GESTRA Steam Systems
SRL 63-a
Installation Instructions 818588-00
Logic Unit SRL 63-a
Contents
Page
Important Notes
Usage for the intended purpose...............................................................................................................4
Safety note..............................................................................................................................................4
ATEX (Atmosphère Explosible) .................................................................................................................4
Explanatory Notes
Scope of supply.......................................................................................................................................5
Description..............................................................................................................................................5
Function..................................................................................................................................................5
Technical Data
SRL 63-a.................................................................................................................................................7
Name plate / marking..............................................................................................................................8
Dimensions .............................................................................................................................................8
Installation
Installing the logic unit SRL 63-a.............................................................................................................9
Functional Elements
SRL 63-a.................................................................................................................................................9
Electrical Connection
Connecting the terminal strips...............................................................................................................10
Tools.....................................................................................................................................................10
Wiring diagram of logic unit for monitoring SRL 63-a.............................................................................11
Basic Setting
Factory setting ......................................................................................................................................12
Start-up, Operation, Alarms and Testing
SRL 63-a...............................................................................................................................................12
Troubleshooting
Fault finding ..........................................................................................................................................15
2
Contents
Page
Appendix
Decommissioning................................................................................................................................. 15
Disposal ............................................................................................................................................... 15
CE Declaration of Conformity ................................................................................................................ 15
TÜV approval ........................................................................................................................................ 16
3
Important Notes
Usage for the intended purpose
The logic unit SRL 63-a may be used in steam boiler plants only in conjunction with external low-level
alarms or high-level alarms for monitoring the separate flushing of the connecting lines to the measuring
pot.
Any other use is deemed as not being in compliance with the intended purpose. The user shall be solely
responsible for the associated risks. The manufacturer shall not be liable for any damage resulting from
improper usage.
Safety note
The equipment must only be installed and commissioned by suitably qualified staff.
Maintenance and service work must only be performed by adequately trained persons who have a recognized level of competence.
Danger
The terminal strip of the logic unit SRL 63-a is electrically live during operation!
Because of the electrical currents which may flow, serious injuries are possible!
Before working on the terminal strips, always ensure that the unit is de-energized!
ATEX (Atmosphère Explosible)
In accordance with the European Directive 94/9/EC, the unit must not be used in potentially explosive areas.
4
Explanatory Notes
Scope of supply
SRL 63-a
1 Logic unit for monitoring, in a field case for wall mounting
1 Installation manual
Description
For the installation of low-level limiters of "high-integrity design" in measuring pots mounted outside of
the boiler, it is imperative that the periodic purging of the connecting lines to the boiler be monitored properly.
To achieve this, the connecting lines are shut off one after the other at defined intervals and the measuring
pot is drained.
The logic unit SRL 63 monitors compliance with the preset times and the sequence of valve operations; in
addition, it bypasses the low-level limiter to ensure that the system is not shut down during purging.
The logic unit for monitoring the purging cycle consists of a compact PLC, a safety time-lag relay and a
coupling relay. The design complies with prEN 50156.
Function
Fig. 1 depicts a system with a level electrode in the boiler and the second electrode in an
external measuring pot.
Level switch
NRS 1-7/9
Level electrode
NRG 1x-11,
NRG 16-36
Level switch
NRS 1-7/9
D
E
Logic unit
SRL 63-a
Fig.1
F
Safety
circuit
5
Explanatory Notes – continued –
Function – continued –
The logic unit monitors the following times:
■ Interval time: This is the time interval at which, depending on the mode (24h / 72h operation), the con-
necting lines have to be purged.
■ Standby period: The purging process must be initiated during this time. The standby period begins
when the interval time has elapsed.
■ Purging time: During this period, the purging process must be performed through actuation of the
valves. Actuation of the valves is signalled by means of the limit switches; similarly, when the electrode
of the low-level limiter is exposed, this is sensed through the output contact of the corresponding level
switch. If a signal is not received within the purging time, the safety circuit is opened. Since a low-level
limiter may be bypassed for a maximum of 5 minutes, monitoring of the purging time is a safety-relevant function.
