Lamtec BT300 BurnerTronic User manual

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

2
Table of Contents
Table of Contents
1 Important Information about the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Validity of these Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Standards, Directives and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Classification of the Safety Instructions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Product-specific Dangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.1 Commissioning Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.1.1 Electronic Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.1.2 Basic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.2 Tasks fulfilled by "authority on the subject" during Approval Test . . . . . . . . . . . 12
2.2.2.1 Checking for Correct Parameter Setting in System . . . . . . . . . . . . . . . . . . . . . . 12
2.2.2.2 Checking the Fuel/Air Ratio Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.2.3 Checking Burner Sequencer Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Security Advice - Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Electrical Connection Flame Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Life Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Technical Data BurnerTronic BT300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3.1 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3.1.1 Actuators 662R550.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3.1.2 Actuators 662R5001... / 662R5003... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.2 Flame Sensor/Flame Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4 Design and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2 Connecting Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2.1 Terminal assignment BT300 - Connection example . . . . . . . . . . . . . . . . . . . . . 33
4.2.2 Terminal assignment BT335 - Connection example . . . . . . . . . . . . . . . . . . . . . 34
4.2.3 Optional Connections for the Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2.4 Optional Connections for the Flame Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2.5 LSB Module Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3 Flame Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3.1 Integral Flame Monitoring (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3.2 Flame Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3.2.1 KLC 20/KLC 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3.2.2 KLC 10/KLC 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.4 Process Sequence Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.5 Leakage Test for Main Gas Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.5.1 Calculation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.5.2 Leakage Test Process Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.5.3 Reaction on Gas Deficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.5.4 Valve Leakage Test Venting Over the Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.6 Staged Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.7 Flue Gas Recirculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.8 Continuous Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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Table of Contents
4.9 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.9.1 Operation after Power ON/Long RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.9.2 Direction of Rotation/Position Damper Closed . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.9.3 Detection of Actuators with Mixed-up Connections . . . . . . . . . . . . . . . . . . . . . . 65
4.9.4 Adjusting of Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6 Operating Control and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.1 User Interface UI3xx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.1.1 Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.1.2 Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.1.3 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.1.4 Information Menu Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.1.4.1 Burner Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.1.4.2 Recalling Fault History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.1.4.3 Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.1.4.4 Display of Check Sums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.1.4.5 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.1.4.6 Positions of Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.1.4.7 Check Digital Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.1.4.8 Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.1.5 Manual Menu Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.1.6 Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.1.7 Settings Menu Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.1.7.1 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.1.7.2 Program Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.1.7.3 Configuration of Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.1.7.4 Setting Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.1.7.5 Deleting Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.1.7.6 Adjusting Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.1.7.7 User Interface Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.1.7.8 Edit Parameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.1.7.9 Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.1.7.10 Programming a Staged Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.1.8 Menu Path Dataset Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.2 Other Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.3 LSB Remote Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.3.1 Functional Description, Connecting USB-CAN Module . . . . . . . . . . . . . . . . . . . 95
6.3.1.1 Installation Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.3.1.2 Installing the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.3.1.3 Installing the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.3.1.4 First Connection with the Target Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.3.1.5 Release Codes/Release Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.3.2 Offline/Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.3.2.1 Offline Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.3.2.2 Online Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.3.2.3 Connecting the BT 300 with the PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.3.3 Read Out Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.3.4 Parameters of Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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Table of Contents
6.3.4.1 Setpoint Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.3.4.2 Curve Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.3.4.3 Setting Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.3.5 Programming of Fuel/Air Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.3.6 Programming a Staged Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.3.6.1 Setting the Stage Operation up to v3.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.3.6.2 Setting the Stage Operation up to v3.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.3.7 Software Interface LSB Remote Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.3.7.1 File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.3.7.2 Access Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
6.3.7.3 BurnerTronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
6.3.7.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
6.3.7.5 Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.1 Data backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.2 Firmware Update BT300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.3 User Interface Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.4 Replacing of BurnerTronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
8 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
8.1 Firing-Rate Controller Module LCM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
8.1.1 Range Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
8.1.2 Enter Setpoint of Firing Rate Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8.1.3 Operating Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
8.1.4 Control by atmospheric conditions and external setpoint presetting . . . . . . . . 166
8.1.5 Setpoint Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8.1.6 Start-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8.1.7 Thermostat and Control Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
8.1.8 Control Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
8.1.9 Checking the Safety Limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.1.10 Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.1.11 Aides for Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.1.12 External/Manual Firing-rate Presetting (Terminals 16 - 19) . . . . . . . . . . . . . . . 174
8.1.13 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.1.14 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8.1.15 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
8.1.15.1 Galvanic Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
8.1.15.2 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
8.1.16 Technical data LCM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
8.2 Dual Fuel Module DFM300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.2.1 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
8.2.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
8.2.3 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
8.2.3.1 Galvanic Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
8.2.3.2 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
8.2.4 Technical Data DFM300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
8.2.5 Adapter System Rast5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.2.5.1 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.2.5.2 Technical Data Rast5-Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

