GESTRA Steam Systems
TRG 5-11
TRG 5-41
Installation Instructions 818697-00
Temperature Sensor
TRG 5-11, TRG 5-41
1
Contents
Page
Important Notes
Usage for the intended purpose .............................................................................................................4
Safety note ............................................................................................................................................ 4
Danger ...................................................................................................................................................4
PED (Pressure Equipment Directive) ........................................................................................................4
ATEX (Atmosphère Explosible) .................................................................................................................4
Explanatory Notes
Scope of supply ......................................................................................................................................5
Description ........................................................................................................................................... 5
Function ................................................................................................................................................5
System components ..............................................................................................................................5
Design ...................................................................................................................................................5
Technical Data
TRG 5-11, TRG 5-41 ...............................................................................................................................
Corrosion resistance ...............................................................................................................................7
Sizing .....................................................................................................................................................7
Name plate /marking ..............................................................................................................................7
Dimensions ............................................................................................................................................8
Component Parts
TRG 5-11, TRG 5-41 ...............................................................................................................................
Key ....................................................................................................................................................... 10
Installation
TRG 5-11 ..............................................................................................................................................
TRG 5-41 .............................................................................................................................................. 11
Attention .............................................................................................................................................. 11
Note .....................................................................................................................................................11
Tools ....................................................................................................................................................11
Heat treatment of welds .......................................................................................................................11
Examples of installation ........................................................................................................................12
Key ....................................................................................................................................................... 13
Wiring
TRG 5-11, TRG 5-41 ............................................................................................................................. 13
Note .....................................................................................................................................................13
Tools ....................................................................................................................................................13
Wiring diagram .....................................................................................................................................14
11
6
9
2
Contents – continued –
Page
Commissioning
Check wiring ........................................................................................................................................15
Apply mains voltage ............................................................................................................................. 15
Measure fluid temperature ...................................................................................................................15
Operation
TRG 5-11, TRG 5-41 ............................................................................................................................. 16
Note .....................................................................................................................................................16
Troubleshooting
Fault-finding list for malfunctions .........................................................................................................16
Maintenance
Spare parts .......................................................................................................................................... 17
Replace sensing element ......................................................................................................................17
Decommissioning
Danger ................................................................................................................................................17
Disposal ...............................................................................................................................................17
Annex
Declaration of Conformity CE ................................................................................................................18
3
Important Notes
Usage for the intended purpose
Use temperature sensors TRG 5-11 and TRG 5-41 only in conjunction with temperature switch TRS 5-7
for measuring temperatures.
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 temperature sensors TRG 5-11 and TRG 5-41 are fixed in vessels or pipes. When
loosening the temperature sensor hot water, steam, gas, corrosive or toxic fluids might
escape. This presents the danger of poisoning or severe scalding and acid burns to the
whole body. Installation and maintenance work should only be carried out when the
system is depressurized! If necessary wear protective clothing.
The temperature sensor becomes hot during operation. This presents the risk of severe
burns to hands and arms.
All installation and maintenance work must only be performed when the system is cold!
PED (Pressure Equipment Directive)
The equipment complies with the requirements of the Pressure Equipment Directive PED 97/23/CE.
TRG 5-11 and TRG 5-41 can be used with fluids of group 2. With CE marking.
ATEX (Atmosphère Explosible)
According to the European Directive 94/9/EC the equipment must not be used in explosion risk areas!
4
Explanatory Notes
Scope of supply
TRG 5-11
1 Temperature sensor TRG 5-11, PN 1
1 Installation manual
TRG 5-41
1 Temperature sensor TRG 5-41, PN 160
1 Installation manual
Description
TRG 5-11 and TRG 5-41 are temperature sensors with integral thermocouples to DIN EN 60584.
The temperature sensors work in conjunction with the temperature switch TRS 5-7 and serve as safety
temperature limiters according to DIN 3440/prEN 14597 for signalling excessively high temperatures.
Application in combination with GESTRA safety temperature limiter TRS 5-7 in steam boilers,
(pressurized) hot water plants and furnaces according to DIN 30683 up to 1000 °C , e. g. for limiting
furnace or flue gas temperatures.
