1

�

Installation Instructions 810393-02Level Electrode NRGS 11-1Level Electrode NRGS 16-1Level Electrode NRGS 16-1S

NRGS 11-1NRGS 16-1NRGS 16-1S

2

Contents

Usage for the intended purpose ................................................................................... 7Safety Note .................................................................................................................... 7Danger ........................................................................................................................... 7

Important Notes

Warning ....................................................................................................................... 16Fault finding list ........................................................................................................... 16Declaraction of conformity .......................................................................................... 18

Annex

Page

Explanatory Notes

Scope of supply ............................................................................................................. 8System description ........................................................................................................ 8Function ......................................................................................................................... 8Designs ......................................................................................................................... 8Technical data ......................................................................................................... 9, 10

NRGS 11-1, NRGS 16-1 ............................................................................................. 10NRGS 16-1 S (marine applications) ..................................................................... 10, 11Table ‘Functions’ ......................................................................................................... 11Examples of installation .............................................................................................. 19

Installation

Wiring

Wiring diagram NRGS 11-1, NRGS 16-1, NRGS 16-1 S ........................................... 12Fill control .................................................................................................................... 13Discharge control ........................................................................................................ 13

Standard Setting

Factory setting ............................................................................................................. 14Switch selection of measuring range ......................................................................... 14

Warning ....................................................................................................................... 15Check wiring ............................................................................................................... 15Check correlation of switching functions ................................................................... 15Apply mains voltage ................................................................................................... 15

Commissioning

3

Fig. 1 Fig. 2

∅ 42

Dimensions

173173

140

338

140

6243

6, 9

36,

1436

500,

100

0, 1

500

NR

GS

11-

1: 2

40

NR

GS

16-

1: 3

38

4

Parts Drawings

Fig. 4

Fig. 5Fig. 3

N 8

A B

C

D

50 65–

70≥14

∅ 40

1" BSP, DIN 228

N10

0.5

5

Fig. 6

Parts Drawings

E F G

Fig. 7

12

34

5

L

K J

I H

6

LED “Low-level alarm”

LED “Pump ON”

LED “Pump OFF”

LED “High-level alarm”

Code switch “Measuring range”

Electrode thread 1" BSP, DIN 228

Seating surface

Joint ring (of stainless steel 1.4301) D 33 x 39 to DIN 7603

Flange DN 50, PN 40 to DIN 2635

Housing screws M4

Cable entry PG 9 / PG 16

Housing cover

Terminal strip

PE connection

Terminal strip ‘Test’

Thermal fuse Tmax 102 °C

Plug

Key

B

C

D

F

G

H

I

J

K

L

1

2

3

5

A

E

4

7

Important Notes

Safety Note

Danger

When loosening the electrode live steam or hot water might escape. Thispresents the danger of severe injury. It is therefore essential not todismantle the electrode unless the boiler pressure is verified to be zero.The terminal strip of the NRGS 11-1, NRGS 16-1, NRGS 16-1 S is liveduring operation. This presents the danger of electric shock. Cut offpower supply before fixing or removing the housing cover.

Installation must only be performed by qualified staff.Qualified staff are those persons who – through adequate training in electricalengineering, the use and application of safety equipment in accordance withregulations concerning electrical safety systems, and first aid & accidentprevention – have achieved a recognised level of competence appropriateto the installation and commissioning of this device.

Usage for the intended purpose

Use compact system for level monitoring type NRGS 11-1, NRGS 16-1,NRGS 16-1 S only for level indication in electrically conductive liquids.

8

Explanatory Notes

Scope of Supply

Function

Designs

NRGS 11-11 Compact system type NRGS 11-1, PN 61 Joint ring (of stainless steel 1.4301) D 33 x 39 to DIN 76031 Installation manual

NRGS 16-11 Compact system type NRGS 16-1, PN 401 Joint ring (of stainless steel 1.4301) D 33 x 39 to DIN 76031 Installation manual

NRGS 16-1 S1 Compact system type NRGS 16-1 S (flanged design for marine application)1 Flange DN 50, PN 40, DIN 26351 Installation manual

System Description

The compact system NRGS 11-1, NRGS 16-1, NRGS 16-1 S works according tothe conductivity measurement principle.

With the NRGS 11-1, NRGS 16-1, NRGS 16-1 S a maximum of 4 levels can besignalled in conductive liquids:

■ 4 levels with one switchpoint each

■ High-level alarm, low-level alarm, pump ON, pump OFF with oneswitchpoint each

The NRGS 1...-1(S) has a switching controller integrated in the electrode case forthe control of all functions. External switchgear is therefore not required.

