GESTRA NRGS 15-1, Original Installation & Operating Manual

Page 1: ...Original Installation Operating Manual 850690 00 Level Switch NRGS 15 1 EN USA English ...

Page 2: ...nnel qualifications 10 Notes on product liability 10 Function 11 Technical data 12 Rating plate identification 14 Overall view of the NRGS 15 1 15 Dimensions of the NRGS 15 1 16 Setting functions 17 Selecting a function 17 Setting functions 19 Setting the time delay 19 Setting the response sensitivity 20 Preparing for installation 21 Installation 22 Installing the NRGS 15 1 step 1 24 Functions tab...

Page 3: ...Checking switchpoints and functions 30 Fault indications and troubleshooting 31 Indications diagnosis and corrective action 31 Replacing the electronic circuit board 34 Taking out of service 35 Removing the level switch 35 Disposal 36 Returning decontaminated equipment 36 UL components 36 Annex 37 Setting other functions 37 Installation in non metallic tanks 37 ...

Page 4: ...1cm Copyright All rights reserved Any misuse particularly reproduction and dissemination to third parties is not permitted The General Terms Conditions of GESTRA AG apply Scope of delivery product package 1 x NRGS 15 1 level switch comprising 1 x level electrode with four tips 1 x terminal box with level switch 1 x Installation Operating Manual ...

Page 5: ... 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 acces sible 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 hand over...

Page 6: ...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: ...nt 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 bar and a t...

Page 8: ... 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 indicates the technical features of the equipment Applicable directives and standards The NRGS 15 1 level switch has been tested and approved for use in the sc...

Page 9: ...eck 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 NRGS 15 1 level switch 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 transport and i...

Page 10: ...d brought into service by qualified and competent staff Operation Boiler service technician Staff trained by the plant operator Maintenance work Specialist staff Maintenance and refits 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 Notes on product liability The manuf...

Page 11: ...witching channels 2 and 3 are defined via the code switch The switchpoints of each switching channel depend on the level and are determined by shortening the relevant electrode tips The following functions are possible n Electrode rod 1 exposed switching channel 1 energizes relay 1 low water 1 n Electrode rod 2 exposed switching channel 2 energizes relay 2 low water 2 n Electrode rod 3 exposed or ...

Page 12: ...A slow blow at 240 V External 125 mA slow blow at 120 V Response sensitivity electrical conductivity of water at 77 F 25 C 5 5000 ppm 10 10000 µS cm switch selectable Electrode voltage 20 Vss Output 4 volt free relay contacts 8 A 250 V AC 30 V DC cos ϕ 1 IEC 61810 Ensure interference suppression RC combination for contactor Energizing de energizing delay Relays 1 and 2 1s fixed Relay 3 0 30s set v...

Page 13: ... EN 60529 Protection class Class II with functional ground via boiler wall Installation class 3 Overvoltage category CAT III Admissible ambient temperature at power on 32 158 F 0 70 C during operation 14 158 F 10 70 C Transport temperature 4 176 F 20 80 C 100 hours only switch on after a defrosting period of 24 hours Storage temperature 4 158 F 20 70 C only switch on after a defrosting period of 2...

Page 14: ... Germany 250V T2 5A Input rating 240VAC Frequency 50 60Hz Output rating 120VAC or 240VAC Pilot Duty 2 5 A Ambient temperature 158 F 70 C Environmental rating NEMA 4 Wiring AWG 16 20 Cu only OPERATING CONTROL E513189 Input rating 120VAC Protection Manufacturer Disposal information De energizing delay Response sensitivity Service pressure temperature Safety information Equipment designation Fig 1 Ra...

Page 15: ...USA Installation Operating Manual 850690 00 A Overall view of the NRGS 15 1 E A B C D Key A Terminal box with level switch B Cover tube for four tip level electrode C Electrode thread D Electrode rods E Spacer Fig 2 ...