Function
The temperature sensors feature an exchangeable temperature sensing element, consisting of two
thermocouples type K (NiCr-Ni, Chromel-alumel) according to DIN IEC 584, class 2. To ensure short
response times the temperature sensors are installed without an additional thermowell. The voltage
generated in the thermocouple as a function of the temperature reading is compared in the safety
temperature limiter with the adjusted switch-off temperature. When the adjusted temperature limit
is exceeded, the follow-up function that has to be provided on site (e. g. a temperature alarm) will be
triggered.
System components
TRS 5-7
Temperature switch TRS 5-7. Two-channel (redundancy) limiter with periodic self-checking routine to
VDE 0116.
Design
TRG 5-11
Temperature sensor with protection tube to DIN IEC 751.
The temperature sensing element B can be removed.
TRG 5-41
Temperature sensor with weld-in protection sleeve to DIN IEC 751.
The temperature sensing element B can be removed.
5
Technical Data
TRG 5-11, TRG 5-41
Type approval
DIN · STW (STB) · 986 98S
EG 01 202 931-B-01 000 7
Service pressure
TRG 5-11: 1 bar g (14.5 psi g)
TRG 5-41: 150 bar g (2176 psi g)
Max. service temperature
TRG 5-11: 1000 °C (1832 °F)
TRG 5-41: 650 °C (1202 °F)
Admissible flow velocities
TRG 5-41: in water 5 m/s
in gases 60 m/s
Connections
TRG 5-11: Protection tube (stop flange or screwed socket optional)
TRG 5-41: Protection weld-in tube
Length of sensor
TRG 5-11: 710 mm nominal length
TRG 5-41: 200 mm length of protection tube
Materials
TRG 5-11: Protection tube made of X 10 CrAl 24 (1.4762)
Screwed sockets made of 9 SMnPb 28 (1.0718)
TRG 5-41: Protection weld-in tube made of X 8 CrNiNb 16-13 (1.4961)
Max. admissible ambient temperature at terminal box
120 °C (248 °F)
Protection of terminal box
IP 54
Temperature sensing element
Thermocouple type K (NiCr-Ni) to DIN IEC 584, class 2.
Weight
TRG 5-11: approx. 1.02 kg at nominal length 710 mm
TRG 5-41: approx. 1.1 kg
6
Technical Data – continued –
Corrosion resistance
Provided that the equipment is used for the intended purpose, its safety is not impaired by corrosion.
Sizing
The housing must not be subjected to sharp increases in pressure. The dimensional allowances for
corrosion reflect the latest state of technology.
Name plate / marking
Equipment designation
Fig. 1
Fig. 2
7
Technical Data – continued –
Dimensions
75710
∅ 15
∅ 11
140200 75
Fig. 3
TRG 5-11
Fig. 4
8
25
50
40
∅ 24 h7
∅ 6
26
8
32
3.5
50
16
Form D 4
65
55
75
Fig. 5
TRG 5-41
∅ 12.5
Component Parts
TRG 5-11, TRG 5-41
A
B
C
Fig. 6
TRG 5-11
D
Fig. 7
E
G
Fig. 8
E
H
Fig. 9 Fig. 10
TRG 5-41
9
Component Parts – continued –
Key
A Cover
B Sensing element
C Temperature sensor
D Measuring tip TRG 5-11
E Mounting flange
F Screwed socket ¾"
G Protection tube
H Measuring tip TRG 5-41
I Insulation (provided by customer)
J Elbow
K Twin PG thread (page 14)
10
Installation
TRG 5-11
1. Provide a bore for the sensor d = 16 mm on site.
2. Insert the temperature sensor
225 mm into gases,
Fig. 6.
3. To fix the sensor use either a mounting flange or a gas-tight screwed socket,
TRG 5-41
1. Provide a bore for the protective tube d = 24 mm on site.
2. Unscrew the cover of the temperature sensor
3. Insert the protective tube
160 mm into gases. If a short installation length is required provide an angled piece for the sensor
and ensure that the tip points against the flow direction,
4. Weld the protection tube in place. Use only gas-welding process 111 and 141 to ISO 4063.
5. Place copper ring D 18 x 22 onto the protection tube
sensor C onto the protection tube. Slightly fasten the cover of the temperature sensor with an
open-end spanner.