The conductivity of the liquid is used to signal the liquid level. Some liquids areconductive, which means that they allow an electric current to flow throughthem. For the safe functioning of this device a minimum conductivity of the liquidto be measured is required.The conductivity measurement method can detect two conditions: electrode tipsubmerged or exposed, meaning switchpoint reached or not reached. Beforeinstallation, the length of the electrode tip must be cut to the required switchinglevels, e. g. for high-level/low-level alarm, controlling of a valve or pump.

NRGS 11-1, NRGS 16-1:Screwed design 1" BSP, DIN ISO 228. Fig. 1

NRGS 16-1 S:Flanged design for marine applications DN 50, PN 40, DIN 2635. Fig. 2

9

Technical Data

Type Approval N°NRGS 11-1: TÜV · WRB · 01-388NRGS 16-1: TÜV · WRB · 01-388NRGS 16-1 S: GL 99250-96 HHLR 98/20075RINA No ELE/30298/1

Max. service pressureNRGS 11-1: 6 bar g at 159 °CNRGS 16-1: 32 bar g at 238 °CNRGS 16-1 S: 32 bar g at 238 °C

ConnectionsScrewed 1" BSP, DIN ISO 228Flanged DN 50, PN 40, DIN 2635

MaterialsCase: Die cast aluminium 3.2161 (G AlSi8Cu3)Stem: S. S. 1.4571 (CrNiMoTi 17 12 2)Flange: Forged steel 1.0460 (C 22.8)Measuring electrodes: S. S. 1.4571 (CrNiMoTi 17 12 2)Electrode insulation: PTFESpacer disc: PTFE

Lengths supplied1500 mm1000 mm1500 mm

Mains supply230 V +/- 10 %, 50/60 Hz115 V +/- 10 %, 50/60 Hz124 V +/- 10 %, 50/60 Hz (option)

Power consumption5 VA

FuseThermal fuse Tmax = 102 °C

SensitivityRange 1: 10 µS/cmRange 2: 0.5 µS/cm

Electrode voltage10 Vss

Output4 volt-free relay contacts.Max. contact rating with a switchting voltage of 24 V, 115 V and 230 V a. c.:ohmic 4 A, inductive 0.75 A at cos ϕ 0.5. Max contact rating with a switchingvoltage of 24 V d. c.: 4 AContact material: silver, hard-gold plated

Explanatory Notes – continued –

10

5. Check seating surfaces of threads or flange provided on vessel or boilerstandpipe. Fig. 5

6. Place joint ring onto seating surface of electrode Fig. 3. Use only joint ring(of stainless steel 1.4301) D 33 x 39 to DIN 7603 supplied with electrode.

7. Apply a light smear of silicone grease (e. g. Molykote®111 ) to electrode thread .8. Screw level electrode into threads or flange provided on vessel or boiler standpipe

and tighten with a 41 mm open-end spanner. The torque required is 140 Nmwhen cold.

Explanatory Notes – continued –

Installation

NRGS 11-1, NRGS 16-1, NRGS 16-1S

NRGS 11-1, NRGS 16-1

Energizing/deenergizing delay3 sec., factory set

Indicators and adjustors4 red LEDs for signalling “electrode submerged”, “output relay energized”1 four-pole code switch for changing sensitivity

Cable entryCable gland with integral cable clamp2 x PG 9 (M 16)1 x PG 16 (M20)

ProtectionIP 65 to DIN EN 60529

Max. admissible ambient temperature70 °C

WeightNRGS 11-1: approx. 1.4 kgNRGS 16-1: approx. 1.8 kgNRGS 16-1 S: approx. 2.5 kg

1. Determine required measuring lengths of electrode tips and enter data in table Fig. 3.2. Cut electrode tips 1 , 2 , 3 and 4 accordingly.3. Deburr faces of electrode tips.4. Strip off 50 mm of PTFE insulation from the ends of electrode tips.

Molykote® 111 is a registered trademark of DOW Corning Corp., Midland Michigan, USA

Technical Data – continued –

C

A

B

11

Installation – continued –

Table 1

NRGS 16-1 S

9. Check seating surfaces and place flat gasket on connection standpipe.0. Place blind flange with bore together with level electrode onto connection

standpipe and fix with bolts. Tighten bolts in diagonally opposite pairs. Fig. 41

Function

e. g. First low-level alarm

e. g. Feed pump ON

e. g. High level alarme. g. Fee pump OFF

Function Electrode tip

3

4

2

1

Length [mm]

Attention

■ The seating surfaces of the threads or flange provided on the vessel orboiler standpipe must be accurately machined. Fig. 5

■ Do not bend electrode tip when mounting.■ Do not lag electrode body.

