GESTRA NRG 16-50, Original Installation & Operating Manual

Page 1: ...Level Electrodes NRG 16 51 NRG 17 51 NRG 19 51 Original Installation Operating Manual 850692 00 EN USA English ...

Page 2: ...0 Notes on product liability 10 Function 11 Technical data 12 Rating plate identification 13 Overall view of the NRG 16 51 NRG 17 51 NRG 19 51 14 Dimensions of the NRG 16 51 NRG 17 51 NRG 19 51 with four pole connector 15 Overall view of the NRG 16 51F NRG 17 51F NRG 19 51F 16 Dimensions of the NRG 16 51F NRG 17 51F NRG 19 51F with aluminum terminal box 17 Preparing for installation 18 Installatio...

Page 3: ...Connecting the level electrode 28 NRG 16 50 NRG 17 50 NRG 19 50 with four pole connector 28 NRG 16 50F NRG 17 50F NRG 19 50F with aluminum terminal box 28 Wiring diagram 29 Bringing into service fault indications and troubleshooting 30 Taking out of service 30 Removing the NRG 1 51 level electrode 30 Removing the NRG 1 51F level electrode 30 Disposal 31 Returning decontaminated equipment 31 UL com...

Page 4: ... Conditions of GESTRA AG apply Scope of supply product package NRG 16 51 1 level electrode NRG 16 51 1 washer with set screw enlarged measuring surface optional 1 retaining ring optional 1 Installation Operating Manual NRG 17 51 1 level electrode NRG 17 51 1 washer with set screw enlarged measuring surface optional 1 retaining ring optional 1 Installation Operating Manual NRG 19 51 1 level electro...

Page 5: ... full and follow all instructions Please also read the instructions for use of any accessories The Installation Operating Manual is part of the product package Keep it in an easily accessible location Availability of this Installation Operating Manual Make sure this Installation Operating Manual is always available to the operator If you pass on or sell the equipment to a third party please also h...

Page 6: ...dangerous situation that results in death or serious injury WARNING Warning of a dangerous situation that may possibly result in death or serious injury CAUTION Warning of a situation that may result in minor or moderate injury ATTENTION Warning of a situation that results in damage to property or the environment ...

Page 7: ...rating point of the plant The operating point describes the operating parameters within which a plant or boiler is operated in its nominal range In a steam boiler for example these parameters would be output pressure and temperature The design data may be a lot more stringent however A boiler that is operated at 145 psi 10 bar and 356 F 180 C may be designed to withstand a pressure of 870 psi 60 b...

Page 8: ...15 Requirements for Automatic Electrical Water Level Sensing Controls Applicable directives and standards Improper use There is a danger of death due to explosion if the equipment is used in potentially explosive atmospheres Do not use the equipment in potentially explosive atmospheres Do not bring any equipment into service that does not have its own specific rating plate The rating plate indicat...

Page 9: ... work Check that the plant is not carrying live voltage before commencing work Danger to life Hot steam or hot water can suddenly escape from a faulty NRG 1 51 level electrode Shocks and impacts during transport or installation can result in damage to or leaks in the level electrode causing pressurized hot steam or hot water to escape through the pressure relief hole To prevent damage during trans...

Page 10: ...d and brought into service by qualified and competent staff Operation Boiler service technician Staff trained by the plant operator Maintenance work Specialist staff Fitting and maintenance work may only be performed by authorized staff who have undergone specific training Refits Specialist staff Persons trained by the plant operator to work with pressure and temperature Fig 1 Notes on product lia...

Page 11: ...4 in 100 mm for water If smaller connection pipes are used these must have a minimum NPS of 1 inch The level pot must have a suitable flushing device at its lowest point This device flushes the connection pipes to the boiler and enables the function of the water level limiter to be tested No shut off valves of any type shall be placed in the piping between the boiler and the low water cutoff Safet...

Page 12: ...ole connector polyamide PA NRG 1 51F Terminal box 3 2161 G AlSi8Cu3 Lengths supplied 19 68 in 500 mm 39 37 in 1000 mm 59 05 in 1500 mm Electrical connection NRG 1 51 Four pole connector cable glands M 16 NRG 1 51F Aluminum terminal box cable gland M 20 Protection IP 65 according to EN 60529 NRG 1 51 NEMA type 1 according to NEMA 250 NRG 1 51F NEMA type 4 according to NEMA 250 Admissible ambient te...