The interval time is started when the logic unit is switched on. The display of the PLC shows the full hours
of the remaining time. This can be synchronized at any time by closing an interconnection valve (E or D),
i.e. the purging time begins and the interval time is reset to its initial value (e.g. 24h, 72h etc.).
During operation, the standby period is started at the end of the interval time, which is immediately reset
to its initial value (e.g. 24h, 72h etc.). The PLC then starts the purging time when an interconnection valve
(E or D) leaves the end position "Open".
During the purging time, the output contact of the low-level limiter is bypassed. This bypass is triggered
by the undelayed contact of the safety time-lag relay and limited to 5 minutes by the delayed contact of
this relay.
Once all valves signal that they have reached their initial positions and the level switch of the low-level
limiter senses that the level electrode is exposed, the purging process has ended and the bypassing of the
low-level limiter is terminated.
In the event that the mains supply fails during the purging time, the bypassing of the low-level limiter is
cancelled and the safety circuit is opened. If the mains supply is switched on again, the bypass remains
deactivated and the safety circuit is only closed again after the purging process has been completed properly.
Expiry of the purging time and standby period, as well as deactivation of the safety circuit, are indicated
by means of pilot lamps.
Note
The safety circuit is opened when the standby time or the purging time is exceeded, and it
is only closed again when the purging process has been completed properly.
6
Technical Data
SRL 63-a
Inputs
5 volt-free contacts from the limit switches of the valves
1 volt-free contact from a second SRL which may be mounted at the same boiler (interlock)
1 volt-free contact from the low-level limiter
Outputs
2 volt-free change-over contacts each for bypassing/deactivating the safety circuit
Thermal current Ith : 4A, switching capacity acc. to AC-15: 3A / 230V a.c.
1 volt-free change-over contact as a signalling contact for a second logic unit
Contactors must be interference-suppressed as per manufacturer's instructions (RC combination)
3 contacts for internal or external indication of status (pilot lamps)
Interval time
Adjusted at our works within the range 2 to 336 hours, in compliance with TRD 24/72h
Standby period
Adjusted at our works within the range 15 minutes to 2 hours, in compliance with TRD 1h
Purging time
Set at our works to 5 minutes
Indicators and adjustors
1 control panel at the PLC for triggering a test
3 pilot lamps for standby period / purging time, bypassing of the low-level limiter and deactivation of the
safety circuit
Mains voltage
230V +10 / -15%, 50 - 60Hz
Voltage of the safety circuit
230V, 50 - 60Hz, optional 24V, 50 - 60Hz
Power consumption
26W
Protection
Enclosure: IP 65 to EN 60529
Permissible ambient temperature
Maximum 55°C
Case
Field case for wall mounting, with clear lid
Case material: Polystyrene / polycarbonate, colour light gray
Cable entry / electrical connection
5 cable glands, M 16, electrical connection via two terminal strips
Weight
Approx. 3.3 kg
7
Technical Data – continued –
A
Name plate / marking
Safety note
Manufacturer
Fig. 2
Safety
circuit
Fuse
Betriebsanleitung
beachten
See installati on
instructions
Voir instructions de
montage
250 V ~ T 2,5 A
GESTRA AG
Münchener S tr. 77, D-28215 Bremen
Überwachungslogik
Data for spare parts inventories
VS.-Nr.: XX
26 W
Mat.Nr.:
392230
Designation
Mains voltage /
IP 65 50 / 60 Hz230 V
Power consumption /
Protection
Range of application
Times
Disposal
CE marking
Dimensions
Wall mounting lugs
308
295
281
5.2260
2
.
