BAN - 818954 - 07 - NRG16 50 NRG17 50 NRG19 50 NRG111 50 - en
BAN - 818954 - 07 - NRG16 50 NRG17 50 NRG19 50 NRG111 50 - en
NRG 16-50
NRG 17-50
NRG 19-50
NRG 111-50
EN
English
Original Installation Instructions
818954-08
Contents
Page
Important Notes
Technical data
Installation
Examples of installation
2 NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08
Contents - continued -
Page
Electrical connection
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50, four-pole connector..................................................18
Key........................................................................................................................................................18
Connection of level electrode.................................................................................................................19
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50, with four-pole connector..........................................19
NRG 16-50 F, NRG 17-50 F, NRG 19-50 F, NRG 111-50 F, with aluminium terminal box .........................19
Tools......................................................................................................................................................19
Wiring diagram......................................................................................................................................20
Key........................................................................................................................................................20
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08 3
Important Notes
The level electrodes NRG 1...-50 are used in conjunction with level switch NRS 1-50 as water level
limiters for steam boilers and (pressurised) hot water installations.
Water level limiters switch off the heating when the water level falls below the set minimum level (low water).
Function
When the water level falls below the low level, the level electrode is exposed and a low level alarm is
triggered in the level switch NRS 1-50. This switchpoint "Low water level (LW)" is determined by the
length of the electrode tip.
The electrode operation is based on the conductive measuring principle using the electrical conductivity
of the water for signalling water level. The self-monitoring function ensures that an alarm will also be
triggered if the electrode insulation is contaminated or has developed a leak or if there is a malfunction
in the electrical connection.
The level electrode is installed inside steam boilers, vessels or inlet lines of hot-water systems. The
protective tube mounted on site (see section Examples of Installation - pages 16, 17) ensures correct
functioning.
One level electrode NRG 1...-50 can be installed together with one GESTRA level electrode, one level
switch or transmitter for water level control and low level alarm in one single protection tube or level pot.
If the level electrode is installed in an isolatable level pot outside the boiler, make sure that the connec-
ting lines are rinsed regularly. In addition, the logic unit SRL is required to monitor the purging times and
the purging sequence.
If the connecting lines for steam ≥ 40 mm and water ≥ 100mm, the installation is considered to be
internal. In this case the rinsing processes do not have to be monitored.
Safety note
This equipment is a safety accessory and must only be installed, wired 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
Attention
The name plate specifies the technical features of the equipment. Do not commission or
operate any item of equipment that does not bear its specific name plate.
4 NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08
Important Notes - continued -
Note
The level electrodes NRG 1...-50 are simple items of electrical equipment as specified in
EN 60079-11 section 5.7. The equipment must be equipped with approved Zener barriers
if used in potentially explosive areas (zones 1 and 2). The equipment does not bear an Ex
marking.
Note that the requirements of the IEC 61508 are not met if the NRG 1...-50 + Zener barri-
ers + NRS 1-50 are interconnected!
