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NRS 1-9Installation Instructions 810831-00Water-Level Limiter / Controller NRS 1-9

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Contents

Important Notes

Page

Explanatory Notes

Installation

Wiring

Basic Adjustments

Commissioning

Performance Tests

Annex

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

Scope of supply ............................................................................................................. 8Description ..................................................................................................................... 8Function ......................................................................................................................... 8Design ............................................................................................................................ 9Technical data ............................................................................................................... 9

NRS 1-9 ....................................................................................................................... 10Example of installation ................................................................................................ 15

Wiring diagram ......................................................................................................... 3, 10

Check wiring ................................................................................................................ 11Apply power ................................................................................................................. 11

Low level limiter ........................................................................................................... 12High level limiter .......................................................................................................... 12Water level controller ................................................................................................... 12

Fault finding list for troubleshooting ............................................................................ 13

Declaration of conformity ............................................................................................. 14

Change-over for sensitivity .......................................................................................... 11

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Wiring Diagram

Fig. 1

NRS 1-9

NRG 16-36

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Functional Elements / Dimensions

Fig. 4Fig. 3

5

Fig. 2

A

A

BF

1

2

3

45

6

C

D

120

75

37.5

158

9

5

MAX 95%

MAX 55C

D

D

E

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Functional Elements

Fig. 5

G

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Key

Cover screws

Cover

Base

Cable entry

Mounting clip

Hole for wall mounting

Code switch for setting sensitivity

LED High level alarm

Switch Test 2 / Inspection

LED Low level alarm

Test button Test 1

LED Pump ON

LED Power

A

B

C

D

E

F

G

1

2

3

4

5

6

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Important Notes

Safety Note

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 with regula-tions concerning electrical safety systems, and first aid & accident prevention have achieved a recognised level of competence appropriate to the installation andcommissioning of this critical safety device.

The terminal strip of the NRS 1-9 is live during operation. This presentsthe danger of electric shock. Cut off power supply before fixing orremoving the housing cover.

Danger

Usage for the intended purpose

Water level controllers and water level limiters serve as safety equipment ininstallations requiring official approval. Use switching controller/limiter NRS 1-9 only

for monitoring and indicating liquid levels.

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Explanatory Notes

Description

Function

Self-monitoring water level controller & limiter with automatic self-testing routinedesigned for use in conjunction with level electrode NRG 16-36. This equipmentcombination controls the water level, detects the max. allowable water level(high level alarm) and the min. allowable water level (low level alarm).

Application in compliance with the German regulations for use in steam andhot-water plants according to TRD 602 and TRD 604, sheets 1 and 2.

The switching controller NRS 1-9 features a two channel circuit and is provided witha self-monitoring and routine testing function in accordance with DIN 57116/VDE0116. The two channels are designed to monitor the operation of each other(redundancy). The periodic self-checking logic unit checks the integrity of the cablebetween the electrode and the switching controller, and the two channel circuits for

malfunction.Unless it finds a fault, this internal test does not interfere with the output contacts ofthe controller and therefore the boiler operation is not interrupted.A manual test push button is also provided. When the push button TEST 1 ispressed, it simulates a fault in the electrode. There is also a toggle switch TEST 2/Inspection for checking the function of the self-checking circuitry. The outputcontact relays of the switching controller are of the normally closed type and willtherefore signal alarm condition in the event of mains failure.

The switching controller can signal the following four operating conditions:

Normal operation (feedwater control)

Alarm (high water level) Alarm (low water level)

Alarm (fault in switching controller or level electrode)A green LED indicates power ON. Low water level alarm or malfunction of the lowwater level limiter system is indicated by the two red LEDs. The failure of onechannel (loss of redundancy) is signalled by the lighting up of one red LED. Theother green LED indicates feedwater pump is running. High water level alarm issignalled by another red LED.The use of SMART combination electrode NRG 16-36 in conjunction with switching

controller NRS 1-9 provides fail safe protection against a first fault, i. e. the systemwill still continue to provide the safety function even after the occurrence of a firstfault.

