Lamtec BT300 BurnerTronic User manual

www.lamtec.de
Sensors and Systems for Combustion Engineering
Manual
BT300 BurnerTronic

2
Table of Contents
Table of Contents
1 Important Information about the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Validity of these Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Standards, Directives and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Classification of the Safety Instructions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Product-specific Dangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.1 Commissioning Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.1.1 Fuel/Air Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.1.2 Basic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.2 Tasks fulfilled by "authority on the subject" during Approval Test . . . . . . . . . . . 11
2.2.2.1 Checking for Correct Parameter Setting in System . . . . . . . . . . . . . . . . . . . . . . 11
2.2.2.2 Checking the Fuel/Air Ratio Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.2.3 Checking Burner Sequencer Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Security Advice - Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Electrical Connection Flame Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Life Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.1 BT300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.2 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3.2.1 Actuators 662R550... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3.2.2 Actuators 662R5001... / 662R5003... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.3 Flame Sensor/Flame Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4 Mounting and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 Connecting Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.1 Optional Connections for the Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.2 Optional Connections for the Flame Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.3 LSB Module Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.3 Flame Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3.1 Integral Flame Monitoring (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3.2 Flame Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3.2.1 KLC 20/KLC 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3.2.2 KLC 10/KLC 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4 Process Sequence Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5 Leakage Test for Main Gas Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.5.1 Calculation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.5.2 Leakage Test Process Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.5.3 Reaction on Gas Deficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.5.4 Valve Leakage Test Venting Over the Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.6 Staged Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.7 Flue Gas Recirculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.8 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.8.1 Operation after Power ON/Long RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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Table of Contents
4.8.2 Direction of Rotation/Position Damper Closed . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.8.3 Detection of Actuators with Transposed Connections . . . . . . . . . . . . . . . . . . . . 56
4.8.4 Adjusting of Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5 Operating Control and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.1 User Interface UI300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.1.1 UI300 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.1.2 Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.1.3 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.1.4 Information Menu Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.1.4.1 Burner Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1.4.2 Recalling Fault History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.1.4.3 Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1.4.4 Display of Check Sums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1.4.5 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.1.4.6 Positions of Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.1.4.7 Check Digital Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1.5 Manual Menu Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.1.6 Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.1.7 Settings Menu Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.1.7.1 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.1.7.2 Program Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.1.7.3 Configuration of the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.1.7.4 Set Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.1.7.5 Deleting Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.1.7.6 Adjusting Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.1.7.7 UI300 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.1.7.8 Edit Parameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.1.8 Menu Path Dataset Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.2 Other Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.3 LSB Remote Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.3.1 Functional Description, Connecting USB-CAN Module . . . . . . . . . . . . . . . . . . . 82
5.3.1.1 Installation Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.3.1.2 Install Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.3.1.3 Install Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.3.1.4 First Connection with the End Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.3.1.5 Release Codes/Release Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.3.2 Offline/Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.3.2.1 Offline Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.3.2.2 Online Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.3.2.3 Connecting the BT 300 with the PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.3.3 Read Out Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.3.4 BT300 Curve Dialogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.3.4.1 Setpoint Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.3.4.2 Curve Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.3.4.3 Set Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.3.5 Programming of Fuel/Air Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.3.6 Programming a Staged Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.3.7 Software Interface LSB Remote Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.3.7.1 File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

