GESTRA Steam Systems TRG 5-6x Installation Instructions 818597-00 Temperature Sensors TRG 5-63, TRG 5-64 Temperature Sensors TRG 5-65, TRG 5-66 Temperature Sensors TRG 5-67, TRG 5-68
Contents Important Notes Page Usage for the intended purpose...4 Safety note...4 Classification pursuant to article 1 of the Pressure Equipment Directive (PED)...4 ATEX (Atmosphère Explosible)...4 Explanatory Notes Scope of supply...5 System description...5 Function...5 Technical Data TRG 5-63, TRG 5-64, TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68...6 Tolerances of the precision resistor according to EN 60751...7 Corrosion resistance...8 Sizing...8 Name plate / Marking...8 Dimensions TRG 5-63 and TRG 5-64...9 Dimensions TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68...10 Functional Elements TRG 5-63, TRG 5-64, TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68...11 Key...11 Installation TRG 5-63 and TRG 5-64...12 TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68...12 Tools...12 Examples of Installation...13 Key...13 Wiring TRG 5-63, TRG 5-64, TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68...14 Connecting the measuring element...14 Key...14 Wiring diagram...15 2
Contents Commissioning Page Check wiring... 16 Apply mains voltage... 16 Measure fluid temperature... 16 Tools... 16 Operation TRG 5-63, TRG 5-64, TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68... 17 Malfunctions Fault finding list for troubleshooting... 17 Maintenance Spare parts... 18 Replace measuring element... 18 Annex Decommissioning... 19 Disposal... 19 Declaration of Conformity... 19 3
Important Notes Usage for the intended purpose Use temperature sensors TRG 5-63, TRG 5-64, TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68 only in conjunction with temperature transmitter TRV 5-40 for measuring temperatures. The equipment must only be used within the admissible pressure and temperature ratings. Any type of use differing from the usage described above must be considered as improper. The resulting risk will have to be borne by the user alone. The manufacturer hereby expressly rejects any claims for any damage resulting from improper usage. Safety note The equipment must only be installed 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 The temperature sensors TRG 5-63 or TRG 5-64 are screwed into vessels or pipes. When loosening the temperature sensor steam or hot water might escape! This presents the risk of severe scalding all over the body! Dismantle the temperature sensor only if the vessel pressure is verified to be 0 bar. The temperature sensor becomes hot during operation. Touching the hot equipment presents the risk of severe burns to hands and arms. All installation, removal and maintenance work must only be performed when the system is cold. Classification pursuant to article 1 of the Pressure Equipment Directive (PED) Category Designation IV Safety accessory CE marking CE 0525 ATEX (Atmosphère Explosible) According to the European Directive 94/9/EC the equipment must not be used in explosion risk areas. 4
Explanatory Notes Scope of supply TRG 5-63, TRG 5-64, TRG 5-65, TRG 5-66, TRG 5-67, TRG 5-68 1 Temperature sensor 1 Installation manual System description The TRG 5-6x are temperature sensors with integrated platinum resistance thermometers Pt 100 to EN 60751. The temperatures sensed by the temperature sensor are converted by the temperature transmitter TRV 5-40 and provided as a data telegram on the CAN bus. The CANopen protocol is used for the data transfer via CAN bus. The temperature sensor can be used as a measuring sensor for a safety temperature control monitor/limiter in conjunction with temperature transmitter TRV 5-40 and the switching controller NRS 1-40.1 and as sensor for a temperature limiter/controller in conjunction with temperature transmitter TRV 5-40 and the control unit TRS 5-40. The equipment combinations can be used as controls, monitors or limiters in steam boilers and (pressurised) hot water installations to TRD and EN 12952 and EN 12953. Function The temperature sensors TRG 5-63, TRG 5-65, TRG 5-66 and TRG 5-67 feature one integrated platinum resistance thermometer Pt 100 each. The temperature sensors TRG 5-64 and TRG 5-68 are equipped with two platinum resistance thermometers Pt 100 for the connection of additional indicating equipment. The resistance value of these thermometers changes as a defined function of the temperature. The resistance thermometer is supplied with a constant current by the temperature transmitter and the voltage generated by the changing of the resistance value is measured and processed in the transmitter. 5