Scope of supply

NRS 1-9

1 Water level controller/water level limiter (plug-in unit for installation in controlcabinets)

1 Installation manual

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Technical Data

Type approval no.TV WR/WB 99-370Input8 connections for one level electrode NRG 16-36, PN 40Output contacts

For level limiter part:Two volt-free relay contactsFor level controller part:One volt-free working contact for feedwater on-off control.One volt-free relay contact for high level alarm.Contact material silver, hard gold plated.Max. contact rating with switching voltages of 24 V, 115 V and 230 V a.c.:4 A resistive, 0.75 A inductive at cos 0.5Max. contact rating with switching voltage of 24 V d.c.: 4 ADelay of response

The low water level alarm signal is factory set to react after a time delay of1 or 3 seconds (up to 25 sec. delay is possible).The controller as well as the high water level alarm signal is factory set to react aftera time delay of 2 seconds.SensitivityRange 1: 10 S/cm at 25CRange 2: 0.5 S/cm at 25CThe selection of the above range is done via a code switch.Indicators and adjustorsOne green LED Power, two LEDs Low level alarm, one test button TEST 1, one

toggle switch TEST 2/INSPECTION, one LED Feedwater control on, one LEDHigh level alarm and one four-pole code switch.Mains supply230 V +/ 10 %, 50/60 Hz (please state voltage when ordering)Special voltage: 115 V +/ 10 %, 50/60 Hz or 24 V +/ 10 %, 50/60 Hz;24 V d. c. supply is also possible with the inverter type URN-1.ProtectionIP 20 in accordance with DIN 40050Admissible ambient temperature0 to 55C

Case materialsBase: ABS plastic, black. Cover: polystyrene, highly shock resistant, stone grey.Weight0.6 kg

Explanatory Notes continued

Design

NRS 1-9b:Plug-in unit in plastic case for snapping onto a 35 mm rail (TS 35 x 15 according to

DIN EN 50022-35) or for installation in control

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NRS 1-9

Installation

On supporting rail1. Snap switching controller onto supporting rail.

2. Loosen cover screws and unplug cover from its base .3. Select cable entry and remove corresponding seal.

On mounting panel1. Loosen cover screws and unplug cover from its base .2. Unscrew mounting clip .3. Drill the hole marked in the base to 4.3 mm diameter.4. Select cable entry and remove corresponding seal.5. Fasten base with two screws M4 onto mounting panel.

Tools

Screwdriver (5.5/100)

Wiring Diagram

see page 3

NRS 1-9Use four-core overall screened cable, e. g. IY(ST)Y 2 x 2 x 0.9 or LIYCY 4 x 0.5 mm.Max. cable length 250 m.

Connect terminal strip in accordance with wiring diagram, fig. 1

Wiring

A B CD

A B C

E

F

D

Attention

To protect the switching contacts fuse circuit with 2.5 A (slow blow fuse)

or according to TRD regulations (1.0 A for 72 hrs operation). The screen must not make any other electrical contact.

Note

Connect screen only to terminals 16 and 21 of the switching controller.

The mains voltage is indicated on the name plate.

When switching off inductive loads, voltage spikes are produced thatmay impair the operation of control and measuring systems. Inductiveloads should be provided with commercial arc suppressor RCcombinations, e. g. 0.1 F/100 W.

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Tools

Screwdriver for slotted screws, size 2.5, completely insulated according toVDE 0680.

Commissioning

Check wiring

Check whether switching controller NRS 1-9 and the associated electrode

NRG 16-36 are wired in accordance with wiring diagram, fig. 1.

Apply power

Apply mains voltage. The green LED lights up, fig. 2.6

Tools

Wiring continued

Basic Adjustments

Change-over for sensitivity

The switching controller can be set to two different sensitivities. For this purpose acode switch consisting of four individual switches is provided on the rear of thecontroller.

Range 1: Sensitivity from 10 S/cm (factory setting)Range 2: Sensitivity from 0.5 S/cm1. Cut off power supply to switching controller.

2. Loosen cover screws and unplug cover from its base , fig. 1.3. Move all four individual switches of the code switch to the desired range using

a small screwdriver, fig. 5.

Screwdriver for slotted screws, size 2.5, completely insulated according toVDE 0680.

A B C

G

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1. Check length of electrode tip (see installation instructions for NRG 16-36).2. Completely open valves of water-level gauge glass on steam boiler.

3. Fill boiler with feedwater until the level exceeds the required max. level.After the response delay of 2 sec. the red LED must light up, fig. 2.

4. Decrease level in the boiler until the level falls below high level, the red LEDmust extinguish.

High-level limiter

Water level controller

1. Check length of electrode tips (see installation instructions for NRG 16-36).2. Lower water level in boiler until electrode tip 2 (lower switch point) is completely

exposed, fig. 1.3. The green led must light up, fig. 2.

Simultaneously the switching function for feedwater control (PUMP ON)is released.

4. When the water level reaches electrode tip 3 (upper switch point), LED mustextinguish. Simultaneously the switching function for feedwater control (PUMPOFF) is released.