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Table of Contents
5.3.7.2 Access Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.3.7.3 BurnerTronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.3.7.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.3.7.5 Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.1 BT300 Data Back-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.2 Firmware Update BT300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.3 Firmware Update UI300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.4 Replacing of BurnerTronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.1 Firing-Rate Controller Module LCM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.1.1 Range Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.1.2 Enter Setpoint of Firing Rate Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.1.3 Operating Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.1.4 Control by atmospheric conditions and external setpoint presetting . . . . . . . . 148
7.1.5 Setpoint Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.1.6 Start-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.1.7 Thermostat and Control Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.1.8 Control Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.1.9 Checking the Safety Limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.1.10 Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.1.11 Aides for Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.1.12 External/Manual Firing-rate Presetting (Terminals 16 - 19) . . . . . . . . . . . . . . . 154
7.1.13 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.1.14 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.1.15 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.1.15.1 Galvanic Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.1.15.2 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.1.16 Technical data LCM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.2 Dual Fuel Module DFM300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.2.1 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
7.2.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7.2.3 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
7.2.3.1 Galvanic Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
7.2.3.2 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
7.2.4 Technical Data DFM300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
7.2.5 Adapter System Rast5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.2.5.1 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.2.5.2 Technical Data Rast5-Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
7.3 Variable Speed Drive Module VSM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7.3.1 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7.3.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
7.3.3 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7.3.3.1 Galvanic Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7.3.3.2 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7.3.4 Technical Data VSM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7.4 Expansion Module for LSB - LEM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
7.4.1 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

5
Table of Contents
7.4.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
7.4.3 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
7.4.3.1 Galvanic Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
7.4.4 Technical Data LEM300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
7.5 Field Bus Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.5.1 Field Bus Module for PROFIBUS PBM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.5.1.1 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.5.1.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7.5.1.3 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7.5.1.4 PROFIBUS Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
7.5.1.5 Technical Data PBM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7.5.2 Field Bus Module for MODBUS TCP EBM100 . . . . . . . . . . . . . . . . . . . . . . . . 194
7.5.2.1 IP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
7.5.2.2 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
7.5.2.3 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.5.2.4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
7.5.2.5 Ethernet Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
7.5.2.6 Technical Data EBM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
7.5.3 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
8 Disposal Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
10.1 Display Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
10.2 Indication Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

6
1 Important Information about the Manual
1 Important Information about the Manual
1.1 Validity of these Instructions
This manual is valid for the burner control system BurnerTronic BT300 in any configuration.
The information contained in this document refer to the software versions BT300 v3.5 and
UI300 v3.8. If you use any other software version as mentioned previously some of the de-
scribed functions may not be available or not all available functions work as described in this
document.
1.2 Standards, Directives and Approvals
BT300 applies to the following standards and directives:
European Directives:
Harmonised European Standards:
USA and Canada:
Australia:
South Africa:
Russia/Belarus/Kazakhstan:
EAC
2004/108/EU EMC Directive
2014/35/EU Low Voltage Directive
2009/142/EU Gas Appliance Directive
2014/68/EU Pressure Equipment Directive, Conformity Assessment cat. IV mod. B and D
2011/65/EU RoHS
EN 298
EN 13611
EN 1643 Integrated valve leakage check, gas line DIN DVGW PÜZ N6-2510 ASO 324
EN 12067-2
ISO 23552-1
EN 50156-1, no. 10,5
SIL 3 DIN EN 61508 part 1-7 (BT331, BT341)
MH48669 Controls, Primary Safety Certified for Canada - Component
UL 372
UL 1998
AGA AS 4625 - 2008
EN 298 - 2012
SAGA Act 85 of 1993
PER R 734 -2009

7
2 General Safety Instructions
2 General Safety Instructions
2.1 Classification of the Safety Instructions and Warnings
The following symbols are used in this document to draw the user's attention to important safe-
ty information. They are located at points where the information is required. It is essential that
the safety information is observed and followed, and that applies particularly to the warnings.
DANGER!
This draws the user's attention to imminent danger. If it is not avoided, it will result in death or
very serious injury. The plant including its surroundings could be damaged.
WARNING!
This draws the user's attention to the possibility of imminent danger. If it is not avoided, it may
result in death or very serious injury. The plant including its surroundings could be damaged.
CAUTION!
This draws the user's attention to the possibility of imminent danger. If it is not avoided, it may
result in minor injuries. The plant including its surroundings could be damaged.
NOTICE
This draws the user's attention to important additional information about the system or system
components and offers further tips.
The safety information described above is incorporated into the instructions.
Thus, the operator is requested to:
1 Comply with the accident prevention regulations whenever work is being carried out.
2 Do everything possible within his control to prevent personal injury and damage to prop-
erty.