Technical Data TRG 5-63, TRG 5-64, TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68 Measuring element (3-wire connection) TRG 5-63 1x Pt 100 to EN 60751, class A* TRG 5-64 2 x Pt 100 to EN 60751, class A* TRG 5-65, TRG 5-66 1 x Pt 100 to EN 60751, up to 300 C class A*, > 300 C class B* TRG 5-67 1 x Pt 100 to EN 60751, class B* TRG 5-68 2 x Pt 100 to EN 60751, class B* Service pressure, service temperature TRG 5-63, TRG 5-64 Nominal length 100, 160, 250 mm 36 bar at 251 C Nominal length 400 mm 18 bar at 400 C TRG 5-65, TRG 5-66 160 bar at 345 C 120 bar at 540 C TRG 5-67, TRG 5-68 150 bar at 650 C Admissible flow velocity TRG 5-63, TRG 5-64 Air 25 m/s Superheated steam 25 m/s Water 3 m/s TRG 5-65, TRG 5-66, TRG 5-67, TRG 5-68 Air 60 m/s Superheated steam 60 m/s Water 5 m/s Connection TRG 5-63, TRG 5-64 Screwed 1/2" BSP, ISO 228-1 TRG 5-65, TRG 5-66, TRG 5-67, TRG 5-68 Welding sleeve, for sizes refer to section "Dimensions" Length of protection tube see section "Dimensions" 6
Technical Data continued TRG 5-63, TRG 5-64, TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68 continued Materials TRG 5-63, TRG 5-64 Protection tube 1.4571, X6 CrNiMoTi 17 122 TRG 5-65, TRG 5-66 Welding sleeve 1.7335 TRG 5-67, TRG 5-68 Welding sleeve 1.4961 Ambient temperature at terminal box Max. 70 C Protection IP 66 to DIN EN 60529 Cable entry / Wiring EMC cable gland with integrated cable gland M 20x1.5 Weight TRG 5-63, TRG 5-64 Approx. 0.5 kg TRG 5-65, TRG 5-66 Approx. 0.6 kg TRG 5-67, TRG 5-68 Approx. 1 kg Tolerances of the precision resistor according to EN 60751 * Class A and B, admissible tolerances of the precision resistor Admissible deviation in ±2 ±1.5 ±1 ±0.5 Class B C Class A C Class A Class B -200-100 0 100 200 300 400 500 600 700 800 Temperature in C ±4 ±3 ±2 ±1 Admissible deviation in C 7
Technical Data continued Corrosion resistance If the equipment is used for the intended purpose, its safety is not impaired by corrosion. Sizing The housing must not be subjected to sharp increases in pressure. The dimensional allowances for corrosion reflect the latest state of technology. Name plate / Marking Thread Material Protection Designation of the equipment Nominal length Pressure/temperature range Manufacturer TRG 5-63 / 1 2 L= 100 36 bar / 251 C GESTRA AG Münchener Str. 77 D-28215 Bremen 391666 CE marking Spare part specification TRG 5-64 L= 100 / 1 2 36 bar / 251 C GESTRA AG Münchener Str. 77 D-28215 Bremen 391666 TRG 5-65 L= 115 160 bar / 345 C 120 bar / 540 C GESTRA AG Münchener Str. 77 D-28215 Bremen 391666 TRG 5-66 L= 140 160 bar / 345 C 120 bar / 540 C GESTRA AG Münchener Str. 77 D-28215 Bremen 391666 TRG 5-67 L= 200 150 bar / 650 C GESTRA AG Münchener Str. 77 D-28215 Bremen 391666 TRG 5-68 L= 200 150 bar / 650 C Fig. 1 GESTRA AG Münchener Str. 77 D-28215 Bremen 391666 8
Technical Data continued Dimensions TRG 5-63 and TRG 5-64 120 84 9 A. F. 27 A 15 9 26 B ½" BSP to DIN 228-1 L C [mm] 30 30 30 30 L [mm] 100 160 250 400 C 26 N10 ½" BSP to DIN 228-1 0.5 N8 Fig.2 Fig. 3 9
Technical Data continued Dimensions TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68 140 84 11 17/24 A. F. D L E F C G L C D E F G Fig.4 TRG 5-65 TRG 5-66 TRG 5-67 TRG 5-68 [mm] 115 140 200 200 [mm] 30 30 30 30 [mm] 25 25 25 25 [mm] 18 18 24 24 [mm] 40 65 65 65 [mm] 9 9 12.5 12.5 10
