Spirax Sarco LC2650 User manual

IM-P402-128 EMM Issue 7
Commissioning password
Current legislation states that in order to prevent tampering and potentially
hazardous programming errors, access to the pass codes required to enter
commissioning mode should only be available to qualified and trained personnel.
Enter commissioning
This is done from the run mode by pressing and holding down the
OK
button for 5 seconds.
The run mode display will disappear and the display will show 'PASS CODE' with '8888' at
the bottom right corner of the screen. The flashing leading digit indicates the position of the
cursor. The default, or factory set pass code is 7452 but this can be changed from within
the commissioning mode. The pass code can be entered by using the and buttons
to increase or decrease the flashing value and the and buttons to move the cursor.
Pressing the OK button will enter the pass code. If an incorrect pass code is used, the display
automatically returns to the run mode.
This page MUST be removed after
commissioning and kept in a safe,
access controlled location.
© Copyright 2017
Printed in GB
IM-P402-128
EMM Issue 7
4028051/7
LC2650
Level controller
Installation and Maintenance Instructions
1. Safety information
2. User instructions and
delivery information
3. System overview
4. Mechanical
installation
5. Electrical installation
6. Commissioning
- Quick set-up
- Full
7. Communications
8. Maintenance
9. Fault nding
10. Technical information
- Default settings
11. Appendix
- Summary of the
Modbus protocol
12. Menu map
OK
LC2650
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IM-P402-128 EMM Issue 7

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Safe operation of this product can only be guaranteed if it is properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11) in
compliance with the operating instructions. General installation and safety
instructions for pipeline and plant construction, as well as the proper use of tools
and safety equipment must also be complied with.
Your attention is drawn to IEE Regulations (BS 7671, EN 12953, EN 12952 and
EN 50156). Elsewhere, other regulations will normally apply.
All wiring materials and methods shall comply with relevant EN and IEC standards
where applicable.
Warning
This product is designed and constructed to withstand the forces encountered during
normal use. Use of the product other than as a boiler controller, or failure to install
the product in accordance with these Instructions, product modifications or repair
could:
-Cause injury or fatality to personnel.
-Cause damage to the product / property.
-Invalidate the marking.
These instructions must be stored in a safe place near the product installation at all
times.
Warning
This product complies with Electromagnetic Compatibility Directive 2014/30/EU and
all its requirements.
This product is suitable for Heavy Industrial Environments. A fully detailed EMC
assessment has been made and has the reference number UK Supply BH LC2650 2008.
The product may be exposed to interference above the limits of Heavy Industrial
Immunity if:
-The product or its wiring is located near a radio transmitter.
-Excessive electrical noise occurs on the mains supply. Power line protectors
(ac) should be installed if mains supply noise is likely. Protectors can combine
filtering, suppression, surge and spike arrestors.
-Cellular telephones and mobile radios may cause interference if used within
approximately 1 metre (39") of the product or its wiring. The actual separation
distance necessary will vary according to the surroundings of the installation
and the power of the transmitter.
This product complies with Low Voltage Directive 2014/35/EU by meeting the
standards of:
-EN 61010-1:2010 Safety requirements for electrical equipment for measurement,
control, and laboratory use.
1. Safety information

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Static precautions (ESD)
Static precautions must be observed at all times to avoid damage to the product.
Level control and level limiting products in steam boilers
Products / systems must be selected, installed, operated, and tested in accordance
with:
-Local or National standards and regulations.
-Guidance Notes, (Health and Safety Executive BG01 and INDG436 in GB).
-The requirements of Approvals Authorities.
-Boiler Inspection Bodies.
-Boiler manufacturer’s specifications.
Two independent low water limiting systems must be installed on steam boilers.
Level probes must be installed in separate protection tubes / chambers, with
sufficient clearance between the tips, and earth.
Each probe must be connected to an independent controller. The alarm relays must
isolate the boiler heat supply at low alarm status.
A high water alarm may be part of the water level control, or a separate system.
An independent high water alarm system must be fitted if it is considered a safety
requirement.
In this case, the relays must simultaneously isolate the feedwater supply and the
boiler heat supply at high alarm status. All boiler water limiters require regular
functional testing.
The level probe and controller is only part of the control system. To complete the
system, additional circuitry (wiring, relays, alarm bell / lamp etc.) is required.
A suitable water treatment regime must be used to ensure continuous safe and
correct operation of the control and limiter systems. Consult the above authorities
and a competent water treatment company.