Page 13: ... NRG 17 51 F NRG 19 51 F NRG 16 51 F 1 11 5NPT 1 4404 316L IP65 667psi 46bar 500 F 260 C 464psi 32bar 460 F 238 C 1450psi 100bar 592 F 311 C Betriebsanleitung beachten See installation instructions Hier öffnen Open here Ouvrir ici Voir instructions de montage Pmax Tmax GESTRA AG Münchener Str 77 28215 Bremen Made in Germany Tamb 158 F 70 C T Rating plate identification Fig 1 Fig 2 Equipment design...

Page 14: ...rating Manual 850692 00 Overall view of the NRG 16 51 NRG 17 51 NRG 19 51 Fig 5 B A C E F D A Terminal box or four pole connector B Cable entry C Cover tube D Electrode thread Key E Measuring electrode F Electrode extension G Enlarged measuring surface G ...

Page 15: ... with four pole connector Fig 6 NRG 16 51 NRG 17 51 with enlarged measuring surface 59 05 in 1500 mm 3 54 in 90 mm 10 71 in 272 mm 1 11 5 NPT 0 38 in 8 mm 0 91 in 23 mm Thermal insulation provided on site 0 8 in 20 mm Fig 7 NRG 19 51 5 9 in 150 mm 11 18 in 284 mm 1 11 5 NPT 0 8 in 20 mm 0 38 in 8 mm 59 05 in 1500 mm Size 41 ...

Page 16: ...stallation Operating Manual 850692 00 Overall view of the NRG 16 51F NRG 17 51F NRG 19 51F Fig 8 A Terminal box or four pole connector B Cable entry C Cover tube D Electrode thread Key E Measuring electrode F Electrode extension A B D E F C ...

Page 17: ...nal box Fig 9 NRG 16 51F NRG 17 51F Fig 10 NRG 19 51F 13 35 in 338 mm 13 78 in 350 mm 1 11 5 NPT 1 11 5 NPT 5 5 in 140 mm 5 5 in 140 mm w 2 76 in 70 mm 6 9 in 175 mm w 2 76 in 70 mm 5 9 in 150 mm 59 05 in 1500 mm 3 54 in 90 mm 59 05 in 1500 mm Size 41 Thermal insulation provided on site Thermal insulation provided on site 0 8 in 20 mm 0 8 in 20 mm ...

Page 18: ... freezing At temperatures below freezing use a suitable heat source e g control cabinet heater etc Connect all parts of the plant to a central grounding point to prevent equalizing currents Use a cover to protect the equipment from direct sunlight condensation and heavy rain Use UV resistant cable ducts for routing the connecting cable Take further measures to protect the equipment from lightning ...

Page 19: ...steam can cause scalding Hot steam or hot water can escape suddenly if the level electrode is unscrewed under pressure Reduce the boiler pressure to 0 psi 0 bar and check the pressure before unscrewing the level electrode Only remove the level electrode at 0 psi 0 bar boiler pressure WARNING The hot level electrode can cause severe burns The level electrode gets very hot during operation Always le...

Page 20: ...20 NRG 16 51 NRG 17 51 NRG 19 51 USA Installation Operating Manual 850692 00 Installation Fig 12 1 2 3 4 0 a Fig 13 NRG 16 51 NRG 17 51 NRG 19 51 5 6 7 Fig 11 ...

Page 21: ... Push the retain ing spring 3 onto the electrode extension 4 until it is securely seated in the hole 2 6 Fit the enlarged measuring surface Push the washer 6 onto the enlarged measuring surface in such a way that the surface projects 0 08 in 2 mm beyond the underside of the washer Secure the washer with the set screw 5 in this position Push the supplied retaining ring 7 over the electrode extensio...

Page 22: ...remain visible The electrode body does not sit on the flange i e the underside of the hexagon is not in contact with the flange also see Fig 14 If it is in contact the internal thread is outside tolerance In this case the flange must be replaced After the electrode has been installed with PTFE sealing tape you must ensure there is adequate electrical contact between the electrode and the boiler wa...