Functional Elements TRG 5-63, TRG 5-64, TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68 H MAX 70 C I K MAX 95% IP 66 J Fig.5 Key A B C D E F G H I J K L Sealing surface Joint ring 13x26 Temperature sensitive length Thread area Diameter of the welding sleeve Cone-shaped part Tip of the cone Cover of terminal box Measuring element Terminal box EMC cable gland M 20x1.5 Protection tube / welding sleeve 11
Installation TRG 5-63 and TRG 5-64 1. Clean sealing surfaces A. 2. Put joint ring B onto the sealing surface A (make sure that the material of the joint ring is suitable for the application in question). 3. Screw in the temperature sensor and fasten it with an open-end spanner 27 mm A. F. The torque required when cold is 150 Nm. TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68 1. Provide a penetration for the socket-weld end on site. 2. Unscrew the upper part of the temperature sensor from the welding sleeve L. 3. Weld the welding sleeve L in place. Arc-weld the equipment only manually in place, applying welding process 111 and 141 in accordance with ISO 4063. 4. Put copper ring onto the welding sleeve L and screw the upper part of the temperature sensor into the welding sleeve L. Fasten the upper part of the temperature sensor when cold with an open-end spanner (17 or 24 mm A. F.). Attention Only qualified welders certified according to EN 287-1 may weld welding sleeves into pressurized lines or vessels. Note Tools When installing the electrode in pipes weld the elbow M onto the pipe, ensuring that the temperature sensitive part C of the temperature sensor is exposed to the fluid against the flow direction. Fig.8 and Fig.9 is per- Install the temperature sensor in such a way that the temperature sensitive part manently submerged in the fluid. Fig.2 and Fig.4 Do not completely insulate the temperature sensors. See Examples of Installation Fig.6 and Fig.7 Open-end spanner 17 mm A. F. Open-end spanner 24 mm A. F. Open-end spanner 27 mm A. F. C 12
Installation continued Examples of Installation N 100 100 Fig.6 L Fig.7 L M M Fig.8 Fig.9 Key L M N Protection tube / welding sleeve Elbow Thermal insulation 13
Wiring TRG 5-63, TRG 5-64, TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68 Use screened four-core cable for wiring, e. g. Ölflex 110 CH, produced by Lapp, 4x0.5 mm². Max. cable length between temperature sensor and temperature transmitter TRV 5-40: 25 m. Connecting the measuring element 1. Take cover H off the terminal box J. 2. Unscrew dome nut O of the cable gland K and take out the lamellar insert Q Fig.10. 3. Cut off outer cable sheath T and expose braided screen R over a length of approx. 10-15 mm. 4. Push dome nut O and lamellar insert Q with sealing ring P onto the cable T. 5. Bend braided screen R outwards at a right angle (90 ). 6. Fold braided screen R towards outer sheath, i. e. by another 180. 7. Push lamellar insert Q with sealing ring P into gland body S and turn it briefly around both sides of the cable axis and snap anti-rotation element into place. 8. Firmly screw on dome nut O. 9. Connect the connecting cable in accordance with the wiring diagram to the measuring element I. 10.Replace cover H and tighten screw securely. O P T Q R S Fig. 10 Key O P Q R S T 14 Dome nut Sealing ring Lamellar insert Braided screen Gland body Screened cable
Wiring continued Wiring diagram red Fig. 11 3 1 2 black yellow red Fig. 12 3 2 1 Note Additional indicating devices can be connected to the terminals marked in yellow and black of the TRG 5-64, and TRG 5-68. Fig.12 15
Commissioning Check wiring Check that the temperature sensor TRG 5-6x and its associated temperature transmitter TRV 5-40 have been wired in accordance with the wiring diagram (see page 15). Apply mains voltage 1. Apply mains voltage or bus supply voltage to the control unit NRS 1-40.1. Measure fluid temperature Use the following table to ascertain the current temperature of the fluid, using the resistance value of the Pt 100. 1. Take cover H off the terminal box. 2. Connect test cable directly to the measuring element I. 3. Use an ohmmeter for measuring the resistance value. 4. Look up the corresponding resistance value in the table, interpolate if necessary and read off the temperature. 