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Table of Contents
8.3 Variable Speed Drive Module VSM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
8.3.1 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8.3.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8.3.3 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8.3.3.1 Galvanic Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8.3.3.2 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8.3.4 Technical Data VSM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8.4 Expansion Module for LSB - LEM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8.4.1 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8.4.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8.4.3 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8.4.3.1 Galvanic Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.4.4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8.5 Field Bus Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.5.1 Field Bus Module for PROFIBUS PBM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.5.1.1 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.5.1.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
8.5.1.3 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
8.5.1.4 PROFIBUS DP Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
8.5.1.5 Technical Data PBM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
8.5.2 Field Bus Module for MODBUS TCP EBM100 . . . . . . . . . . . . . . . . . . . . . . . . 218
8.5.2.1 IP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
8.5.2.2 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
8.5.2.3 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
8.5.2.4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
8.5.2.5 Ethernet Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
8.5.2.6 Technical Data EBM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
8.5.3 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
8.5.4 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
8.5.4.1 Bit Encoding: Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
8.5.4.2 Bit Encoding: Operating Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
8.5.4.3 Bit Encoding: Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
8.5.4.4 Bit Encoding: Curve Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
8.5.4.5 Bit Encoding: Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
8.5.4.6 Coding: O2 Controller Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
8.5.4.7 Bit Encoding: State of Actual Value of O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
8.5.4.8 Bit Encoding: Cause of Faults of O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
8.5.4.9 Bit Encoding: Operating Mode of CO Controller . . . . . . . . . . . . . . . . . . . . . . . 236
8.5.4.10 Bit Encoding: State of Actual Value of CO . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
8.5.4.11 Bit Encoding: Cause of Fault of CO Controller. . . . . . . . . . . . . . . . . . . . . . . . 237
8.5.4.12 Bit Encoding: State of Flue Gas Temperature and Efficiency . . . . . . . . . . . . 237
8.5.4.13 Bit Encoding: Status of Intake Air Temperature . . . . . . . . . . . . . . . . . . . . . . . 238
8.5.4.14 Encoding FAT State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
8.5.4.15 Units Fuel Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
8.5.4.16 Bit Encoding: Operating Condition CO/O2. . . . . . . . . . . . . . . . . . . . . . . . . . . 239
8.5.4.17 State Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
8.5.4.18 Allocation of the Texts to the Text Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . 243

6
Table of Contents
9 Disposal Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
10 EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
11 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
11.1 Display Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
11.2 Indication Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

7
1 Important Information about the Manual
1 Important Information about the Manual
1.1 Validity of these Instructions
This manual is valid for BT300 BurnerTronic in any configuration.
The content of this document refers to software version BT300 v3.9 and UI300 V3.12 (HW V
1)/4.4 (HW V 2). Oth-er software versions may cause that some of the functions described in
this document are not available or have another functionality 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:
NOTICE
To comply with the UL listed certificate BT300 + UI300 + LCM100 + VSM100 + DFM300 +
LEM100 must be installed in the same control cabinet.
The wiring in the control cabinet must be carried out according to the rules of NFPA70.
Australia:
2004/108/EU EMC Directive
2014/35/EU Low Voltage Directive
(EU)2016/426 Gas Appliance Directive
2014/68/EU Pressure Equipment Directive, Conformity Assessment cat. IV mod. B & 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

8
1 Important Information about the Manual
South Africa:
Russia/Belarus/Kazakhstan:
EAC
NOTICE
Respect the national safety regulations and standards.
SAGA Act 85 of 1993
PER R 734 -2009

9
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.

10
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.
• 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
Use ESD equipment while working on electrics/electronics.
• The external safety devices are not monitored during continuous fan ventilation (post-
purge) after a normal shutdown. This means the combustion air fan cannot be switched
off by actuating a hazard switch interconnected in the burner safety interlock chain. For
this reason, additional measures must be taken in the combustion system for the emer-
gency shutdown of the combustion air fan.

