly.
Switchpoint 2 is saved.

LED illuminated LEDs flash slowly

briefly

LED illuminated LEDs flash slowly

briefly

LED illuminated LEDs flash slowly

briefly

Press button briefly.
Switchpoint 1 is now active.

Press button briefly.
Raise liquid level until switchpoint 1

within the adjusted control range is
reached.

18

LED illuminated LEDs flash slowly

briefly

LED illuminated LEDs flash slowly

briefly

Commissioning – continued –

Establish control range – continued –

Press button twice briefly.
Switchpoint 1 is saved.
The NRS 2-40 is again in operating

mode.

Operation

Normal operation

Normal operation – switching controller is
working.

All LEDs go out as soon as the setpoint is
reached.

The LED “Power” is illuminated.

Alarm

There are two alarm conditions:

■ High-level alarm

■ Low-level alarm

LED illuminated

twice briefly

LEDs go out upon reaching the setpoint

LED “Power” illuminated

High-level alarm

LED 1 changes after the de-energizing
delay from rapid flashing to lighting.

Low-level alarm

LED 4 changes after the de-energizing
delay from rapid flashing to lighting.

illuminatedflashes

flashes illuminated

19

Operation – continued –

Relay test high/low level alarm (MIN/MAX)

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

LEDs illuminated

briefly

Hold down button .

LED 4 goes out

LED 4 goes out.
A low-level alarm is simulated for

switchpoint 4.

Hold down button .

LED 1 goes out

LED 1 goes out.
A high-level alarm is simulated for

switchpoint 1.

System Malfunctions

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

■ Max. admissible temperature in electrode terminal box exceeded

■ No or faulty communication between switching controller and electrode

■ Fault in CAN bus

■ Failure of 24 V power supply unit built in level controller NRS 2-40

20

Danger

The terminal strip of the NRS 2-40 is live during operation.
This presents the danger of electric shock.
Cut off power supply before mounting or removing the equipment.

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 strips
of the bus nodes
e. g.

NRS ...

and

NRG ...

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 ...

21

System Malfunctions – continued –

System malfunction 1

The four indicator LEDs flash slowly.
High/low-level alarm

LEDs flash slowly

Fault:
Remedy:

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

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

System malfunction 2

LEDs flash rapidly

The four indicator LEDs flash rapidly.
High/low-level alarm

Fault:
Remedy:

Fault:
Remedy:

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

Incorrect node ID(s).
Set correct nodes ID(s), referring to section “Basic Adjustments” or “Annex”.

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

22

System Malfunctions – continued –

System malfunction 3

LED “Bus status” flashes slowly.

LED flashes slowly

Fault:
Remedy:

Malfunction in CAN bus.
Restart system.

LED “Bus status” flashes slowly.
High/low-level alarm

Fault:
Remedy:

Data transfer in CAN bus interrupted.
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, referring to the wiring diagram.

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

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. apply power
and restart system.

Fault:

The overall length of the bus cable does not correspond to the selected
baud rate.

Remedy:

Change baud rate settings of all nodes according to the indications
specified in “Annex”.

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

LED flashes slowly

23

System Malfunctions – continued –

System malfunction 4

LED “Power” flashes slowly.

LED flashes slowly

Fault:

Remedy:

Fault:
Remedy:

The power supply unit (PSU) is overloaded and may be misused for
other components.
Check load of power supply unit. Be sure to use the PSU only for the
voltage supply of bus-based network components.

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

Power supply unit defective.
Replace power supply unit.

24

Malfunctions

Danger

The terminal strip of the NRS 2-40 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:

Device does not work properly

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 intererence 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 system after installation.

LED “Power” does not light up.
Apply power. Connect the equipment properly, referring to wiring
diagrams.

Incorrect function at analogue output. The following actual value indicator
shows incorrect values.
Correct the switchpoint settings and the control range settings of the
electrode.

: Switchpoints and actual value indication drift continuously towards 100 %.

: Deposits have accumulated on the electrode rod. Remove the level

electrode and clean the electrode rod.

Fault

: A high-level alarm is raised although the liquid level is below high level.

Remedy

Fault
Remedy

: Deposits have accumulated on the electrode rod.

Clean the electrode rod.
Defective electrode insulation. Replace level electrode.

: Liquid level below switchpoint “LOW LEVEL”, device fails to switch.

: Check installation of level electrode and vent hole in the protection tube.

If an external measuring pot is used make sure to open the isolating
valves.

25

Malfunctions – continued –

Fault-finding list for troubleshooting– continued –

Fault

: “HIGH-LEVEL” switchpoint exceeded – no indication.

Remedy:

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

Level switch defective. Replace equipment.

26

Annex

Danger

The terminal strip of the NRS 2-40 is live during operation.
This presents the danger of electric shock.
Cut off power supply before mounting or removing the equipment.

Factory set default node IDs

Switching
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 setting .

Attention

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

A 8

Level
electrode

Fig. 10

8

27

Annex – continued –

Node ID
S1
S2
S3

ON
ON
ON

OFFS4
OFFS5

S6

ON

OFFS7

Fig. 11 (Factory setting)

S8

OFF

S9 S0

ON

ONON

16
32
64

OFF

OFF 125 kBit/s

ON

ON

OFF 1000 m

ON
ONON

Fig. 13 (Factory setting 250 kBit/s)

ON
ON
ON

39

1
2

S1
S2

4
8

S4

S7

Fig. 12 (Example)

Baud rate

Cable length

250 kBit/s

100 kBit/sOFFOFF 335 m

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

Node ID

OFF

ON

OFFS3

ON

OFFS5
OFFS6

ON

125 m

250 m

500 m

1000 m

74

1
2
4

8
16
32

64

28

Annex – continued –

Declaration of conformity

We hereby declare that the equipment NRS 2-40 conforms to the following
European 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 61 000-6-2

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

Bremen, 23

Head of the Design Dept.

Uwe Bledschun

(Academically qualified engineer)

Key

Terminal strips

A

Supporting rail 35 x 15 to DIN EN 50022

C

rd

GESTRA GmbH

July 2002

Quality Assurance Manager

(Academically qualified engineer)

Lars Bohl

29

Example of Installation

A

Fig. 14

A

100

C

73

118

Fig. 15

30

20 20

For your notes

31

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E-mail: [e-mail]

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E-mail: [e-mail]

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

®

GESTRA GmbH

P. O. Box 10 54 60, D-28054 Bremen, Münchener Str. 77, D-28215 Bremen
Telephone [phone] - 0, Fax [phone] - 393
E-Mail [e-mail], Internet www.gestra.de

A Unit of Flowserve Corporation

810371-02/903 · ©2000 GESTRA GmbH · Bremen · Printed in Germany

32