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Lamtec BT300 BurnerTronic User Manual

Lamtec BT300 BurnerTronic
254 pages
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www.lamtec.de
Sensors and Systems for Combustion Engineering
Manual
BT300 BurnerTronic
S
oftware versions BT300 v3.9 and
UI300 V3.12 (HW V 1)/4.4 (HW V 2)

Table of Contents

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Lamtec BT300 BurnerTronic Specifications

General IconGeneral
CategoryControl Systems
Flame SafeguardYes
Fuel TypesGas, Oil
DisplayLCD
ApprovalsCE, UL
Control TypeMicroprocessor-based
ModelBT300
ManufacturerLamtec
ApplicationIndustrial Burners
Operating Temperature-20°C to +60°C
CommunicationModbus, CAN

Summary

1 Important Information about the Manual

1.1 Validity of these Instructions

Specifies the validity of the manual for BT300 BurnerTronic in any configuration.

1.2 Standards, Directives and Approvals

Lists the European Directives, Harmonised European Standards, USA/Canada and Australian standards applied.

2 General Safety Instructions

2.1 Classification of the Safety Instructions and Warnings

Explains the symbols used in the document to draw attention to important safety information.

2.2 Product-specific Dangers

Details specific dangers related to the BT300 safety device and its operation.

2.2.1 Commissioning Notes

Provides essential notes and documentation requirements for commissioning the BT300.

2.3 Security Advice - Mounting

Offers security advice and installation guidelines for mounting the BT300 unit.

2.4 Installation Notes

Provides important notes regarding the installation procedures and wiring of the BT300.

2.5 Electrical Connection Flame Sensor

Details precautions and guidelines for the electrical connection of the flame sensor.

3 Product Description

3.1 Functional Description

Describes the BT300's integration of fuel/air ratio control, safety interlocks, and optional modules.

3.2 Life Cycle

Outlines the designed lifetime of the BT300 device in terms of start-up cycles and usage years.

3.3 Technical Data BurnerTronic BT300

Provides detailed technical specifications for the BT300 BurnerTronic unit.

4 Design and Functions

4.1 System Overview

Presents a system overview diagram of the BurnerTronic BT300 and its connected modules.

4.2 Connecting Diagrams

Illustrates terminal assignments and connection examples for BT300 and BT335 models.

4.3 Flame Monitoring

Details the integral flame monitoring system and describes various types of flame sensors.

4.4 Process Sequence Charts

Explains the key to process sequence charts and lists various process steps with their durations.

4.5 Leakage Test for Main Gas Valves

Covers calculation examples, process flow, and reaction on gas deficiency for valve leakage tests.

4.6 Staged Operation

Describes the BT300's ability to shift burner firing rate in stages for oil operation.

4.7 Flue Gas Recirculation

Explains how to recirculate exhaust gases using combustion air fan or a recirculation fan.

4.8 Continuous Purge

Details the requirement for continuous ventilation and the function of continuous purge.

4.9 Actuator

Covers actuator operation, direction of rotation, mixed-up connections, and adjustment procedures.

5 Assembly

5 Assembly

Provides instructions and notices for mounting the BT300 basic unit, including support points.

6 Operating Control and Displays

6.1 User Interface UI3xx

Describes the operating and display elements of the UI3xx user interface, including display, keys, and navigation.

6.1.2 Menu Functions

Explains the five main menu paths: INFO, MANUAL, SETTINGS, and DATA PROCESSING.

6.1.3 Main Menu

Illustrates the main menu structure with symbols for information, manual operations, and settings.

6.1.4 Information Menu Path

Shows the path to access information like burner details, error history, and software version.

6.1.4.1 Burner Details

Explains how to display operating hours and burner starts for oil and gas operations.

6.1.4.2 Recalling Fault History

Details how to display burner faults and O2 faults, including fault codes and diagnostic codes.

6.1.4.3 Software Version

Describes how to display the software versions for UI300 and BT300.

6.1.4.4 Display of Check Sums

Explains how to display check sums, which indicate if parameters have been changed.

6.1.4.5 Serial Number

Shows how to display the serial numbers for UI300 and BT300.

6.1.4.6 Positions of Actuators

Illustrates how to check the actual position of channels (oil, air) and optional channels.

6.1.4.7 Check Digital Inputs/Outputs

Details how to check the status of digital inputs and outputs for fuel selection, burner status, etc.

6.1.4.8 Flue Gas Recirculation

Shows how to indicate the recirculation delay and flue gas temperature for activation.

6.1.5 Manual Menu Path

Explains how to use the MANUAL path for switching the burner ON/OFF and presetting the firing rate.

6.1.6 Fault Indication

Guides on displaying burner faults and O2 faults, including fault codes and diagnostic codes.