5. Replace cover H and tighten screw securely. C 0 10 20 30 40 50 60 70 80 90 100 /deg 0 100.00 103.90 107.79 111.67 115.54 119.40 123.24 127.07 130.89 134.70 138.50 0.385 100 138.50 142.28 146.06 149.82 153.57 157.32 161.04 164.76 168.47 172.16 175.84 0.373 200 175.84 179.51 183.17 186.82 190.46 194.08 197.70 201.30 204.88 208.46 212.03 0.361 300 212.03 215.58 219.13 222.66 226.18 229.69 233.19 236.67 240.15 243.61 247.06 0.350 400 247.06 250.50 253.93 257.34 260.75 264.14 267.52 270.89 274.25 277.60 280.93 0.338 500 280.93 284.26 287.57 290.87 294.16 297.43 300.70 303.95 307.20 310.43 313.65 0.327 600 313.65 316.86 320.05 323.24 326.41 329.57 332.72 335.86 338.99 342.10 345.21 0.315 700 345.21 348.30 351.38 354.45 357.51 360.55 363.59 366.61 369.62 372.62 375.61 0.304 800 375.61 378.59 381.55 384.50 387.45 390.38 0.295 Basic values of the precision resistors according to DIN 43760 for Pt 100. Tools Screwdriver for slotted screws, size 2.5, completely insulated according to DIN VDE 0680-1 Screwdriver for slotted screws, size 8 16
Operation TRG 5-63, TRG 5-64, TRG 5-65, TRG 5-66, TRG 5-67 and TRG 5-68 Operation in conjunction with temperature transmitter TRV 5-40 in (pressurised) hot water installations and steam plants according to TRD and EN 12952 as well as EN 12953. Note To analyse and eliminate malfunctions see section "System Malfunctions" in the installation manual of the TRV 5-40. Malfunctions Fault finding list for troubleshooting Switchpoint "MAX temperature" not yet exceeded - but a MAX temperature alarm is raised Fault: The temperature sensor is defective. Remedy: Check whether the temperature sensor (Pt 100) gives correct readings. (Basic values of the precision resistors according to DIN 43760 for Pt 100). In case of incorrect readings replace the measuring element of the temperature sensor. If faults occur that are not listed above or cannot be corrected, please contact our service centre or authorized agency in your country. 17
Maintenance Spare parts Resistance thermometer type Designation Item Stock code TRG 5-63 Dimension L = 160 mm see Fig.1 Measuring element 1xPt 100 I 052260 TRG 5-64 Dimension L = 160 mm see Fig.1 Measuring element 2xPt 100 I 052264 TRG 5-65 Measuring element 1xPt 100 I 052386 TRG 5-66 Measuring element 1xPt 100 I 052388 TRG 5-67 Measuring element 1xPt 100 I 1500623 TRG 5-68 Measuring element 2xPt 100 I 1500624 Replace measuring element The measuring element I can be replaced during operation if necessary. 1. Switch off bus supply voltage. 2. Take cover H off the terminal box. 3. Disconnect the measuring element I. 4. Slacken fixing screws for measuring element. Pull out measuring element. 5. Insert new measuring element and fasten fixing screws. 6. Re-attach measuring element I. 7. Replace cover H and tighten screw securely. 8. Apply bus supply voltage. 18
Annex Decommissioning Disposal Danger Risk of severe burns and scalds to the whole body! Before removing the temperature sensor make sure that the vessel or the pipe are depressurised (0 bar) and cooled down to room temperature (20 C). Dismantle the temperature sensor and separate the waste materials, using the material specification as a reference. Electronic component parts such as the circuit board must be disposed of separately! For the disposal of the temperature sensor observe the pertinent legal regulations concerning waste disposal. Declaration of Conformity We hereby declare that the temperature sensor TRG 5-6x conforms to the following European guidelines: LV guideline 73/23/eec version 93/68/eec EMC guideline 89/336/eec version 93/68/eec Pressure Equipment Directive (PED) 97/23/EC of 29 May 997 Applied conformity assessment procedure: Annex III, Module B and D, verified by the Notified Body 0525. This declaration is no longer valid if modifications are made to the equipment without consultation with us. Bremen, 27th June 2005 GESTRA AG Head of Design Dept. Dipl.-Ing. Uwe Bledschun Academically qualified engineer Quality Assurance Representative Dipl.-Ing. Lars Bohl Academically qualified engineer 19
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