8
2 General Safety Instructions
2.2 Product-specific Dangers
Please observe the safety instructions to avoid personal injury and damage to property and
the environment!
The BT300 is a safety device! The device must not be opened, interfered with or modified.
LAMTEC assumes no liability for damages arising as a result of unauthorised interference!
• After commissioning and after each maintenance action check the exhaust gas values
across the entire power range.
• Qualified specialist staff are required to carry out all activities (assembly, installation, ser-
vicing, etc.).
• The burner or boiler manufacturer will ensure that the BT300 base unit is compliant with
protection class IP40 or IP54 for outdoor use in accordance with DIN EN 60 529.
• Before working in the connection area, switch off the power supply to the plant from all
poles. Ensure that it cannot be switched back on and that the plant is voltage-free. There
is a risk of electric shock when the plant is not switched off.
• Place and secure the protection against contact on the BT300 and on all connected elec-
trical parts. The cover must fulfil the design, stability and protection requirements of
EN 60730.
• Plug connectors X30 - X34 have no protective separation from the mains voltage. To re-
place or disconnect the plug connectors, all poles of the plant must be disconnected from
the mains.
• After each activity (e.g. assembly, installation, servicing, etc.) check wiring and
parameters to make sure it is in good working condition.
• If the equipment is dropped or suffers impact, you should no longer commission it. The
safety functions may also be impaired but fail to show any obvious external damage.
• When the ratio curves are being programmed, the adjuster will continually monitor the
quality of the plant's combustion (e.g. using an exhaust gas analysis station). In the event
that the combustion values are inadequate or the conditions are potentially harmful, the
adjuster will take suitable action, e.g. switch off the system manually.
• These operating instructions describe many possible applications and functions and
should be used as guidelines. Carry out functional tests on the test bench and/or in the
plant application to ensure correct functioning and document the results.
Follow additional instructions to guarantee safety and reliability while operating the BT300:
• Condensation and humidity are to be avoided. If necessary, make sure that the installation
is sufficiently dry before you switch it on.
• Avoid static charge having a destructive effect in case of touching the device's electronic
components.
NOTICE
LAMTEC recommends that you use ESD equipment while working on electrics/electronics.

9
2 General Safety Instructions
2.2.1 Commissioning Notes
• Check all safety functions during commissioning!
• There is no feature to prevent RASTx connector plugs being transposed. Therefore en-
sure the correct assignment of the plant's plugs prior to commissioning.
• Check electromagnetic emissions specific to the application.
• While installing and commissioning the plant, the person in charge of the plant/heating
technician needs to document the following:
– Parameter set values
– Setting values (e.g. curve progressions)
– Values describing the fuel/air ratio control.
This data can be printed using LSB remote software or alternatively being kept as a hand-
written note.
Retain this documentation and have it checked by the ’authority on the subject’.
WARNING!
For BT300 parameter settings which deviate from the application standards can be carried out
in access level 2. For this reason, check whether the parameter settings are consistent with
the corresponding application standards (e.g. EN 298, EN 230, EN 676, EN 267, etc.) or the
respective plant has to be approved separately.
WARNING!
While unlocking the safety interlock chain in the mode ’BURNER OFF’ BT300 does not lock
the system. BT300 prevents a burner start-up until safety interlock chains are locked.
In case your application needs an interlock of the plant while unlocking the safety interlock
chain also in ’BURNER OFF’ mode you must take suitable measures at the plant.
NOTICE
Should the safety times be changed, these changes must be documented on the devices
Bring an additional sticker for the device.
Note the changed safety times on this sticker.
The details on this sticker must be clear for reading and non-smudge.
2.2.1.1 Fuel/Air Ratio Control
• Guarantee proper operation by ensuring adequate excess air.
In order to do this, set the values for fuel and combustion air in such a way that
– combustion chamber pressure
– fuel pressure
– temperature and pressure of the combustion air
can ensure proper operation through the entire range of burner firing rate until next peri-
odic inspection.
• Pay attention to wear and tear of actuators and actuator elements.
• Measure characteristic values of combustion process to document proper operation.