6.1.7 Settings Menu Path

Outlines the settings menu path for configuring password, curves, controller, and display options.

6.1.7.1 Password

Describes how to enter and manage passwords for access levels to protect settings.

6.1.7.2 Program Sequence

Explains how to set durations for pre-purge and post-purge periods, and valve leakage tests.

6.1.7.4 Setting Curves

Details how to make curve changes to BT300, including saving and deleting curve sets.

6.1.7.5 Deleting Curves

Provides instructions on how to delete firing-rate curves from the BT300.

6.1.7.6 Adjusting Controller

Explains how to adjust PID controller, CO/O2 controller, and O2 trim settings.

6.1.7.7 User Interface Settings

Guides on how to set the UI300's display for brightness, contrast, and screen saver.

6.1.7.8 Edit Parameter

Explains how to edit parameters up to Release Level 2, including confirming or discarding modifications.

6.1.7.9 Flue Gas Recirculation

Details how to set the recirculation delay and flue gas temperature for activating flue gas recirculation.

6.1.7.10 Programming a Staged Operation

Guides on setting staged operation by adjusting switching thresholds for valves ON/OFF.

6.1.8 Menu Path Dataset Processing

Explains how to save/restore BT300 datasets and the process for transferring data.

6.2 Other Displays

Describes various displays like 'No connection', 'Termination', 'CO/O2 Hint', and 'CO Hint'.

6.3 LSB Remote Software

Introduces the LSB Remote Software for configuring and maintaining BT300, including installation prerequisites.

6.3.1 Functional Description, Connecting USB-CAN Module

Covers the functional description of LSB Remote Software and the connection of the USB-CAN module.

6.3.1.1 Installation Prerequisites

Lists the system requirements and installation bundle needed for the LSB Remote Software.

6.3.1.2 Installing the Software

Explains the process of installing the LSB Remote Software and its components.

6.3.1.3 Installing the Software

Describes the symbols used in the software installation process.

6.3.1.4 First Connection with the Target Device

Guides on establishing the first connection with the target device using LSB Remote Software.

6.3.1.5 Release Codes/Release Levels

Explains the software's DEMO mode and the process of entering activation keys for full functionality.

6.3.2 Offline/Online

Distinguishes between the two operating modes of the software: Offline and Online.

6.3.2.1 Offline Mode

Describes the OFFLINE mode for displaying stored data without a permanent connection to BT300.

6.3.2.2 Online Mode

Explains the ONLINE mode where the end device is synchronised and monitored.

6.3.2.3 Connecting the BT 300 with the PC

Provides steps for connecting the BT300 to a PC using LSA100 or LCM100 and USB/CAN converter.

6.3.3 Read Out Faults

Guides on how to read out fault history from the burner control system via LSB Remote Software.

6.3.7.2 Access Rights

Explains how to enter passwords, change passwords, and manage customer IDs within the software.

6.3.7.3 BurnerTronic

Covers reading/editing parameters, editing curves, obtaining fault history, and checking I/O status.

6.3.7.4 Options

Details options for flashing memory, connecting/disconnecting LSB modules, and changing software language.

6.3.7.5 Help

Explains how to call up help for LSB Remote Software and get information about software versions.

7 Maintenance

7.1 Data backup

Describes how to create protected data sets for storage (back up) of the current device status.

7.2 Firmware Update BT300

Provides steps for updating BT300 firmware using LSB Remote Software and the Flash Tool.

7.3 User Interface Firmware Update

Guides on preparing and processing the UI300 firmware update using LSB Remote Software.

7.4 Replacing of BurnerTronic

Details hazards during electrical shock and provides steps for transferring data to a new burner control unit.

8 Options

8.1 Firing-Rate Controller Module LCM100

Describes the LCM100 module for adding firing rate control functions to the BurnerTronic.

8.1.1 Range Limits

Explains how to set limit values for switching the burner on and off and informs about denied start-ups.

8.1.2 Enter Setpoint of Firing Rate Controller

Guides on using arrow keys to select and set switching points for the firing rate controller.

8.1.3 Operating Description

Describes the burner start-up process and when the firing rate controller becomes active.

8.1.4 Control by atmospheric conditions and external setpoint presetting

Explains how to configure firing rate control based on atmospheric conditions and external setpoints.

8.1.5 Setpoint Changeover

Details switching setpoints via input terminal 5 and implementing external setpoint defaults.

8.1.6 Start-up Sequence

Describes the start-up cycle of the firing rate controller to slow down burners' firing rate during starting.

8.1.7 Thermostat and Control Range

Explains how the thermostat function switches the burner on/off based on temperature/pressure.

8.1.8 Control Range

Defines the control range around the setpoint and the parameters for switch-on/shut-off.