Page 23: ...51 USA Installation Operating Manual 850692 00 Fig 16 Installing the NRG 16 51F NRG 17 51F NRG 19 51F with aluminum terminal box GESTRA Steam Systems GESTRA K K H 1 2 3 4 5 6 1 2 3 4 6 5 6 5 4 3 2 1 K K Fig 15 d b c f e Installation ...

Page 24: ...he arrow on this cover points to the rating plate 2 Remove the cable lugs from the pins Fig 15 3 Slacken the nut e using a size 19 open ended wrench Do not unscrew completely Fig 16 4 Screw in the level electrode as described in step 2 points 7 10 below 5 Rotate the terminal box in the desired direction 180 The terminal box can be rotated 180 ATTENTION Rotating the terminal box 180 will damage the...

Page 25: ...r level limiter Fig 18 Protective tube provided on site if electrode is used as an internal water level limiter combined with level control or high level alarm g h i n j k l 0 8 in 20 mm 0 8 in 20 mm NPS 2 DN 50 1 11 5 NPT 0 8 in 20 mm 90 0 39 in 10 mm o m g h j n k l i o m NPS 4 DN 100 1 93 in 49 mm 0 8 in 20 mm 1 11 5 NPT 118 11 in 3000 mm 0 8 in 20 mm 1 11 5 NPT 90 0 39 in 10 mm 0 8 in 20 mm ...

Page 26: ...j Electrode rod d 0 32 in 8 mm k Protective foam tube level pot l Low water LW m Reducer n High water HW o Electrode spacing 0 55 in 14 mm air gaps and creepage paths CD Center distance of standpipes Fig 19 Level pot if electrode is used as an external high level alarm 1 11 5 NPT g n l m CD h o j k Pipe diameter DN Pipe diameter 2 DN 2 Pipe diameter 2 DN 2 Pipe diameter DN Connecting pipe shall no...

Page 27: ...850692 00 Electrical connection NRG 16 51 NRG 17 51 NRG 19 51 with four pole connector Fig 20 z y v w x A Key v Screw M 4 w Cover x Upper part of connector y Connection plate z Insulating plate A Level electrode contact plate B Cable clamp C Cable gland M 19 PG 11 B C ...

Page 28: ...t x of the connector 6 Pull the cable through the cable gland C and upper part x of the connector and insert the terminals of the connection plate y as shown in the wiring diagram 7 Press the connection plate y into the upper part of the connector and correctly align the cable 8 Secure the cable with the cable clamp B and cable gland C 9 Put on the cover w and insert the screw v 10 Position the up...

Page 29: ...7 8 9 10 11 12 13 14 15 1 2 3 1 NRG 1 51F LW HW 2 3 4 5 6 Electrical connection Wiring diagram Fig 22 Connecting the level electrode with four pole connector D Fig 21 CGP CGP Terminal strip NRS 1 51 Fig 23 Connecting the level electrode with aluminum terminal box Key D Level electrode NRG 1 51 CGP Central grounding point in control cabinet NRG 1 51 NRG 1 51F ...

Page 30: ...e gland 3 To dismantle the equipment unscrew the electrode thread 0 Fig 12 when it has cooled down and is no longer under pressure Taking out of service DANGER Danger to life Escaped hot steam can cause scalding Hot steam or hot water can escape suddenly if the level electrode is unscrewed under pressure Reduce the boiler pressure to 0 psi 0 bar and check the pressure before unscrew ing the level ...

Page 31: ...y if accompanied by a completed and signed return note and also a completed and signed declaration of decontamination The return confirmation and declaration of decontamination must be attached to the outside of the return package as processing will otherwise be impossible and the products will be returned to the sender at their expense Please proceed as follows 1 Let GESTRA AG know about the retu...

Page 32: ...35 00 GESTRA AG Bremen GESTRA AG Münchener Straße 77 28215 Bremen Germany Tel 49 421 3503 0 Fax 49 421 3503 393 e mail info de gestra com Web www gestra com You can find our authorized agents around the world at www gestra com ...