10
2 General Safety Instructions
2.2.1.2 Basic Device
Check the following items prior to commissioning:
• Valves must be assigned correctly to valve outputs on BT300.
• Correct setting of time parameters (especially safety and pre-purge times).
• Flame sensor functioning well in case of:
• flame blow-off during operation (incl. flame-out response time)
• parasitic light is present during pre-purge period
• at a missing flame formation while end of safety period starts
• Activation of the valve leakage control function of gas valves and correct leakage meas-
urement, when required by an application.
2.2.2 Tasks fulfilled by "authority on the subject" during Approval Test
By specifying the assigned DIN registration number and product ID number the manufacturer
confirms that model BT300 burner control system is consistent with type-tested system.
The connection between actuators and actuator elements for fuel and combustion air and also
to any additional actuator elements used must be form-fit.
2.2.2.1 Checking for Correct Parameter Setting in System
While installing and commissioning the plant the person in charge of the plant/heating techni-
cian needs to document the following:
• Parameter set values
• Setting values (e.g. curve progressions)
• Values describing fuel/air ratio control.
This data can be printed using LSB Remote Software or alternatively being kept as a hand-
written note.
Retain this documentation and have it checked by the ’authority on the subject’.
NOTICE
For BT300 parameter settings which deviate from application standards can be carried out in
access level 2. For this reason, check whether the parameter settings are consistent with the
corresponding application standards (e.g. EN 676, EN 267, etc.) or the respective plant has
to be approved separately.

11
2 General Safety Instructions
2.2.2.2 Checking the Fuel/Air Ratio Control System
Save setting values (curve parameters) for actuator elements, fuel and combustion air through
the complete range of burner firing rate in sufficient number.
Select setting values of fuel and combustion air considering combustion chamber pressure,
fuel pressure, temperature and pressure of the combustion air in order to guarantee proper
operation with adequate excess air through the entire range of burner firing rate.
The burner/boiler manufacturer has to document this by measuring reference values of the
combustion process.
2.2.2.3 Checking Burner Sequencer Part
Check the following:
• Correct setting of time parameters (especially safety and pre-purge periods).
• Whether an ionisation flame sensor or a corresponding flame scanner is used since only
these are capable of running in continuous operation.
• Functioning of flame sensor
– in case of flame blow-off during operation
– parasitic light being present during pre-purge period
– missing flame formation at the end of the safety-period
• Check the performance of all available and/or essential incoming signals, such as:
– Air pressure
– Gas pressure - min./oil pressure - min.
– Safety interlock chain (e.g. STB)
• Activated Leakage control function for gas valves if required for application purposes.
– If necessary, ensure a correct leakage quantification.
2.3 Security Advice - Mounting
• Compliance with national safety regulations and standards is obligatory at all times.
• During the assembly and installation process, you must meet the standard requirements
of DIN VDE 0100, 0550 and DIN VDE 0722
• To mount the BT300 basic unit, use screw fittings with an M4 thread (UNC32) and a max-
imum tightening torque of 1.8 Nm for fastening all four fixing points. Keep in mind that
housings have improved mechanical stability when connected on surrounding contact sur-
faces.
Generally connect to an even mounting surface.
NOTICE
Deterioration of the 0.8 Nm servomotor through opening.
Opening the servomotor in a different position other than the cap of the electrical connection,
destroys the servomotor.
The warranty expires.
Open the servomotor at the cap of the electrical connection only.