8
16
I1 I2 I 3 I4 I5 I 6 I7 I 8L+ M
Interval:
Int ervall:
24 h
24h
Rest: 8:27 h
Remaining:
2h
ESC
Q1 Q2 Q3 Q4
Standby
Bereit
Bypass
Überbrückt
Shutdown
bschalten
272.5
281
Cable glands
84.5
Fig.3
5 x M16
281
10
5
.
1
8
Installation
Installing the logic unit SRL 63-a
The case of the logic unit is intended for wall mounting; it should be installed near the external measuring
pot.
Functional Elements
SRL 63-a
I1 I2 I3 I4 I5 I6 I7 I8L+ M
Fig.4
Interval:
24h
Control panel
Remaining:
2h
ESC
Q1 Q2 Q3 Q4
9
Electrical Connection
Connecting the terminal strips
Connect the terminal strips as shown in the wiring diagram.
The measuring pot is provided with three shut-off valves. Valves D and E are each equipped with two limit
switches, for the "OPEN" position (D1 / E1) and for the "CLOSED" position (D2 / E2). The drain valve F is
only fitted with one limit switch, for the "CLOSED" position.
For connecting the limit switch, we recommend a control cable, e.g. Ölflex 110H, 7x1mm², length max.
100m.
External pilot lamps can be connected to terminals 11 to 14.
Note
Check whether the mains voltage matches the voltage of the safety circuit. If this is not the
case, it is necessary to use a logic unit with the correct voltage for the safety circuit.
Attention
If both low-level limiter electrodes of a boiler are installed in external measuring pots, simultaneous purging and bypassing of the low-level limiters is not admissible.
To prevent this happening, the two logic units must be interlocked by means of parallel con-
nections between the terminals 16 to 20 of either unit.
In addition:
■ To protect the relay contacts, fit the safety circuit with a fuse T 2.5A (slow-blow) or
1A (TRD 604, 72 h operation).
Tools
■ Screwdriver for slotted screws, size 2.5, fully insulated to VDE 0680-1.
■ Cross-head screwdriver, size 2.
10
Electrical Connection – continued –
Wiring diagram of logic unit for monitoring SRL 63-a
SRL 63-a
I1 I2 I3 I4 I5 I6 I7 I8L+ M
Interv al:
24h
Rem aining:
2h
Standby
Bypass
Q1 Q2 Q3 Q4
1234567891011121314151617181920
X1
L1 N PE
Bypass
Standby
Shutdown
1
2
3
4
5
6
7
8
18
X1
D1
D2
E1
E2
19
16
17
2. SRL
Shutdown
1234567
X3
External voltage!
20
Burner safety circuit
Connection for low-level limiter
12 34567
X3
Attention
N
Fig.5
Boiler
Valve:
D = steam
E = water
F = drain
10
9
F1
Attention
D1
D2
E1
E2
External voltage!
N
Burner safety circuit
Connection for high-level alarm
F1
11
Basic Setting
Factory setting
Logic unit SRL 63-a
The logic unit for monitoring is delivered with the following factory settings:
■ Interval time: 24 hours
■ Standby period: 1 hour
■ Purging time: 5 minutes
■ Voltage of safety circuit: 230V AC
Start-up, Operation, Alarms and Testing
SRL 63-a
Fig.6
I1 I2 I3 I4 I5 I6 I7 I8L+ M
Interval:
24h
Control panel
Remaining:
2h
ESC
Q1 Q2 Q3 Q4
Start-up
Switch on the mains voltage. Interval time starts running. Remaining time is indicated.
Restarting the interval time
Perform the purging process
(see "Operation").
12
Green pilot lamp "Standby"
flashes; yellow pilot lamp "Bypass" is alight.
Purging time is running.
Low-level limiter is
bypassed.
Start-up, Operation, Alarms and Testing – continued –
SRL 63-a – continued –
Operation
Interval time is running. No pilot lamp is alight. Trouble-free operation
Interval time expires and begins
again.
Perform the purging process
as shown on the PLC display.