Attention
■ Only qualified welders certified according to EN 287-1 may weld protective sleeves
into pressurized lines.
C such that its measuring tip D reaches 120 mm into liquids or
Fig. 8, Fig. 9.
C from the protection tube G, Fig. 5, Fig. 10.
G such that the measuring tip H reaches 100 mm into liquids or
Fig. 13, Fig. 14.
G and screw the cover of the temperature
Note
■ When installing the equipment in pipes weld an elbow J onto the pipe, ensuring that
the measuring tip points against the flow direction of the fluid, Fig. 13, Fig. 14.
■ Install the temperature sensor such that its measuring tip D/ H is permanently
immersed in the fluid,
■ Do not completely insulate the temperature sensor. See Examples of Installation,
Fig. 11, Fig.12.
Fig. 11, Fig. 12.
Tools
■ Open-end spanner 24 mm A. F.
Heat treatment of welds
A subsequent heat treatment of the welds may be required if it is specified by the plant operator.
11
Installation – continued –
Examples of installation
I
Fig. 11
TRG 5-11
D
≥ 100
I
Fig. 12
TRG 5-41
≥ 100
H
II
Fig. 13
TRG 5-41
12
J
J
Fig. 14
TRG 5-41
Installation – continued –
Key
D Measuring tip TRG 5-11
H Measuring tip TRG 5-41
I Insulation (provided by customer)
J Elbow
K Twin PG thread (page 14)
Wiring
TRG 5-11, TRG 5-41
Use 2 x 0.35 mm² compensating line as supply line. Note that two supply lines per temperature sensor
are required for the safety temperature monitoring function.
Note
■ Two supply lines per temperature sensor are required for the safety function
“Temperature monitoring”.
■ The supply lines must go through the twin PG thread into the terminal box, Fig. 16.
Tools
■ Screwdriver for slotted screws, size 2.5, completely insulated to DIN VDE 0680-1
13
Wiring – continued –
Wiring diagram
Fig. 15
Colour code
F
Colour code
Colour codeColour code
Fig. 16
14
Commissioning
Check wiring
Make sure that the TRG 5-11 or TRG 5-41 and the associated control unit TRS 5-7 are wired in
accordance with the wiring diagram,
Apply mains voltage
Switch on mains voltage for temperature switch TRS 5-7.
Measure fluid temperature
Use the following table indicating the voltages of the thermocouples to ascertain the current
temperature of the fluid.
1. Connect the test wires directly to the terminal box.
2. Measure the voltage with a voltmeter.
3. Find the corresponding value in the table below, read off the temperature and, if necessary,
determine the exact value by interpolation.
°C 0 – 10 – 20 – 30 – 40 – 50 – 60 – 70 – 80 – 90
– 100
– 3.553 – 3.852 – 4.138 – 4.410 – 4.669 – 4.912 – 5.141 – 5.534 – 5.550 – 5.730
0 0 – 0.392 – 0.777 – 1.156 – 1.527 – 1.889 – 2.243 – 2.586 – 2.920 – 3.242
°C 0 10 20 30 40 50 60 70 80 90
0 0 0.397 0.798 1.203 1.611 2.022 2.436 2.850 3.266 3.681
100
4.095 4.508 4.919 5.327 5.733 6.137 6.539 6.939 7.338 7.737
200 8.137
300 12.207 12.623 13.039 13.456 13.874 14.292 14.712 15.132 15.552 15.974
400 16.395 16.818 17.241 17.664 18.088 18.513 18.938 19.363 19.788 20.214
500 20.640 21.066 21.493 21.919 22.346 22.772 23.198 23.624 24.050 24.476
600 24.902 25.327 25.751 26.176 26.599 27.022 27.445 27.867 28.288 28.709
700 29.128 29.547 29.965 30.383 30.799 31.214 31.629 32.042 32.455 32.866
800 33.277 33.686 34.095 34.502 34.909 35.314 35.718 36.121 36.524 36.925
900 37.325 37.724 38.122 38.519 38.915 39.310 39.703 40.096 40.488 40.879
1000 41.269 41.657 42.045 42.432 42.817 43.202
1100 45.108
1200 48.828 49.192
1300 52.398 52.747
Basic resistance values according to EN 60584 for thermocouples type K (Ni-Cr/Ni-Al)
8.537 8.938 9.341 9.745 10.151 10.560 10.969 11.381 11.793
45.486 45.863 46.238 46.612 46.985 47.356 47.726 48.095 48.462
Fig. 15.