12
2 General Safety Instructions
NOTICE
Damaging the servomotors with 1.2 Nm and 9.0 Nm through opening.
Opening the servomotor destroys the servomotor.
The warranty expires.
2.4 Installation Notes
• Lay high-voltage ignition cable always separately and in safe distance from device and
other cables.
• Only trained, qualified personnel may open the BurnerTronic’s cover.
• Observe local and national regulations when wiring the electric cables inside the burner.
• Tighten the screw terminals of the BT300 using a tightening torque of > 0.5 Nm.
• Supply the feed cable with L, N and PE only. The N neutral conductor must not have po-
tential difference to the PE protective conductor.
• The pre-fuse for the BT300 should be max.10 A slow-blow.
• Phase, neutral and central point conductors must not be interchanged (this would lead to
dangerous malfunctioning, loss of protection against contact, etc.).
• The strain relief for the connected cables must comply with standards (e.g. DIN EN 60730
and DIN EN 60335).
• Make sure that no spliced strands can come into contact with any of the adjacent connec-
tions. Use appropriate end sleeves.
• The burner manufacturer is obligated to supply unused connections on the BT300 with
dummy plugs.
• To replace or disconnect the plug connectors, all poles of the plant must be disconnected
from the mains.
• Make a form-fit connection between the actuators and actuating elements for fuel and
combustion air, as well as a form-fit connection for any additional actuator element.
• Optional components with safety extra low voltage (SELV) must be safely separated from
the mains. Otherwise this can cause an electrical shock or damage the device due to a
short-circuit.
• You may connect only passive devices or devices without feedback effects at the 230V
outputs of the BT300 (like relays without additional voltage connection). In case of error it
must be guaranteed that BT300 is not fed with 230 V by this terminals.
• To avoid disruption of the UI300’s display during ignition, a damping resistor of 1 ... 5 k
must be installed in the high-voltage ignition line.
• To avoid disturbance on the Bus, the termination must be active on the first and the last
device connected to the bus must be terminated (see chapter 4.2.3 LSB Module Integra-
tion).

13
2 General Safety Instructions
2.5 Electrical Connection Flame Sensor
Interruptions and losses in signal transmission need to be minimised:
• Do not wire the sensor cable with other cables.
Flame signal is reduced through line capacities. Use a separate 7-pole cable.
• Consider the permitted length of sensor cables.
• The ionisation flame sensor supplied from the mains is not protected against contact. Pro-
tection against accidental contact is therefore obligatory.
• Ground the burner according to instructions – grounding the boiler itself is not sufficient!
• Position ignition electrode and ionisation flame sensor where spark cannot hit ionisation
flame sensor (risk of electrical overloading).