1

1

5

5

Performance Tests

Low-level limiter

1. Check length of electrode tip (see installation instructions for NRG 16-36).

2. When switching on the mains voltage the green LED should light permanently,fig. 2.

3. Completely open valves of water-level gauge glass on steam boiler.

4. Fill boiler with feedwater (2 cm above required min. level).

5. Decrease level in boiler until the level falls below min. level. After the responsedelay the two red LEDs must light up.

6. A low-level alarm can be simulated by pushing the button TEST I whilst theelectrode tip is submerged. Push the button until the response delay has expired.Both red LEDs must light up.

7. To check the function of the checking circuitry of the switching controller proceed

as follows: Operate switch TEST II/INSPECTION in the direction of the arrowwith the electrode tip submerged. After max. two minutes the two red LEDsshould signal low-level alarm.The button TEST I must not be operated during this test nor must the levelfall below the low level mark.After the test return switch into its original position. After the response delay thetwo red LEDs must extinguish.

6

3

3

4

4

2

3

3

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Annex

Fault finding list for troubleshooting

Fault: After raising the water level above the low-level mark, the red LEDsare not extinguished or only after quite a considerable period.

Remedy: Check whether a vent hole has been provided in the protection tube. If theelectrode is fitted in an external chamber, check position of isolatingvalves.

Fault: The switching controller signals high-level alarm before the level in theboiler has reached the high level mark.

Remedy: Check length of high water level electrode tip. Check whether theelectrode tip has contact with the chamber/protection tube or other boiler

internals. Check correct wiring of level switch and electrode in accordancewith wiring diagram, fig. 1.

Fault: After decreasing the water level below the high-level mark, the red LEDis not extinguished or only extinguishes after quite a considerable period.

Remedy: Check whether a vent hole has been provided in the protection tube. If theelectrode is fitted in an external chamber, check position of isolatingvalves.

If faults occur that are not listed above please contact our subsidiary or agency inyour country.

Fault: One or both red LED(s) light up without the level having fallen belowthe low-level mark.

Remedy: This means electronic failure within the switching controller, i. e. failure ofone or both channels. Replace switching controller.

Fault: The switching controller signals low-level alarm before the level in theboiler has fallen below the low level mark.

Remedy: Check length of low-water level electrode tip. Measure the conductivity ofthe process or boiler water and compare the values obtained with themarking on the name plate. Check correct wiring of switching controllerand electrode in accordance with wiring diagram, fig. 1.

3

3

4

The terminal strip of the NRS 1-9 is live during operation. This presentsthe danger of electric shock. Cut off power supply before fixing or

removing the housing cover.

Danger

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Key

Annex continued

Cover screws

Cover

Base

Hole for wall mounting

Mounting clip

Support rail TS 35 x 15 to DIN EN 50022-35

We hereby declare that the equipment NRS 1-9 conforms to the following Europeanguidelines:

LV guideline 73/23/eec version 93/68eec EMC guideline 89/336/eec version 93/68/eec

which are based on the following harmonized standards:

LV standard EN 60947-5-1: 1991

EMC standard EN 50 081-2, EN 50 082-2

This declaration is no longer valid if modifications are made to the equipment withoutconsultation with us.

Bremen, 1st January 2000GESTRA GmbH

Dipl.-Ing. Uwe Bledschun(Academically qualified engineer)

Declaration of conformity

Dr. Anno Krautwald

A

B

I

C

F

H

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Example of Installation

Fig. 6

Fig. 7

A

B

I

CH

F

F

MAX 55 C

MAX 95%

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810831 00/903 2000 GESTRA G bH B P i t d i G

GESTRA GmbHP. O. Box 10 54 60, D-28054 Bremen, Mnchener Str. 77, D-28215 BremenTelephone +49 (0) 421 35 03- 0, Fax +49 (0) 421 35 03 - 393E-Mail gestra.gmbh@flowserve.com, Internet www.gestra.de

A Unit of Flowserve Corporation

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Burrel Road, Haywards HeathWest Sussex RH 16 1TLTel. 00 44 14 44 / 31 44 00Fax 00 44 14 44 / 31 45 40E-mail: sales@flowserve.com

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Divisione ItalgestraVia Prealpi, 30 20032 Cormano (MI)Tel. 00 39 02 / 66 32 51Fax 0039 02/ 66 32 55 60E-mail: info@italgestra.it

GESTRA ESPAOLA S.A.Luis Cabrera, 86-88E-28002 MadridTel. 00 34 91 / 5 152 032

Fax 00 3491/ 4 136 747; 5152036E-mail: gestra@gestra.es

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Tl. 0 0331/ 34432660Fax 00331/ 34432687E-mail: gnation@flowserve.com

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Tel. 00351 22 / 6198770Fax 00351 22 / 6107575E-mail: gestra@gestra.pt