Lamtec LT3 User manual

www.lamtec.de
Sensors and Systems for Combustion Engineering
Quick Reference for End Users
Lambda Transmitter LT3
Combination Probe KS1D

2
Table of Contents
Table of Contents
1 Important Information about the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Validity of these Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Information on Using this Operating Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Classification of the Safety Instructions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Proper Use - Conditions of Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Permissible Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Safety Equipment/Safety Measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Designs and Accessories of the KS1D Combination Probe. . . . . . . . . . . . . . . . . . . . . . 11
3.2 C: Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Display and Operational Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.1 Password Entry Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.2 Information Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.3 Calibration Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.4 Settings Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Status Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4 Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4.1 Main Menu - Password Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4.2 Main Menu - Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.3 Main Menu - Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.4.4 Main Menu - Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5 LSB Remote Software (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.6 External Operation via Programming Unit (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1 Checking/Calibrating the KS1D Combination Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1.1 Checking/Calibrating the Air Voltage (Offset) . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1.2 Checking/Calibrating the O2Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1.3 Checking/Calibrating the CO/H2Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1.4 Reading the Measured Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1.5 Enter the Password for the Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1.6 Activate/deactivate Maintenance Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1.7 Response of the Internal Resistance Regulation. . . . . . . . . . . . . . . . . . . . . . . . 32
5.1.8 Premature Cold Start Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1.9 Calibrating the Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1.9.1 Offset Calibration perform to 21 % O2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1.9.2 Calibrating the O2Electrode in the Operating Point . . . . . . . . . . . . . . . . . . . . . 37
5.1.9.3 Perform a Calibration of the CO/H2Electrode. . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.10 Checking/Calibrating with Test Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.11 Checking/Calibrating with Reference Measurement . . . . . . . . . . . . . . . . . . . . . 43
5.1.12 Simple Function Test of the CO/H2Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.13 Wear-and-Tear Parts of the KS1D Combination Probe . . . . . . . . . . . . . . . . . . . 44
5.2 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.1 Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3
Table of Contents
5.2.2 Filter Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.3 Analogue Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.4 Replacing a Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.5 Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.6 Limit Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6 Correcting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.1 Faults and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.1.1 Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.1.2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.1.3 Call of the Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.1 Decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.1.1 Protection Against Emissions from Gas Carrying Channels . . . . . . . . . . . . . . . 55
8 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.1 Analogue Outputs via LSB Module Current, alternative Voltage, LSB address 19 . . . . 56
8.1.1 Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.1.2 Factory Setting of Analogue Outputs via LSB Module. . . . . . . . . . . . . . . . . . . . 57
8.1.3 Conversion of the Output Range via the User Interface . . . . . . . . . . . . . . . . . . 58
8.2 Digital Outputs via LSB Module, LSB Address 03 and 51 . . . . . . . . . . . . . . . . . . . . . . . 59
8.2.1 Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.2.2 Factory Setting of the Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.2.3 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.2.4 Diagnosis of the Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.3 Digital Inputs via the LSB Module, LSB Address 11 and 55. . . . . . . . . . . . . . . . . . . . . . 63
8.3.1 Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.3.2 Factory Settings of the Digital Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.3.3 Diagnosis of the Digital Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.4 Technical Data for HART Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.4.1 Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.4.2 HART Commands and DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.5 Field Bus Module for PROFIBUS PBM100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.5.1 DIP Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.5.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.5.3 PROFIBUS DP Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.5.4 Communication Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.5.5 External Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.6 LSB Module for Calculating Combustion Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.6.1 Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.1 Storage Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10 Disposal Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10.1 Environmental Protection, Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
11 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11.1 Wet/Dry Measurement Deviations, Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4
1 Important Information about the Manual
1 Important Information about the Manual
1.1 Validity of these Instructions
This manual describe the Lambda Transmitter LT3 with all required components. The infor-
mation in this document applies to the software version V0.106. If you utilise a different ver-
sion, this can lead to other effects to your device than those described in this manual.
NOTICE
LT3 Lambda Transmitter cannot be used for LAMTEC CO/O2Control.

5
1 Important Information about the Manual
1.2 Information on Using this Operating Manual
NOTICE
Before starting work, you absolutely must read these instructions!
Carefully observe all warning notes!
They contain important data and information, the compliance with which will ensure the func-
tion of the device and, in turn, reliable measurement results.
The device described here corresponds with the standard configuration.
Particular attention must be paid to information and warnings. These are indicated by re-
spective pictograms. They serve to safeguard your personal safety and help you to avoid op-
erating errors.
This operating manual contains the information required for the product to be used in a man-
nerthat is compliantwithits intended use.It is intendedfortechnically qualified personnelwho
are appropriately trained and who possess the relevant knowledge in the area of measure-
ment, control and steering technology.
This operating manual is an inherent part of the delivery. For reasons of clarity, it is not possi-
ble to cover all possible designs of the described system. Please contact us if you wish to set
up, operate, or maintain the device differently from the instructions given here.

