Lamtec BT300 BurnerTronic User manual

www.lamtec.de
Sensors and Systems for Combustion Engineering
Quick Reference for Endusers
BurnerTronic BT300

2
Table of Contents
Table of Contents
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Validity of these Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Life Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Disposal Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Safety Instructions - Common Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 For Your Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Mounting Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Security Advice - Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Electrical Connection Flame Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Commissioning Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5.1 Fuel/Air Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5.2 Basic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Tasks fulfilled by "authority on the subject" during Approval Test. . . . . . . . . . . . . . . . . . 11
3.6.1 Checking for Correct Parameter Setting in System . . . . . . . . . . . . . . . . . . . . . . 11
3.6.2 Checking the Fuel/Air Ratio Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6.3 Checking Burner Sequencer Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Operating Control and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 UI300 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Information Menu Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4.1 Burner Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4.2 Recalling Fault History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.4.3 Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4.4 Display of Check Sums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4.5 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.6 Positions of Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.7 Check Digital Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4.8 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.5 Manual Menu Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6 Settings Menu Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.6.1 Enter Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.6.2 Program Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.6.3 Other Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6 Leakage Test for Main Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1 Calculation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2 Leakage Test Process Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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Table of Contents
6.3 Valve Leakage Test Venting Over the Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.1 Technical Data BT300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2 Actuators 662R550... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3 Actuators 662R5001... / 662R5003.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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1 General Information
1 General Information
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 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.
1.3 Disposal Notes
The device contains electrical and electronic components and must not be disposed of as do-
mestic waste. The local and currently valid legislation absolutely must be observed.
*The designed lifetime is not the warranty time specified in the Terms of Delivery

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2 Safety
2 Safety
2.1 Safety Instructions - Common Information
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.

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3 For Your Safety
3 For Your Safety
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.
• The hazard risk in the event of external fire, traffic, wind, tidal waves and earthquakes de-
pends on the installation situation and the location of the gas appliance. It shall be as-
sessed separately where appropriate.
• 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.

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3 For Your Safety
3.1 Mounting Notes
• Please consider protection against contact when installing the Gerät. Protection classes
as IP 40 - IP 54 are minimum requirements for outdoor use in accordance with EN 60529
and therefore obligatory.
• The protective cover of the BurnerTronic may only be opened by trained, qualified person-
nel.
• Make sure that settings for safety-relevant parameters are set in line with the requirements
applicable to each type of combustion requiring monitoring and conform to the applicable
standards (by checking device parameters via operating elements or using remote-control
software after commissioning). To verify settings you should also refer to manufacturer’s
documentation of the combustion plant. Protecting the parameters in level 1 by setting a
password will prevent any unauthorised change.
• Save setting values for the actuating elements across the power range of the burner as
follows:
– Quantity of fuel
– Quantity of air
– All additional, safety-relevant actuating variables of the combustion
– While burner is modulating with at least five different firing-rate points
• Make sure that the combustion equipment operates stably and safely throughout the pow-
er range and in all combustion modes. For this purpose you should adjust the following
values correctly:
– Actuating elements
– Parameter settings of the CO/O2controller
– Combustion chamber pressure
– Fuel pressure
– Temperature
– Pressure of combustion air
– Heating value of fuel
• Ensure the connection between the actuators and control valves is form-fit throughout,
gearing this towards the maximum controlling torques of the actuators.
• Only use external flame monitors compliant with DIN EN 298 or DIN EN 230 and author-
ised for continuous operation. Safety time of flame monitor must not extend 1 s.
• If the valve testing system is activated, connect the supply-side solenoid valve to terminal
X01 and the burner-side solenoid valve to terminal X02. Connect the pressure monitor of
the valve testing system to terminal X05. Adjust the gas pressure monitor and the dimen-
sions of the test section in order to make sure that the valve testing system is detecting a
maximum leakage gas volume of 0.1 % in relation to the gas flow rate (minimum 50 dm³/
h) at maximum combustion heat output.
• Consider the potential danger depending on installation situation and position where the-
pressure equipment is being installed. Bear in mind the risk of external fire and the impact
from traffic, wind and earthquake.
• When fixing duomodul plug-in connectors to insulation displacement technology (IDT) use
HZ-M35 a modular crimping tool from Lumberg (see www.lumberg.com).

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3 For Your Safety
3.2 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.
NOTICE
Damaging the servomotors with 1.2 Nm and 9.0 Nm through opening.
Opening the servomotor destroys the servomotor.
The warranty expires.

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3 For Your Safety
3.3 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.
3.4 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).