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08 5
Technical data
Service pressure
NRG 16-50: PN 40, 32 bar at 238 °C
NRG 17-50: PN 63, 60 bar at 275 °C
NRG 19-50: PN 160, 100 bar at 311 °C
NRG 111-50: PN 320, 183 bar at 357 °C
Mechanical connection
Screwed G ¾ A to ISO 228-1 (NRG 16-50, NRG 17-50, NRG 19-50)
Screwed G 1 A to ISO 228-1 (NRG 111-50)
Materials
Screw-in body: 1.4571, X6CrNiMoTi17-12-2 (NRG 16-50, NRG 17-50, NRG 19-50)
Screw-in body: 1.4529, X1NiCrMoCuN25-20-7 (NRG 111-50)
Measuring electrode: 1.4571, X6CrNiMoTi17-12-2 (NRG 16-50, NRG 17-50, NRG 19-50)
Measuring electrode: 1.4122, X39CrMo17-1 (NRG 111-50)
Electrode tip: 1.4401, X5CrNiMo17-12-2
Electrode insulation: Gylon® (NRG 16-50, NRG 17-50, NRG 19-50)
Electrode insulation: special ceramic (NRG 111-50)
NRG 1...-50: Four-pole connector: polyamide (PA)
NRG 1...-50F: Terminal box 3.2161 G AlSi8Cu3
Lengths supplied
500 mm, 1000 mm, 1500 mm, 2000 mm, 2500 mm, 3000 mm
ph value
Max. admissible: 10 (NRG 111-50)
Electrical connection
NRG 1...-50: Four-pole connector, cable glands M 16
NRG 1...-50F: Terminal box made from aluminium, cable gland M 20
Protection
IP 65 to EN 60529
Admissible ambient temperature
Max. 70 °C
Weight
Approx. 1.2 kg (without extension) (NRG 16-50, NRG 17-50, NRG 19-50)
Approx. 2.1 kg (without extension) (NRG 16-50F, NRG 17-50F, NRG 19-50F)
Approx. 1.8 kg (without extension) (NRG 111-50)
Approx. 2.7 kg (without extension) (NRG 111-50F)
6 NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08
Technical data - continued -
Scope of supply
NRG 16-5 NRG 19-50
1 Level electrode NRG 16-50, PN 40 1 Level electrode NRG 19-50, PN 160
1 Joint ring 27 x 32, form D, DIN 7603, 1 Joint ring 27 x 32, form D, DIN 7603,
2.4068, bright annealed 2.4068, bright annealed
1 Washer with set screw 1 Washer with set screw
(measuring surface extension) (optional) (measuring surface extension) (optional)
1 Retaining ring (optional) 1 Retaining ring (optional)
1 Installation manual 1 Installation manual
NRG 17-50 NRG 111-50
1 Level electrode NRG 17-50, PN 63 1 Level electrode NRG 111-50, PN 320
1 Joint ring 27 x 32, form D, DIN 7603, 1 Joint ring 33 x 39, form D, DIN 7603,
2.4068, bright annealed 2.4068, bright annealed
1 Washer with set screw 1 Washer with set screw
(measuring surface extension) (optional) (measuring surface extension) (optional)
1 Retaining ring (optional) 1 Retaining ring (optional)
1 Installation manual 1 Installation manual
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08 7
Technical data - continued -
PN 40 G /4
3
1.4571 IP 65 TÜV . SWB . xx-422
Pressure rating, thread type,
32 bar (464psi) material number, type approval number
Pmax
Tmax
238°C (460°F)
T amb = 70°C (158 °F)
Conformity marking
GESTRA AG D-28215 Bremen 0525
Fig. 1
Betriebsanleitung Betriebsanleitung
beachten beachten
See installation instructions See installation instructions
Voir instructions de Voir instructions de
montage montage
Safety note
Hier öffnen Hier öffnen
Open here Open here
Ouvrir ici Ouvrir ici
32 bar (464psi)
238°C (460°F) Pressure/temperature rating
Pmax 60 bar (870psi) Tamb = 70°C (158 °F)
Tmax 275°C (527°F)
100 bar (1450psi)
311°C (592°F)
Serial number
Fig. 2 Fig. 3
8 NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08
Installation
175
140
GESTRA
b = 70
338
272
100
≤ 3000
≤ 3000
23
Fig. 4 Fig. 5
NRG 16-50, NRG 17-50, NRG 19-50 NRG 16-50F, NRG 17-50F, NRG 19-50F
with four-pole connector and measuring surface with aluminium terminal box
extension
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08 9
Installation - continued -
175
140
b = 70
425
338
136
30
30
≤ 3000
≤ 3000
Fig. 6 Fig. 7
NRG 111-50 NRG 111-50F
10 NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08
Installation - continued -
Note
n One level electrode NRG 1...-50 can be installed together with one GESTRA level elec-
trode, one level switch or transmitter for water level control or low level alarm in one
single protection tube or level pot (inside diameter 100 mm). Fig. 17. If the electrode
NRG 1...-50 is installed inside the vessel, it must be at least 40 mm away from the
upper vent hole.
n The installation of two water-level limiting electrodes NRG 1...-50 in one single stand
pipe is not allowed.
n For the approval of the boiler standpipe the relevant regulations must be considered.
n Refer to pages 16 – 17 for typical installation examples.
n The angle of inclination of the electrode must not exceed 45°, with the length of the
electrode rod being limited to 1000 mm. Fig. 16, 20
n If used in combination with level switch NRS 1-50 with a response sensitivity of
0.5 µS/cm please us a measuring surface extension.
n For outdoor installations please use level electrode NRG 1...-50 F.