8.1.9 Checking the Safety Limiter

Provides instructions for testing the safety limiter by changing the setpoint.

8.1.10 Control Mode

Defines the PID controller characteristics: Adjustment time, P term, I term, and D term.

8.1.11 Aides for Setting

Offers guidance on controller settings (P, I, D terms) and their effects on performance.

8.1.12 External/Manual Firing-rate Presetting (Terminals 16 - 19)

Explains how to interpret external firing rate inputs and select input types via P 0065.

8.1.13 DIP Switch

Details how to configure LCM100 settings using DIP switches for CAN termination and LSB family.

8.1.14 LEDs

Describes the function and relevance of the three LEDs on the LCM100 module (ERR, CAN, PWR).

8.1.15 Electrical Connection

Covers connecting the LCM100 to BT300 via plug X31 and LCM terminals, including cable type.

8.1.15.1 Galvanic Isolation

Explains galvanic isolation for LCM100, defining LV, FELV, and SELV voltage levels.

8.1.15.2 Terminal Assignment

Details terminal assignments for LCM100's 24V power supply, fuel meters, and pressure sensor connections.

8.1.16 Technical Data LCM100

Provides general data, 24 VDC output, input/output specifications, and environmental conditions for LCM100.

8.2 Dual Fuel Module DFM300

Introduces the DFM300 as an expansion module for dual-fuel burners, detailing its connection and configuration.

8.2.1 DIP Switch

Explains how to configure DFM300 settings using DIP switches for LSB family and sensor inputs.

8.2.2 LEDs

Describes the four LEDs on the DFM300 (Fault, LSB, Oil, Gas) and their operational relevance.

8.2.3 Electrical Connection

Details the electrical connections for the DFM300, including signal lines, types, shields, and cable lengths.

8.2.3.1 Galvanic Isolation

Explains galvanic isolation for the DFM300, highlighting dangers of improper wiring and SELV connections.

8.2.3.2 Terminal Assignment

Provides acknowledgement curve set assignments and details fuel selection requirements for terminal 13.

8.2.4 Technical Data DFM300

Lists general data, operating conditions, and environmental specifications for the DFM300 module.

8.2.5 Adapter System Rast5

Introduces the Rast5 module for connecting DFM to BT300 and its role in transposing connectors.

8.2.5.1 Electrical Connection

Details the electrical connection of the Rast5 module to BT300 and DFM, including terminal assignments.

8.2.5.2 Technical Data Rast5-Module

Provides technical data for the Rast5-Module, including housing, mounting, environmental conditions, and protection class.

8.3 Variable Speed Drive Module VSM100

Describes the VSM100 module for speed-controlled compressors, its connection, configuration, and parameters.

8.3.1 DIP Switch

Explains how to configure VSM100 settings using DIP switches for LSB family and sensor inputs.

8.3.2 LEDs

Describes the five LEDs on the VSM100 module (ERR, PWR, CAN, Namur, 3-wires) and their relevance.

8.3.3 Electrical Connection

Details electrical connections for speed control and feedback sensors, including caution for short circuits.

8.3.3.1 Galvanic Isolation

Explains galvanic isolation for VSM100, highlighting dangers of improper wiring and SELV connections.

8.3.3.2 Terminal Assignment

Details terminal assignments for Namur sensor, inductive proximity switch, and frequency converter circuits.

8.3.4 Technical Data VSM100

Provides technical data for VSM100, including power supply, dimensions, environmental conditions, and feedback inputs.

8.4 Expansion Module for LSB - LEM100

Introduces the LEM100 for adding LSB interface to BurnerTronic, detailing its connection and configuration.

8.4.1 DIP Switch

Explains how to configure LEM100 settings using DIP switches for CAN-Bus activation.

8.4.2 LEDs

Describes the two LEDs on the LEM100 module (PWR, CAN-Traffic) and their relevance.

8.4.3 Electrical Connection

Details electrical connections for the LEM100, including DC supply, CAN/LSB, and Ethernet bus.

8.4.3.1 Galvanic Isolation

Explains galvanic isolation for LEM100, highlighting dangers of improper wiring and SELV connections.

8.4.4 Technical Data

Provides technical data for LEM100, including power supply, dimensions, environmental conditions, and protection class.

8.5 Field Bus Modules

Introduces field bus modules, specifically the PROFIBUS PBM100 and MODBUS TCP EBM100.

8.5.1 Field Bus Module for PROFIBUS PBM100

Details the PBM100's role in integrating the burner control system into a PROFIBUS environment.

8.5.1.1 DIP Switch

Explains how to configure PBM100 settings using DIP switches for PROFIBUS DP address and LSB family.

8.5.1.2 LEDs

Describes the four LEDs on the PBM100 (PWR, CAN, PB, ERR) and their operational relevance.