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Symbols
Equipment protected throughout by double insulation or reinforced
insulation.
Functional earth (ground) terminal, to enable the product to function
correctly.
Not used to provide electrical safety.
Clean earth / ground.
Safety earth.
Caution, risk of electric shock.
Caution, risk of danger, refer to accompanying documentation.
Optically isolated current source or sink.
Caution, Electrostatic Discharge (ESD) sensitive circuit. Do not touch
or handle without proper electrostatic discharge precautions.
ac, alternating current.

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1.1 Intended use
i) Check that the product is suitable for use with the intended fluid.
ii) Check material suitability, pressure and temperature and their maximum and
minimum values. If the maximum operating limits of the product are lower than
those of the system in which it is being fitted, or if malfunction of the product
could result in a dangerous overpressure or overtemperature occurrence, ensure
a safety device is included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may
be induced by any system to which they are fitted. It is the responsibility of the
installer to consider these stresses and take adequate precautions to minimise
them.
v) Remove protection covers from all connections and protective film from all name-
plates, where appropriate, before installation on steam or other high temperature
applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some
previous time. Consider: flammable materials, substances hazardous to health,
extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive
noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off in a
gradual way to avoid system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of
closed valves. Do not assume that the system has depressurised even when the
pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.

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1.9 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables
available. Use only genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and / or others in the vicinity require any protective clothing
to protect against the hazards of, for example, chemicals, high / low temperature,
radiation, noise, falling objects, and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the
product according to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where
there is no such system, it is recommended that a responsible person should know
what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of large and / or heavy products may present a risk of injury. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account the
task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot.
Many products are not self-draining. Take due care when dismantling or removing
the product from an installation.
1.14 Freezing
Provision must be made to protect products which are not self-draining against
frost damage in environments where they may be exposed to temperatures below
freezing point.
1.15 Disposal
On disposal of the unit or component, appropriate precautions should be taken in
accordance with Local /National regulations.
Unless otherwise stated in the Installation and Maintenance Instructions this product
is recyclable and no ecological hazard is anticipated with its disposal providing due
care is taken.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment
Law, when returning products to Spirax Sarco they must provide information on any
hazards and the precautions to be taken due to contamination residues or mechanical
damage which may present a health, safety or environmental risk. This information
must be provided in writing including Health and Safety data sheets relating to any
substances identified as hazardous or potentially hazardous.

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2. User instructions and delivery
information
Certain computer programs contained in this product were developed by Spirax-Sarco
Limited ("the Work(s)").
Copyright © Spirax-Sarco Limited 2017
All rights reserved
Spirax-Sarco Limited grants the legal user of this product (or device) the right to
use the Work(s) solely within the scope of the legitimate operation of the product
(or device). No other right is granted under this licence. In particular and without
prejudice to the generality of the foregoing, the Work(s) may not be used, sold,
licensed, transferred, copied or reproduced in whole or in part or in any manner
or form other than as expressly granted here without the prior written consent of
Spirax-Sarco Limited.
2.1 General description
The Spirax Sarco LC2650 is a level controller for conductive liquids. It has two alarm
channels that can be independently configured high or low.
Warning: The minimum conductivity when used with the LP20, PA20 or PA420 is
5 μS / cm or 5 ppm.