6
2 General Safety Instructions
2 General Safety Instructions
2.1 Classification of the Safety Instructions and Warnings
Thefollowing symbols are usedin this document todraw the user'sattentionto 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.

7
2 General Safety Instructions
2.2 Proper Use - Conditions of Use
Operation
The LT3 Lambda Transmitter is an electronic data interpreting device which is used in con-
junction with the KS1D Combination Probe for the continuous measurement of the O2concen-
tration and the oxidising components (CO/H2) in non-combustible gases in the
superstoichiometric area.
Prerequisites
It is assumed that plant planning, mounting, installation, commissioning, maintenance, and
service work will be carried out by sufficiently trained personnel and that this work will be
checked by responsible skilled personnel. It must be particularly noted that
• the operation complies with the technical data and specifications regarding permissible
use, mounting, connection, and environment and operating conditions (refer to the con-
tract documents, the device user information, rating plates, etc.).
• workwillbe carried out inaccordancewith the local, plant-specific circumstancesand with
regard to the operational risks and directives.
• allthemeasures required to preserve thevalue,e.g. for transportation and storageaswell
as maintenance and service, are maintained.
Intended use
The product described here has left the factory in a flawless, safe and checked condition and
itmust bemaintained exclusivelyin themanner thatis describedby themanufacturer.Equally,
the proper transportation, correct storage and setup as well as the careful operation and main-
tenance, are critical for the flawless and safe operation of the device. Sufficiently qualified per-
sonnelmust be usedto install andoperate this product.Theymustbe familiarwiththe security
advice and warnings specified here and ensure they can be implemented flawlessly. Unqual-
ified persons working on the device or the warning information provided here or on the device
not being observed could result in serious personal injury and / or damage to property. The
device is being used as intended if the device is being used solely for the application specified
in the technical description.Auxiliary devices or those from other manufacturers must be rec-
ommended or authorised by LAMTEC. Provided the safety information and operating direc-
tives specified in this manual are observed, this device should not present any risks in terms
of damage to property or the health of personnel.

8
2 General Safety Instructions
2.3 Permissible Users
Qualified personnel
The person responsible for safety absolutely must guarantee that
• only qualified personnel perform work on the system parts.
Due to their training, education, experience, or instruction and due to their knowledge of
pertinent standards, provisions, accident prevention regulations, and system conditions,
qualified personnel are authorized to perform these tasks by the person responsible for
the safety of people and the system. It is decisive that this personnel must be able to rec-
ognise and prevent risks on time.
Experts are considered to be people according to DIN VDE 0105 or IEC 364 or directly
comparable standards like DIN 0832.
• These persons must have access to the provided operating manual and any pertinent or-
der-related documentation during all work and observe these documents within the scope
of preventing risks and damage.
User groups
For the handling of the Lambda Transmitter LT3, three user groups are required:
• Service technicians of LAMTEC or its OEM customers and/or trained customer personnel:
– Qualified technicians/engineers have very good knowledge of the device.
– SERVICE access level - password-protected
• Operators, customer fitters, technicians for instrumentation and control technology, elec-
tricians, and electronic engineers have introductory knowledge of the device.
– CUSTOMER access level - password-protected
• Operating personnel with basic knowledge
– OPERATION access level - no password

9
2 General Safety Instructions
2.4 Safety Equipment/Safety Measures
Hazards from electrical equipment
The LT3 and the Lambda Transmitter Combination Probe is equipment for use in industrial
electricalpower installations.Alwaysswitch offthepower whenworking onmains connections
or mains voltage. If contact protection has been removed, reattach it before switching on the
power supply again. Damage to health or equipment may result from improper use or improp-
er handling.
NOTICE
To avoid damage, always observe the respective security notices.
Preventive measures for improving operating safety
IftheLT3 isusedinconjunctionwithcontrolandsteering technology, theoperatormustensure
that any breakdown or failure of the LT3 device does not cause inadmissible damage or dan-
gerous operating states. To avoid faults which could cause direct or indirect personal or ma-
terial damage, the operator must ensure that:
• the responsible maintenance personnel can be reached at any time and as quickly as pos-
sible
• the maintenance personnel are trained to correctly respond to faults with the LT3 Lambda
Transmitter and the associated malfunctions
• in the case of doubt, the faulty equipment can be switched off immediately
• A switch-off does not lead to direct follow-up problems.
Avoiding consequential damages
To avoid consequential damages in the event of failure, which could cause direct or indirect
personal or material damage, the owner must ensure that qualified personnel can assess the
faults and initiate appropriate measures to tackle them.
Protect against gas leakage from the gas-bearing channel
The Combination Probe KS1Dis fitted directly to the gas-bearing channel via the probe instal-
lation fitting (PIF). If the Combination Probe KS1D or the probe installation fitting (PIF) are dis-
mantled, depending on the plant but particularly in the case of excess pressure, aggressive
and / or hot gas can seep out of the channel and this could pose a serious health hazard to
an unprotected operator if suitable safety measures have not be taken previously. For preven-
tion, suitable protective measures must be taken in advance.
WARNING!
In the case of excess pressure and temperatures in excess of 200 °C in the gas channel, gas-
es could escape when dismantling the Combination ProbeKS1D or the probe installation fit-
ting (PIF).
Always switch off the plant prior to opening. If this is not possible, wear protective clothing
and a mask.
Fix respective warning information in close proximity to the mounting site.
Immediately seal the opening again.