8.5.1.3 Electrical Connection

Details electrical connections for PBM100, noting that terminals should not be used.

8.5.1.4 PROFIBUS DP Communication

Specifies messages transferred from PBM100 to LSB for PROFIBUS DP communication.

8.5.1.5 Technical Data PBM100

Provides technical data for PBM100, including power supply, dimensions, environmental conditions, and protection class.

8.5.2 Field Bus Module for MODBUS TCP EBM100

Details the EBM100's integration into MODBUS TCP fieldbus environment and its IP configuration.

8.5.2.1 IP Configuration

Explains EBM100 network default configuration and how to preset IP addresses via BT300 parameters.

8.5.2.2 DIP Switch

Details how to configure EBM100 settings using DIP switches for LSB family and CAN resistance.

8.5.2.3 LEDs

Describes the LEDs on the EBM100 and RJ45 socket (PWR, CAN, ETH, ERR, ACT, LINK) and their conditions.

8.5.2.4 Electrical Connection

Details electrical connections for EBM100, noting that terminals are not to be used.

8.5.2.5 Ethernet Communication

Specifies data sent on Modbus/TCP, including register, description, and configuration for input data.

8.5.2.6 Technical Data EBM100

Provides technical data for EBM100, including power supply, dimensions, environmental conditions, and protection class.

8.5.3 Appendix

Contains appendices with bit patterns for operating mode, digital inputs/outputs, curve sets, and O2/CO controller states.

8.5.4.1 Bit Encoding: Status

Defines bit patterns for various status indicators related to burner control and module life codes.

8.5.4.2 Bit Encoding: Operating Mode

Provides bit patterns for different operating modes of the BT300, such as Power ON, Burner OFF, and Pre-purge.

8.5.4.3 Bit Encoding: Digital Inputs

Lists bit patterns for digital inputs like safety interlock chains, pressure monitors, and fuel selection.

8.5.4.4 Bit Encoding: Curve Set

Defines bit patterns for available curve sets and their corresponding values.

8.5.4.5 Bit Encoding: Digital Outputs

Lists bit patterns for digital outputs such as fuel valves, fan status, and ignition transformer.

8.5.4.6 Coding: O2 Controller Operating Mode

Details the coding for O2 controller operating modes, including internal errors and inactive states.

8.5.4.7 Bit Encoding: State of Actual Value of O2

Specifies bit patterns for the state of actual O2 values, including underflow, overflow, and maintenance mode.

8.5.4.8 Bit Encoding: Cause of Faults of O2 Trim

Lists bit patterns for causes of O2 trim faults, such as low O2 during pre-purge or probe dynamics issues.

8.5.4.9 Bit Encoding: Operating Mode of CO Controller

Defines bit patterns for CO controller operating modes, including OFF, standby, and active states.

8.5.4.10 Bit Encoding: State of Actual Value of CO

Specifies bit patterns for the state of actual CO values, including underflow, overflow, and measurement warnings.

8.5.4.11 Bit Encoding: Cause of Fault of CO Controller

Lists bit patterns for causes of CO controller faults, such as probe voltage issues or watchdog processor deactivation.

8.5.4.12 Bit Encoding: State of Flue Gas Temperature and Efficiency

Specifies bit patterns for flue gas temperature and efficiency states, including underflow and overflow.

8.5.4.13 Bit Encoding: Status of Intake Air Temperature

Specifies bit patterns for the status of intake air temperature, including underflow and overflow.

8.5.4.14 Encoding FAT State

Lists values and descriptions for FAT states like Switched OFF, Pre-purge, and Ignition.

8.5.4.15 Units Fuel Meter

Provides units for fuel meters in metric (l/h, m3/h, kg/h) and imperial (gal/h, ft3/h, pound/h).

8.5.4.16 Bit Encoding: Operating Condition CO/O2

Details bit encoding for CO/O2 operating conditions, such as low O2 during pre-purge or CO controller faults.

8.5.4.17 State Information

Describes actual status of burner control systems transmitted via Bus, including hints for BT300.

8.5.4.18 Allocation of the Texts to the Text Numbers

Lists text numbers and their corresponding descriptions for error messages and status indications.

9 Disposal Notes

9 Disposal Notes

Advises that the device contains electrical components and must be disposed of according to local legislation.

10 EU Declaration of Conformity

10 EU Declaration of Conformity

Declares conformity of the BT300 Burner Control System with relevant EU directives and standards.

11 Appendix

11.1 Display Symbols

Explains various hint symbols used in the interface, such as fuel selection missing or valve leakage check.

11.2 Indication Symbols

Provides descriptions for navigation symbols, INFO path information, and SETTINGS path information.

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