43.585 43.968 44.349 44.729
49.555 49.916 50.276 50.633 50.990 51.344 51.697 52.049
53.093 53.439 53.782 54.125 54.466 54.807
15
Operation
TRG 5-11, TRG 5-41
Operation in combination with control unit TRS 5-7 in steam plants and (pressurized) hot water
installations to TRD 401, TRG 602, TRD 604, EN 12952, EN 12953 or according to national regulations
as well as in flue gas lines and industrial furnaces.
Note
■ Should malfunctions occur during the commissioning procedure refer to section
“Troubleshooting” on page 16 in order to find, analyse and eliminate the fault.
Troubleshooting
Fault-finding list for malfunctions
Normal operation – temperature alarm
Fault: The temperature switch gives an alarm during normal operation.
Remedy: Check whether the cable leading to the thermocouple is damaged.
Remedy: Check the thermocouple for correct voltage readings. (Basic reference voltages according
to EN 60584 for thermocouples type K (Ni-Cr/Ni-Al)). If the voltage readings are incorrect or
there is no voltage replace the sensing element.
Fault: The temperature switch gives an alarm during normal operation.
Remedy: Refer to the fault-finding list of the temperature switch TRS 5-7.
If faults occur that are not listed above or cannot be corrected, please contact our service centre or
authorized agency in your country.
16
Maintenance
Spare parts
Item
B
F
Screwed socket ¾", material: 1.0718 051599
E
G
Protection tube D4, 24 x 200 mm, 1.4961 143612
K
Replace sensing element
The sensing element B can be replaced during operation if necessary.
1. Remove cover
2. Disconnect wires from terminals.
3. Use a screwdriver to unscrew and remove the sensing element
4. Insert new sensing element and fasten with a screwdriver.
5. Connect terminals according to wiring diagram,
6. Mount cover
A, Fig. 7
A.
Designation
Sensing element 052272 052268
Mounting flange 051600
Twin PG thread 387100 387100
Fig. 15
Stock code Stock code
B.
Decommissioning
Danger
TRG 5-11 TRG 5-41
Risk of severe burns and scalds to the whole body.
Before removing the temperature sensor make sure that the vessel or pipeline is
depressurised (0 bar) and cooled down to room temperature (20 °C).
Disposal
Remove the temperature sensor and separate the waste materials in accordance with the material
specification.
Electronic components (boards) must be disposed of separately.
For the disposal of the temperature sensor observe the pertinent legal regulations concerning waste
disposal.
17
Annex – continued –
Declaration of Conformity
We hereby declare that the equipment TRG 5-11 and TRG 5-41 conform to the following European
guidelines:
■ LV guideline 73/23/EC version 93/68/EC
■ EMC guideline 89/336/EC version 93/68/EC
■ Pressure Equipment Directive (PED) 97/23/EC of 29 May 1997 (provided that the equipment is not
excluded from the scope of this directive according to section 3.3)
■ LV standard EN 50178
■ EMC standard EN 50081-2. EN 50082-2
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, 3rd January 2005
GESTRA AG
Dipl.-Ing. Uwe Bledschun
(Academically qualified engineer)
18
Head of Design Dept.
Dipl.-Ing. Lars Bohl
(Academically qualified engineer)
Quality Assurance Representative
For your notes
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818697-00/806cma · 2004 GESTRA AG · Bremen · Printed in Germany
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