Level electrodes with this suffix (F) feature a terminal box made from aluminium.
Attention
n The seating surfaces of the standpipe or the flange provided on the vessel must be
accurately machined, see Fig. 12.
n If the level electrode NRG 111-50 is to be installed in a flanged standpipe DN 50 use
only the GESTRA hat flange. Fig. 11
n Do not bend electrode tip when mounting.
n Use only the joint rings supplied with the electrode.
NRG 16-50, NRG 17-50, NRG 19-50: 27 x 32, form D, DIN 7603, 2.4068
NRG 111-50: 33 x 39, form D, DIN 7603, 2.4068
n Do not lag electrode body above the hexagonal section.
n Do not insulate electrode thread with hemp or PTFE tape!
n Do not apply conductive paste or grease to the electrode thread!
n Make sure that the air distance between the electrode rod and earth (flange, vessel
wall) is not less than 14 mm. Fig. 11, Fig. 15-21
n Observe the minimum distances for the installation of the electrode!
Tools
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08 11
Installation - continued -
1
a
2 9 0
3 8
4
Fig. 9
30
5 6
110
Fig. 8
7 14
Fig. 11 ∅ 58
NRG 111-50
∅ 33/40
RA 12.5
0.5
Fig. 12
12 NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08
Installation - continued -
Key
1 Measuring electrode 8 NRG 1...-50: Joint ring 27 x 32, form D, DIN 7603,
2.4068, bright annealed
2 Bore
NRG 111-50: Joint ring 33 x 39, form D, DIN 7603,
3 Spring 2.4068, bright annealed
4 Electrode tip 9 Seating surface
5 Set screw 0 Electrode thread
6 Disk (measuring surface extension) a Thermal insulation, provided on site, d = 20 mm
7 Retaining ring (outside of thermal insulation of steam boiler)
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08 13
Installation - continued -
NRG 16-50 F, NRG 17-50 F, NRG 19-50 F, NRG 111-50 F, with aluminium terminal box
Fig. 13 d c b
H
1
2
3
4
5
6
6 5 4 3 2 1
e
6 5 4 3 2 1
K
Fig. 14
14 NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08
Installation - continued -
If one level electrode NRG 1...-50 F is installed together with one level electrode, one level switch or
transmitter (with aluminium terminal box) in a single protection tube or level pot, please observe the
following:
1. Mount the first equipment as specified in the pertinent installation manual.
When installing level electrode NRG 1...-50 F, please observe the following instructions:
1. Loosen screws b and remove housing cover d. Fig. 13. The arrow on the name plate points towards
this cover.
2. Remove cable lugs from terminal lugs. Fig. 14
3. Loosen nut e with 19 mm open-end spanner but do not remove! Fig. 14
4. Screw in level electrode as described in step 2, items 7 – 10.
5. Turn electrode terminal box into desired direction (+/-180°).
The terminal box can be turned through +/-180°.