14
3 Product Description
3 Product Description
3.1 Functional Description
BT300 combines the benefits of an electronic fuel/air ratio control system with up to three mo-
torised actuator elements and optional modules like an analogue output for speed control of
the combustion air fan with an electronic burner control unit. The leakage test, flame monitor-
ing system, power control unit and (optional) CO/O2controller for control and optimisation of
an oil or gas-fired forced-draught burner are all integrated.
BT300 is suitable for virtually all combustion plants. Safety interlock chains, monitors (e.g. gas
and air pressure) and sensors are wired directly to the BT300. This greatly reduces the cost
of additional relays and wiring. The BT300 is designed to be attached to the burner. The short
wiring paths also save money. As a result, BT300 is particularly suitable as standard equip-
ment for monoblock burners.
The compact design of BT300 burner control system also has its advantages during commis-
sioning. Standardisation of wiring and operator interface minimises sources of errors right
from the start. Moreover, intelligent display information is making search for errors much eas-
ier.
The BT300 is available in five designs:
Burner sequencer and fuel/air ratio control can be adjusted for a wide range of combustion
conditions by setting parameters. The BT300 for oil and gas can be set to start with and with-
out pilot burner. The integrated leakage test can be run before ignition or after shutting down
the burner.
Starting without pre-purge using gas is available in accordance with EN676.
The setting of fuel/air ratio curves can be optimised using optional CO/O2control during op-
eration. This helps to counteract conditions that interfere with combustion. This ensures a per-
manent burner operation at the greatest possible efficiency.
Operating and fault messages are displayed by symbols and numbers on UI300 User Inter-
face. Plant-specific configurations and settings of fuel/air ratio control curves are operated via
menu of UI300 User Interface.
• BT320 2 motorised control outputs
1 continuous output 0 ... 10 V, 0/4 ... 20 mA for speed control of the
combustion air fan using VSM100 (optional)
intermittent operation
• BT330 3 motorised control outputs
1 continuous output 0 ... 10 V, 0/4 ... 20 mA for speed control of the
combustion air fan using VSM100 (optional)
Approved for continuous operation only in combination with
flame sensors capable of running continuously
• BT331 Same range of functions as BT330 but including following certificates:
DIN EN 61508:2002 parts 1-7 for SIL 3
Performance Level PLE according DIN EN ISO 13849-1
• BT340 3 motorised control outputs
Oil-gas dual-fuel operation via DFM300
1 continuous output 0 ... 10 V, 0/4 ... 20 mA for speed control of the
combustion air fan using VSM100 (optional)
approved for continuous operation only in combination with
flame sensors capable of running continuously
• BT341 Same range of functions as BT340 but also including following certificates:
DIN EN 61508:2002 parts 1-7 for SIL 3
Performance Level PLE according DIN EN ISO 13849-1

15
3 Product Description
An operating and start-up counter is integrated.
The optional LCM100 power control unit with two setpoints, external setpoint shift (control by
atmospheric condition) and start-up control is also available.
3.2 Life Cycle
BurnerTronic BT300 burner management system has a designed lifetime *of 250,000 burner
start-up cycles, which, under normal operating conditions in heating mode, correspond to ap-
prox. 10 years of usage (starting from the production date given on the type plate).
This lifetime is based on the endurance tests specified in standard EN230/EN298 and the ta-
ble containing the relevant test documentation as published by the European Association of
Component Manufacturers (Afecor) (www.afecor.org).
The designed lifetime is based on use of BT300 according to the manufacturer’s basic docu-
mentation. After reaching designed lifetime in terms of number of burner start-up cycles, or
the respective time of usage, the BT300 must be replaced by authorized personnel.
3.3 Technical Data
3.3.1 BT300
*The designed lifetime is not the warranty time specified in the Terms of Delivery
1 RAST5 plug connector optionally
A cutting and clamping technique (SKT) *
B screw terminals *
2RAST2.5 plug connector for actuator,
User interface and LAMTEC SYSTEM
BUS in cutting and clamping technique
* please note plug-in direction

16
3 Product Description
Fig. 3-1 Dimensions BT320 ... 340 (terminal assignment BT330/BT340 only)
Fig. 3-2 UI300 side view Fig. 3-3 UI300 front view
Fig. 3-4 UI300 panel cut-out