Note

■ For the approval of the boiler standpipe with connecting flange therelevant local and national regulations must be considered.

■ See four examples of installation on page 19.

Tools

■ Open-end spanner 41 mm A. F. to DIN 894■ Bolt cutter■ Hacksaw■ Flat file, medium cut

Please enter length and function.

D

12

NRGS 11-1, NRGS 16-1, NRGS 16-1S

Use multi-core flexible cable with min. conductor size 1.5 mm2 for wiring.

1. Unscrew screws , remove housing cover Fig. 62. Unscrew union nuts of cable entry .

The electrode terminal can be turned through +/– 180°.

3. Slacken plug with 17 mm open-end spanner but do not remove. Fig. 74. Turn electrode terminal into desired direction (+/- 180°).5. Tighten plug slightly.6. Remove terminal strip from board.7. Connect terminal strip according to wiring diagram, connect PE connection .8. Plug in terminal strip.9. Install housing cover , fasten screws and install cable entry .

Wiring

Wiring diagram

Fig. 8

G

L

H

F

E

L

I

Mains

G E F

13

■ Fuse supply cables with T 250 mA.

■ The connection of the switchpoints 2 and 3 must be provided on site(pump contactor, auxiliary relay)!

Tools

Attention

Wiring – continued –

Fill Control

■ Screwdriver for cross head screws, size 1■ Screwdriver for slotted screws, size 2.5; completely insulated according

to VDE 0680■ Open-end spanner 17 mm A. F. to DIN 894

Discharge Control

Fig. 9

Fig. 10

Mains

Mains

LW

14

The measuring range can be switch selected between ≥ 0.5 µS/cm and ≥ 10 µS/cmby means of code switch :

1. Unscrew screws at the electrode terminal, remove cover , Fig. 6

DIP switch 1 – 4 OFF Measuring range ≥ 0.5 µS/cm.

DIP switch 1 – 4 ON Measuring range ≥ 10 µS/cm.

2. Replace cover and fasten screws .

Standard setting

Factory setting

The compact system is delivered with the following factory settings:

■ Measuring range ≥ 10 µS/cm

Switch selection of measuring range

Attention

■ Screwdriver for cross head screws, size 1■ Screwdriver for slotted screws, size 2.5; completely insulated according

to VDE 0680

■ Do not damage the electronic components when setting the codeswitch.

Tools

5

E G

EG

15

1. Switch on mains supply and check the correct functioning of the equipment atthe corresponding switchpoints. LEDs , , and are provided for visualcheck of switchpoints. Fig. 7

Remove housing cover to check LEDs , , and . See “Wiring”

Commissioning

Warning

1. Check whether the system has been wired according to wiring diagram Fig. 8.

2. Check whether mains supply corresponds to the wiring carried out on theequipment.

The terminal strip of the NRGS 11-1, NRGS 16-1, NRGS 16-1 S is liveduring operation.This presents the danger of electric shock.Cut off power supply before removing or replacing housing cover.

Check wiring

Apply mains voltage

1. Check whether the designated switchpoints – i. e. switch functions – have beencorrelated with the individual electrode rods. See table "Functions", page 11.

Check correlation of switching functions

G 1 2 3 4

4321

16

Annex

Warning

The terminal strip of the NRGS 11-1, NRGS 16-1, NRGS 16-1 S is liveduring operation.This presents the danger of electric shock.Cut off power supply before fixing or removing the housing cover.

Fault finding list

Level has exceeded switchpoint “High Water” – no functionFault: Mains voltage has not been applied.Remedy: Apply mains voltage. Wire equipment according to the wiring diagram.

Fault: The thermal fuse has been triggered.Remedy: In case of defective thermal fuse the mains voltage has not been

connected to terminal : Replace defective thermal fuse(stock code 051 629).The ambient temperature must not exceed 70 °C.

Fault: The electric conductivity is too low.Remedy: Set code switch to ≥ 0.5 µS/cm.

Fault: The electrode housing does not have earth connection to the boiler.Remedy: Clean seating surfaces and insert metal joint ring (of stainless steel

1.4301) 33 x 39 to DIN 7603.Do not insulate compact system with hemp or PTFE tape!

Fault: Electronic board is defective.Remedy: Replace board (stock code 391 422).

Level has fallen below switchpoint “Low Water” – no functionFault: The electrode tips have earth contact.Remedy: Change installation position.