Page 16: ...on Operating Manual 850690 00 Dimensions of the NRGS 15 1 7 10 in 180 mm 14 05 in 357 mm 39 37 in 1000 mm Fig 3 w 2 36 in 60 mm 1 11 5 NPT 5 15 in 130 mm 0 8 in 20 mm max 1 57 in 40 mm Size 41 Thermal insulation provided on site ...

Page 17: ...trol fill control tv 0 30 s Electrode rod 4 High level Function 2 Electrode rod 1 Low level alarm 1 burner off Electrode rod 2 Feedwater pump on fill control Electrode rod 3 Feedwater pump off tv 0 s Electrode rod 4 High level Function 3 Electrode rod 1 Low level alarm 1 Electrode rod 2 Pump off Electrode rod 3 Pump on discharge control tv 0 s Electrode rod 4 High level Setting functions ON 1 2 3 ...

Page 18: ...18 NRGS 15 1 USA Installation Operating Manual 850690 00 4 5 6 7 8 9 10 11 13 14 15 12 1 2 4 5 6 7 4 5 6 7 Fig 4 Setting functions Fig 5 7 6 5 8 9 1234 ...

Page 19: ...ng screws for electronic circuit board Fixing nut for terminal box Terminal lugs for electrode wires functional ground Code switch Potentiometer for time delay Cover screws cross recess head screw M4 Cover of terminal box Note To set functions the time delay and response sensitivity please open the termi nal box To do so undo the cover screws and remove the cover When your settings are complete pu...

Page 20: ...lower conductivity than 5 ppm 10 µS cm at 77 F 25 C please change the sensitivity using the code switch The code switch is located on the electronic circuit board see Fig 5 and is set using a thin blade screwdriver The sensitivity can be set as follows Code switch White toggle switch Sensitivity Sensitivity 5 ppm 10 µS cm at 77 F 25 C default ON 1 2 3 5 4 6 7 8 910 ON 1 2 3 5 4 6 7 8 910 ...

Page 21: ... temperatures below freezing use a suitable heat source e g control cabinet heater etc Connect all parts of the plant to a central ground 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 insects and ani...

Page 22: ...nt or the level electrode n Always install the level switch in a vertical position n Take care not to bend electrode rods during installation n Avoid subjecting electrode rods to hard impacts n Ensure a minimum of 1 2 in 30 mm for insulating the electrode rods n Do not install the terminal box A or upper part of the level electrode cover tube B in the boiler s thermal insulation Fig 2 n Make sure ...

Page 23: ... b 1 95 in 50 mm 0 55 in 14 mm 2 55 2 75 in 65 70 mm a 0 8 in 20 mm a Thermal insulation provided on site d 0 79 in 20 mm outside the thermal insulation of the steam generating unit b Thread 1 11 5 NPT c Spacer Key Thermal insulation provided on site 1 11 5 NPT 1 2 in 30 mm c Size 41 ...

Page 24: ... the electrode tips with a flat file 4 Strip off 1 95 in 50 mm of the PTFE insulation from the lower end of the electrode rod Make sure that the remaining insulation measures at least 1 2 in 30 mm measured from the lower edge of the screw thread See Fig 6 5 Position the PTFE spacers evenly over the cut length Installation Installing the NRGS 15 1 step 1 Functions table Electrode tip Function Wire ...

Page 25: ... 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 7 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 wall To do this after...

Page 26: ...ntroller Fig 9 Protective tube provided on site when used as an internal water level controller in combination with a water level limiter m n 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 q r t o s p u NPS 4 DN 100 0 8 in 20 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 1 93 in 49 mm 0 39 in 10 mm p u t n m r q o s ...

Page 27: ...ange n Perform preliminary inspection of standpipe and flange during the boiler inspection o Protective foam tube level pot p Reducer q Pressure relief hole Key r High water HW s Low water LW t Electrode rod u Electrode spacing 0 55 in 14 mm air gap and creepage path CD center distance 1 11 5 NPT Pipe diameter 2 DN 2 n h j e i m CD u Pipe diameter 2 DN 2 Pipe diameter DN Pipe diameter DN f ...