10
2 General Safety Instructions
WARNING!
Danger from electrical shock
The device contains live parts and touching these parts could cause electric shock.
Before opening the housing, disconnect the mains plug!
Decommissioning/recommissioning
The Lambda Transmitter LT3 Combination Probe KS1D are a high-quality,
electronic measuring system. It therefore requires careful handling in all situations - decom-
missioning, transport, and storage.
NOTICE
Do not switch off the Lambda Transmitter LT3 as long as the KS1D Combination Probe is
mounted.Noteven if the associatedplanthas been brought toastandstill. Residual gases will
cause corrosion and could damage the probe.
Do not store the device outside without any protection!
Always store in a dry location and, if possible, keep in the original packaging.
When uninstalling, protect the ends of cables and the connectors from corrosion and soil-
ing. Corroded connectors can cause malfunctions.
If possible, always transport in the original packaging.

11
3 Product Description
3 Product Description
3.1 Designs and Accessories of the KS1D Combination Probe
The KS1D Combination Probe permits a simultaneous measurement
of the O2concentration and combustible, oxidising gas components (CO/H2) displayed as
CO equivalent (COe), in the flue gases from combustion systems in the superstoichiometric
area (>1) in situ (directly in the flue gas).
Fig. 3-1 Standard design of the KS1D Combination Probe
Fig. 3-2 KS1D Combination Probe without housing
Alternatively:
Fig. 3-3 KS1D Combination Probe in HT design
1 KS1D Combination Probe in standard housing
Standard cable length 2 m, FEP, with connecting plug
2 Probe installation fitting (PIF)
3 Measuring gas extraction device (GED)
1 KS1D-HT Combination Probe high-temperature
Standard cable length 2 m, FEP, with connecting plug
2 Flue gas bypass tube

12
3 Product Description
Fig. 3-4 KS1D Combination Probe for manual cleaning
1 KS1D-HT Combination Probe
2 High dust reception flange with pneumatic fittings

13
3 Product Description
3.2 C: Declaration of Conformity

14
3 Product Description

15
4 Display and Operational Controls
4 Display and Operational Controls
To display and operate LT3, the user interface is integrated into the front door of LT3 (included
in the standard).
Functions:
• Reading of the O2and COemeasured values
• Password entry
• Information regarding the probe, fuel, warnings, faults, software version,
CRC, and serial number
• Calibration of measurement
• Settings maintenance, filter time, analogue output, probe replacement, display,
limit values, and digital outputs
Fig. 4-1 LT3 user interface
Fig. 4-2 Housing with user interface

16
4 Display and Operational Controls
4.1 Operation
Using the arrow keys you can navigate within the menus.
In the process, move the keys and to the right or left by one to make a selection.
ENTER ENTER takes you to menu entries or to the edit mode in the case of selected pa-
rameters or values.
With the keys and the currently selected value can be changed accordingly Hold
down the respective key and the value will count automatically up or down.
BACK BACK leaves the window, menu, or edit mode.
4.2 Menu Structure
4.2.1 Password Entry Menu Structure
Without access level
Customer access level
Service access level

17
4 Display and Operational Controls
4.2.2 Information Menu Structure
4.2.3 Calibration Menu Structure

18
4 Display and Operational Controls
4.2.4 Settings Menu Structure

19
4 Display and Operational Controls
4.3 Status Line
The status line contains information about LT3, including the device family.
Fig. 4-3 UI300 front view status line
1. Status line
Description status line:
Active fault/warning
Operating mode OK
Heat-up (cold start)
Status of limit values 1-4*
Active limit value not triggered
Non-active limit value (off)
Active limit value undershot/exceeded
Active maintenance mode
Without access level
Access level 1 - Customer
Access level 2 - Service
Window number
*If a limit value is exceeded the display shows an upward or downward arrow.