11
2 General Safety Instructions
2.2.1 Commissioning Notes
• During commissioning it is essential to observe all safety accessory.
• There is no way to completely rule out the connection plugs being connected incorrectly.
For this reason, check the correct assignment of the plugs before commissioning the
plant.
• The person responsible for the plant/commissioning engineer must document the follow-
ing values after installing and commissioning a plant:
– Settings/changes to the parameters
– Setting values across the burner firing-rate range (e.g. curve progressions),
– corresponding exhaust gas values where applicable
– media pressure levels where applicable
You can partly use CMS Remote Software to print this data or alternatively keep a hand-
written note of it.
If tests are to be required by third parties in the application area of the device, these doc-
uments must be retained for presentation on request.
NOTICE
In BT300, parameter settings deviating from the application standards can be made.
The parameter settings must correspond to the relevant application standards as applica-
ble (e.g. EN 298, EN 676, EN 267, etc.) The documented evidence of conformity can be
managed via the LSB remote software.
NOTICE
Safety times can be called up via the HMIs UI400 and GUI607/GUI610/GUI615 and the CMS
Remote Software.
WARNING!
No interlocking when opening the safety interlock chains in BURNER OFF mode!
When opening the safety interlock chains in BURNER OFF mode, the BT300 does not per-
form any interlocking. The BT300 only prevents the burner from starting until the safety chains
are closed.
Measures must be taken on the system side if the application requires the plant to be
interlocked when a safety chain is opened even in BURNER OFF mode
2.2.1.1 Electronic 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, stable operation through the entire range of burner firing rate until next
periodic inspection.
• Pay attention to wear and tear of actuators and actuator elements.
• Measure characteristic values of combustion process to document proper operation.
• Observe the maintenance cycle for readjustment of the electronic ratio control depending
on tolerances and operating times.

12
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.
• 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
• Whether an approved self-checking flame sensor is used as only these types allow con-
tinuous operation.
•The function of all existing or required input messages such as:
– air pressure
– Gas pressure - min / oil pressure - min
– Safety chain (e.g. STL)
• Activated valve leakage control function for gas valves if required for application purposes.
–If so, check/adjust the correct leakage rate determination.
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.

13
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 or approved self-checking flame sensor is used as only these types
allow 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 switch
– 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.

14
2 General Safety Instructions
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
NOTICE
To mount the BT300 basic unit, use screw fittings with an M4 thread (UNC32) and a maximum
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 surfaces. Generally
connect to an even mounting surface.
NOTICE
Damaging of the 0.8 Nm actuator through opening.
Opening the actuator in a different position other than the cap of the electrical connection, de-
stroys the actuator.
The warranty expires.
Open the actuator at the cap of the electrical connection only.
NOTICE
Damaging the actuators through opening.
If the actuator is opened, the actuator will be destroyed (applies to actuator with 1.2 Nm,
3.0 Nm and 9.0 Nm).
The warranty expires.

15
2 General Safety Instructions
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 and neutral 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.

16
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).

17
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/O2 controller 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 mono-block 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 easier.
The BT300 is available in six designs:
•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)
Up to version 3.8.0.0 intermittent operation, from serial numbers
22xxxxxx and version 3.9.0.0, the BT320 is also approved for continuous
operation in combination with flame sensors capable of running
continuously
•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
•BT335 3 Motorised control outputs
– Oil-gas dual-fuel operation with limited functions is possible without
DFM300
– Pilot burner is not possible
– External reset is only possible with LCM
– No CPI/POC input
– No connection for QAR2, QAR4, QAR10
– No process status signal possible
– Oil operation is possible only modulating or 2-stage.
– 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
•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

18
3 Product Description
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/O2 control 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.
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
The device has a designed lifetime 1 of 250,000 burner start-up cycles, which, under normal
operating conditions in heating mode, correspond to approx. 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 the device according to the manufacturer’s basic doc-
umentation. After reaching designed lifetime in terms of number of burner start-up cycles, or
the respective time of usage, the device must be replaced by authorized personnel.
3.3 Technical Data BurnerTronic BT300
Fig. 3-1 BurnerTronic BT300
• 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
1The designed lifetime is not the warranty time specified in the Terms of Delivery

19
3 Product Description
1 RAST5 plug connector optionally
2 RAST2.5 plug connector for actuator,
User interface and LAMTEC SYSTEM
BUS in cutting and clamping technique
Fig. 3-2 Dimensions BT320 ... 341 (terminal assignment BT330/BT341 only)