17
3 Product Description
Function
Power supply: 230 V +10/-15 % 47-63 Hz
115 V +10/-15 % 47-63 Hz (on request)
Maximum backup-fuse: 10 A slow-blow
To be used only in a grounded power line network!
Power consumption: max. 30 VA
Switching threshold of ionisation
current:
1 A
Digital signal inputs: Max. line length 10 m/33 ft
Max. line length 20 m/66 ft for the following signals:
Firing rate+ / firing rate-
Boiler safety interlock chain (SIC)
Burner ON
Reset
Alarm
Fuel selection DFM
Digital outputs: 3 fuel valves max. 1 Acos 0,4
VL fan max. 2 Acos 0,4
oil pump max. 2 Acos 0,4
ignition transformer max. 2 Acos 0,2
alarm output max. 1 Acos 0,3
Resolution: 999 digit, 10 bit
Number of curve sets: BT320/33x: 1 curve set (oil or gas)
BT34x: 2 curve sets (oil/gas switchable; DFM300 or LCM100 required)
Number of programs: unlimited (EEPROM)
Field bus-coupling (optional): PROFIBUS DP
Modbus TCP
PROFINET
LEM100 or LCM100 always required
Housing: Polycarbonate + ABS
Dimensions: 200x115x61 mm/7.87x4.53x2.4 in
Weight: 1,0 kg/2.20 lb
Flammability: UL-94 V0
Display UI300
Display: 128x64 pixel, monochrome
White backlighting (dimmable)
Dimensions: 112x64x24 mm/4.41x2.52x0.94 in
Weight: 140 g/0.31 lb
Housing: Basic housing: Polyamide glass fibre reinforced
LCD-display window: Polycarbonate
Flammability: UL-94 V0
Cable length: 1 m/3.28 ft
Environmental Conditions
Operation: Climatic conditions Class 3K5 according to DIN EN 60721-3
Mechanic conditions Class 3M5 according to DIN EN 60721-3

18
3 Product Description
3.3.2 Actuator
3.3.2.1 Actuators 662R550...
Temperature range -20 ... +60 °C/-4 °F ... +140 °F
(condensation is prohibited)
Transport: Climatic conditions Class 2K3 according to DIN EN 60721-3
Mechanic conditions Class 2M2 according to DIN EN 60721-3
Temperature range -20 ... +70 °C/-4 °F ... +158 °F
(condensation is prohibited)
Storage: Climatic conditions Class 1K3 according to DIN EN 60721-3
Mechanic conditions Class 1M2 according to DIN EN 60721-3
Temperature range -20 ... +70 °C/-4 °F ... +158 °F
(condensation is prohibited)
Electronic safety: Degree of protection (DIN EN 60529): BT300 – IP00 housing
IP20 (terminals covered)
UI300 – IP40 (clamping)
IP54 (glued assembly)
Environmental Conditions

19
3 Product Description
DANGER!
Danger by electrical shock!
Shut BT300 down before opening the cover, otherwise it is possible to get in contact with con-
ducting parts. This may cause an electrical shock. Only open BT300 when it is disconnected
it all-pole.
Disconnect BurnerTronic all-pole.
115.4 (+0.3/-1) including axial play
2Cap cannot be removed by hand
3Flexible control cable (black), length 1.5 m
4Plug connector (RAST 2.5) pole number 6
5Brass tube and M4 x 30 DIN 912 cylinder bolt fixed with O-ring
Function
Power supply 24 VDC ±20 %
Floating time 5 s / 90° at 180 Hz
Direction of rotation 0° to 90° right
Torque 0.8 Nm (both directions)
Holding torque 0.4 Nm (no power)
0.7 Nm
Permissible radial load 30 Nm (centre of output shaft)
Permissible axial load 5 N
Axial play of drive shaft 0.1 ... 0.2 mm
Cable length securely connected 0.6 m
pluggable max. 3 m
Environmental conditions
Operation Climatic condition Class 3K3 according to DIN EN 60721-3
Mechanical condition Class 3M3 according to DIN EN 60721-3
Temperature range -20 ... +60 °C (condensation is prohibited)
Transport Climatic condition Class 2K3 according to DIN EN 60721-3
Mechanical condition Class 2M2 according to DIN EN 60721-3
Temperature range -20 ... +70 °C (condensation is prohibited)
Storage Climatic condition Class 1K3 according to DIN EN 60721-3
Mechanical condition Class 1M2 according to DIN EN 60721-3
Temperature range -20 ... +70 °C (condensation is prohibited)
Bursting strength Peak voltage 4 kV
Repeat frequency 2,5 kHz
Electrical safety Protection class 2 as per DIN EN 60730