Fault: The vent hole in the protection tube does not exist, is obstructed or flooded.Remedy: Check protection tube and, if necessary, provide vent hole.

Fault: The isolating valves of the external measuring pot (optional) are closed.Remedy: Open isolating valves.

Switchpoint has been reached – incorrect functionFault: The switching function has not been correctly allocated. Electrode tips

have been cut to the wrong size.Remedy: Identify electrode supply wire and reconnect accordingly.

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

J

5

17

For your notes

18

Declaration of Conformity

Bremen, 4th September 2002GESTRA GmbH

We hereby declare that the equipment NRGS 11-1, NRGS 16-1 and NRGS 16-1 Sconform to the following Euopean guidelines:■ LVD 73/23/eec version 93/68/eec■ EMC guideline 89/336/eec version 93/68/eecwhich are based on the following harmonised standards:■ LV standard EN 60947-5-1: 1991■ EMC standard EN 50 081-2, EN 50 082-2This declaration is no longer valid if modifications are made to the equipmentwithout consultation with us.

Annex – continued –

Flange PN 40, DN 150 (2"), DIN 2527

Flange PN 40, DN 100 (4"), DIN 2527

For the approval of the boiler standpipe with connecting flange the relevant

regulations must be considered.

Vent hole

High water (HW)

Electrode tip d = 5 mm

Protection tube DN 80

Protection tube DN 100

Electrode distance ≥ 14 mm

Electrode distance ≥ 40 mm

Low water (LW)

Reducer K-88.9 x 3.2 – 42.4 x 2.6 W to DIN 2616, part 2

Reducer K-114.3 x 3.6 – 48.3 x 2.9 W to DIN, 2616 part 2

Key

2

3

4

6

7

8

9

10

11

12

1

5

Quality Assurance ManagerLars Bohl

(Academically qualified engineer)

Head of the Design Dept.Uwe Bledschun

(Academically qualified engineer)

19

DN 100

Fig. 13

Examples of installation

∅

20

20

DN 20

DN 20

24.5 24.5

20

∅20

Fig. 11 Fig. 12

Fig. 14

DN 50

≤ 90°

DN 50

1" BSP 1" BSP

1" BSP

1" BSP ¾" BSP ≤ 20

DN 20

≥10

∅ 20

≤ 90°

12

3

5

6

10

11

4

8

∅ 20

12

10

12

53

9

12

3

5

6

1111

∅ 2

0

20

≥ 10

∅ 20

8

4

7

8

10

4

≤ 90°

≤ 15

00

≤ 30

00

ME

≤ 20

12

4

5

10

20810393-02/304cm · © 1998 GESTRA GmbH · Bremen · Printed in Germany

GESTRA GmbHPostfach 10 54 60, D-28054 Bremen, Münchener Str. 77, D-28215 BremenTelefon +49 (0) 421 35 03 - 0, Telefax +49 (0) 421 35 03 - 393E-Mail gestra.gmbh@flowserve.com, Internet www.gestra.de

A Unit of Flowserve Corporation

®

GESTRA Gesellschaften · GESTRA Companies · Sociétés GESTRA · Sociedades Gestra · Società GESTRAVertretungen weltweit · Agencies all over the world · Représentations dans le monde entier · Representaciones en todo el mundo · Agenzie in tutto il mondo

Great Britain

Flowserve Flow Control (UK) Ltd.Burrel Road, Haywards HeathWest Sussex RH 16 1TLTel. 00 44 14 44 / 31 44 00Fax 00 44 14 44 / 31 45 57E-mail: sales@flowserve.com

Italia

Flowserve S.p. ADivisione ItalgestraVia Prealpi, 30 – 20032 Cormano (MI)Tel. 00 39 02 / 66 32 51Fax 00 39 02 / 66 32 55 60E-mail: infoitaly@flowserve.com

GESTRA ESPAÑOLA S.A.Luis Cabrera, 86-88E-28002 MadridTel. 00 34 91 / 5 152 032Fax 00 34 91 / 4 136 747; 5 152 036E-mail: gestra@gestra.es

España

Flowserve Flow Control S. A. S.10 Avenue du Centaure, BP 8263F-95801 CERGY PONTOISE CEDEXTél. 00.33.1 / 34 43 26 60Fax 00.33.1 / 34 43 26 87E-mail: contact@gestra.fr

France Portugal

Flowserve Portuguesa, Lda.Av. Dr. Antunes Guimarães, 1159Porto 4100-082Tel. 00351 22 / 6 19 87 70Fax 00351 22 / 6 10 75 75E-mail: gestra@gestra.pt