Page 28: ...it board 3 Remove approx 1 6 in 40 mm of the cable sheath and strip approx 0 2 in 5 mm of the insulation from the individual wires 4 Unscrew the cable glands 7 pull the mains cable through the lower cable gland and the control cable through the upper gland 5 Following the wiring diagram Fig 12 inside of cover connect the mains cable and control cable to terminal strips 6 and 8 6 Plug terminal stri...

Page 29: ...0 00 Tools n Phillips screwdriver PH2 n Flat blade screwdriver 3 32 in 2 4 mm Electrical connection Wiring diagram Fig 12 4 2 1 5 6 7 8 9 10 11 13 4 3 2 1 4 3 2 1 14 15 12 N L 4 Mains supply Electrode wires S2 F1 S2 disconnector F1 fuse for level switch ...

Page 30: ...vel switch install a disconnector near the equipment in an easily accessible location n Mark the disconnector as an isolating device for the level switch Electrical connection Bringing into service 1 Switch on the mains supply The green LED 5 Power ON lights up LEDs 1 2 3 4 Fig 4 light up depending on the water level 1 Check switchpoints and functions by filling the tank and by draining some water...

Page 31: ... red After 1s MIN output contact 4 5 closed 4 6 open Fill tank until water is above the MIN level Electrode rod 1 is immersed LED 1 is not lit After 1s MIN output contact 4 5 open 4 6 closed MIN water level 2 electrode rod 2 Drain water until it is below MIN level 2 Electrode rod 2 is exposed LED 2 lights up red After 1s MIN output contact 7 8 closed 7 9 open Fill tank until water is above MIN lev...

Page 32: ...l mode On off pump control fill control electrode rods 2 and 3 Using the potentiometer set the time delay to precisely 0 s Drain water until it is below the Pump ON switchpoint Electrode rods 2 and 3 are exposed LEDs 2 and 3 light up Pump output contact 10 12 closed 10 11 open Fill tank until water is above the Pump ON switchpoint Electrode rod 2 is immersed LED 2 is not lit Fill tank until water ...

Page 33: ...ation The upper pressure relief hole is flooded Check level switch installation and make sure that the level in the protective tube corresponds to the actual water level MIN level switchpoint Status and display Error Corrective action Water below MIN level switchpoint LED 1 is not lit Electrode rod is too long Cut electrode rod to appropriate length for the switchpoints Electrode rod has contact w...

Page 34: ...ces and screw in level switch with metal sealing ring Do not insulate with hemp or PTFE tape Electronic circuit board is faulty Replace electronic circuit board Replacing the electronic circuit board To replace the electronic circuit board take the level switch out of service and cut off the power supply 1 Undo the cover screws and remove the cover Figs 4 5 2 Disconnect the electrode wires from th...

Page 35: ...NING The hot level electrode can cause severe burns The level electrode gets very hot during operation Always let the level electrode cool down before performing installation and mainte nance work Only remove level electrodes that have cooled down Removing the level switch Proceed as follows To remove the level switch take it out of service and cut off the power supply 1 Undo the cover screws and ...

Page 36: ...as well as radiation GESTRA AG can accept returned products only 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 expens...

Page 37: ...The level switch can also be installed in non metallic tanks Provided that the safety high level limiter function is not used electrode rod 4must be used as a reference electrode In this case insert the connection of electrode rod 4into the free terminal lug for functional ground In addition cut electrode rod 4to the same length as electrode rod 1and strip insulation over the entire length ON 1 2 ...

Page 38: ...38 NRGS 15 1 USA Installation Operating Manual 850690 00 For your notes ...

Page 39: ...39 NRGS 15 1 USA Installation Operating Manual 850690 00 For your notes ...

Page 40: ...22 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 ...