Purging
Val D OPEN
Val E CLOSED
Val F CLOSED
Purging
Val D OPEN
Val E CLOSED
Val F OPEN
Purging
Waiting for LW alarm
...37 sec.
Purging
Green pilot lamp "Standby" is
alight.
Green pilot lamp "Standby"
flashes; yellow pilot lamp
"Bypass" is alight.
Low-level limiter (LW)
Output contact: level switch
NRS 1-7 / NRS 1-9
Valve D
LW
Standby period is running.
Purging time is running.
Low-level limiter is bypassed.
Boiler
Val D CLOSED
Val E CLOSED
Val F OPEN
Purging
Val D CLOSED
Val E OPEN
Val F OPEN
Purging
Val D OPEN
Val E OPEN
Val F CLOSED
End of purging process Green and yellow pilot lamps
Status on the PLC display in chronological order
(Standby / Bypass) are extinguished.
Valve E
Valve F
Setting shown for the
valve limit switches:
Valves in normal
operational position;
low-water level
(electrode exposed)
Bypassing of low-level limiter is
cancelled.
13
Start-up, Operation, Alarms and Testing – continued –
SRL 63-a – continued –
Alarm
Standby period has expired
without purging process.
Purging process not completed
in the specified purging time (5
min.).
For logic unit 1 and 2, the purging process is started simultaneously.
The safety circuit is only closed after completion of the purging process
Red pilot lamp "Shutdown" is illuminated.
(for sequence, see "Operation").
Safety circuit
interrupted.
Testing the deactivation of the safety circuit
Press the button , then press
until the picture with the cursor
buttons is shown on the PLC display. Now press ESC and simultaneously (see picture
below).
Press the button. The display of Fig.6
The purging time is started. When the purging time has end-
is shown again.
ESC + key
Cursor picture in the PLC display
ed, the safety circuit is interrupted and then closed again after
5 seconds.
14
Danger
The terminal strips of the logic unit SRL 63-a are electrically live during operation!
Because of the electrical currents which may flow, serious injuries are possible!
Before working on the terminal strips (assembly, disassembly, connecting the cables), always ensure that the unit is de-energized!
An external voltage is present at terminal strips X1 (terminals 16 to 20) and X3 (terminals 1 to 5).
Troubleshooting
Fault finding
Faulty program execution, safety circuit interrupted
Fault: PLC display reports that a limit switch is defective.
Remedy: Exchange the faulty limit switch.
Fault: PLC, safety time-lag relay or coupling relay is defective.
Remedy: Exchange the entire logic unit.
Fault: The mains voltage has failed during the purging time, the bypassing of the low-level limiter
has been cancelled, and the safety circuit is interrupted.
Remedy: Switch on the mains voltage and resume the purging process.
Appendix
Decommissioning
After de-energizing the logic unit, undo all the electrical connections and pull the cables out of the glands.
Remove the logic unit.
Disposal
Remove and dismantle the logic unit, and separate the waste materials according to the material data.
Electronic components (PC boards) must be disposed of in the correct manner! For the disposal of the control device, observe the pertinent statutory regulations concerning waste disposal.
CE Declaration of Conformity
We hereby declare that the logic unit for monitoring SRL 63-a conforms to the following European Directives:
■ Low Voltage Directive (LVD) 73/23/EEC, as amended by 93/68/EEC
■ EMC Directive 89/336/EEC, as amended by 93/68/EEC
This declaration is no longer valid if modifications are made to the equipment without prior consultation
with us.
Bremen, 19.04.05
GESTRA AG
Dipl.-Ing. Uwe Bledschun
Head of Design Dept.
Dipl.-Ing. Lars Bohl
Quality Assurance Representative
15
Appendix – continued –
TÜV approval
16
Appendix – continued –
TÜV approval - continued -
17
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Fax 00 34 91 / 41 36 747; 51 52 036
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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
818588-00/306agt ©2006 GESTRA AG Bremen Printed in Germany
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