6. Tighten nut e with a torque of 25 Nm.
7. Plug cable lugs onto terminal lugs.
5. Mount housing cover d and tighten screws b.
Key
b Housing screws M 4
c Cable gland M 20 x 1.5
d Housing cover
e Nut
f Terminal strip
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08 15
Examples of installation
G¾
g 45°
DN 50 h
≥14
∅ 20
20
i
j
≥1
4
≥1
4
k
l
0
00
.1
ax
n
m
o
20
≥10
≤ 90° p
≥ DN 80
∅ 20
Fig. 15 Protection tube (provided on site) if electrode is Fig. 16 Inclined installation, e. g. in ascending inlet lines
used as internal water-level limiter of hot-water installations or vessels
G¾
g
G¾ G¾
190
≥ 20
≥ DN 20
g
h j
Centre distance
DN 100 k
24.5 24.5
m
≤ 3000
p
20
∅ 20
i n
≥ 10
j o
≥ DN 20
o
≥10
≤ 90° p
∅ 20
Fig. 17 Protection tube (provided on site) if electrode is ≥ DN 20
used as internal water level-limiter combined
with water level control or low water level alarm Fig. 18 Level pot ≥ DN 80 if electrode is used as
external water level limiter
16 NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08
Examples of Installation - continued -
NRG 111-50
G1 G1
g
190
g
≤ DN/2
45°
h ≥ DN
DN 50
j
∅ 20
20
Centre distance
i ≥14
j
g
p
k
≥1
4
l ≥1
≥ DN/2
4 o
n o
≥10
0
00 ≥ DN
.1
≤ 90° p
ax
m
∅ 20
20
≥ DN 20
Fig. 19 Protection tube (provided Fig. 20 Inclined installation, e. g. Fig. 21 Level pot ≥ DN 80 if
on site) if electrode is used in steam boilers electrode is used as
as internal water-level external water level
limiter limiter
Key
j High water HW
k Electrode tip d = 8 mm
l Protection tube DN 80 (in France according to AFAQ ≥ DN 100)
m Protection tube DN 100
n Electrode distance ≥ 14 mm (air gap and creepage distance)
o Low water LW
p Reducer DIN 2616-2, K-88.9 x 3.2-42.4 x 2.6 W / DIN 2616-2, K-114.3 x 3.6-48.3 x 2.9 W
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08 17
Electrical connection
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50, four-pole connector
w
s
t
u
Fig. 22
Key
18 NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08
Electrical connection - continued -
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50, with four-pole connector
NRG 16-50 F, NRG 17-50 F, NRG 19-50 F, NRG 111-50 F, with aluminium terminal box
1. Loosen screws b and remove housing cover d. Fig. 13, 14
2. Loosen cable gland c. Pull cable through cable entry.
3. Remove terminal strip f from board.
4. Connect terminal strip according to the wiring diagram.
5. Attach terminal strip.
6. Tighten the cable gland in order to seal the cable entry. Use the supplied sealing plug to seal off
the unused cable entry and tighten the cable gland.
7. Mount housing cover d and tighten screws b.
Tools
n Screwdriver, size 1
n Screwdriver, size 2.5, completely insulated according to DIN VDE 0680-1
n Open-end spanner A.F. 18 (19) mm
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08 19
Electrical Connection - continued -
Wiring diagram
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
z z
* + -
* + -
CEP CEP
NRG 1..-11 NRG 1..-11
3 2 1 NRG 1..-50 3 2 1 NRG 1..-50
y y
Fig. 23
LW / HW
1
2 NRG 1...-50
3
4
5
6
6 5 4 1 3 2
* NRS 1-50 with response sensitivity 0.5 μS/cm: Connect the two internal screens to terminals 5
and 13 and the CEP.
Key
20 NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08
Commissioning, fault indication and troubleshooting
For additional information on commissioning procedures and troubleshooting refer to the installation
manual of the level switch NRS 1-50.
Danger
If faults occur that are not listed above or cannot be corrected, please contact our service centre or
authorized agency in your country.
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08 21
Declaration of Conformity
Directives and Standards
For more information on the conformity of the equipment as well as applied Directives and Standards
please refer to our Declaration of Conformity and associated certificates and/or approvals.
The Declaration of Conformity can be found online at www.gestra.com and associated certificates can
be requested from:
GESTRA AG
Münchener Straße 77
28215 Bremen
Germany
Telefon +49 421 3503-0
Telefax +49 421 3503-393
E-mail [email protected]
Web www.gestra.com
Note that Declarations of Conformity and associated certificates lose their validity if equipment is
modified without prior consultation with us.
22 NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08
For your Notes
NRG 16-50, NRG 17-50, NRG 19-50, NRG 111-50 - Installation Instructions - 818954-08 23
Agencies all over the world: www.gestra.com
GESTRA AG
Münchener Straße 77
28215 Bremen UK Importer:
Germany GESTRA UK Ltd
Telefon +49 421 3503-0 Unit 1 Sopwith Park, Royce Close,
Telefax +49 421 3503-393 West Portway Business Park, Andover,
E-mail [email protected] Hampshire SP10 3TS
Web www.gestra.com United Kingdom