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OK
LC2650
100
50
0
%
SP PV AL
Scroll down menus
Scroll up menus
Clears any errors or alarms
(Press and hold for
5 seconds)
Horizontal arrows are used to
toggle between the Bar graph
and the Trend graph
Graphic display
2.3 Using the buttons
The and buttons are used to:
- scroll up and down through the menus.
The and buttons are used to move between the Bar graph and the Trend graph
The OK button is used to clear errors or alarms (press and hold for five seconds).
Fig. 1 Front panel and keypad definitions
2.2 Front panel
The front panel has an LCD graphics display and five-button keypad.

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2.4 LCD display
The display is divided into three sections:
- Four large digits, displaying the process variable and control parameters.
- Information line. Displays the various control states and process units.
- Three bar graphs, which show a percentage of full scale (percentage of the gauge glass).
After initially applying power to the product, it will automatically enter its run mode. The current
level (PV) will be displayed.
Set point
Information line
Examples:
- Units
- Alarm state
Percentage scale
For bar graphs
10% steps
Alarm
Process variable (level %)
Fig. 2 Graphics display definitions - Bar graph mode
Parameter value
Example:
PV
(% current of gauge glass level)

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PV
AL
PV
AL
Fig. 3 PV (level %) bar graph definitions
Fig. 5 Alarms bar graph definitions
Highest process variable reached
This can be reset by entering the commissioning mode.
Lowest process variable
This can be reset by entering the commissioning mode
Current process variable
Graphical representation of the process variable in terms of
percentage of full scale.
High alarm level
Low alarm hysteresis
High alarm hysteresis
Low alarm level
SP
SP
High limit or top of proportional band
Low limit or bottom of proportional band
Set Point
Fig. 4 Set Point bar graph definitions

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Two element control - Split set point
The Split Set Point is visible only if a STEAM OFFSET percentage is selected in the INPUT
menu.
Fig. 6 Graphics display - Set Point raised to 65% - no steam meter compensation
100%
50%
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SP PV AL
PV has increased due to
sudden high steam demand
causing feedwater valve to
close.

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Fig. 7 Graphics display with steam meter compensation
100%
50%
0%
SP PV AL
A second display is superimposed on the SP graph to show the offset caused by the action
of the steam meter.
With no steam flow, the SP and control band will show a single display.
At 100% steam demand, the superimposed display will move up the column to the maximum
percentage set in the menu. The original SP will still be visible, to indicate the offset 2.
Set Point raised by steam
meter compensation
Original Set Point
Offset

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Trend screen
A trend graph appears if the button is pressed in run mode.
The and buttons are used to toggle between the run mode and trend graph.
The trend graph displays a record of the variation in level over a set time. The most recent
event / value is to the left of the graph.
Time can be set in minutes, hours or days, up to 8 units. Time base setting is carried out via
the TREND menu.
100%
50%
0%
M
Parameter value
Information line
Percentage scale
Timescale designator
M = Minutes
H = Hours
D = Days
Timebase markers
Minute or hour or day
PV% value now PV% value
8 minutes
(or hours or days ago)
Fig. 8 Graphics display definitions - Trend graph mode

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64
VALVE
64
OPENING
64
LEVEL%
ä
ä ä
If an alarm occurs, the pump or valve status will not show.
'ALARM' will be shown first followed by the type of alarm. See Section 9 - 'Fault finding' for
types of errors. The last information line is split into two.
Example of two low alarms:
64
ALARM
64
LOW LOW
64
LEVEL%
ä
ä ä
Alarm 1
status
Alarm 2
status
2.5 Information line
The information line will show level and will alternate with information about alarms and the
pump or valve status.
Example of valve status:

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2.6 View parameter mode
Press the button or downward button to view and step through the parameters selected.
Each parameter will remain on view for a further 2 minutes unless a button is pressed again.
After initially applying power to the product, it will automatically enter its run mode. The
current level (percentage) will be displayed. In run mode the general data is displayed on
several screens, which can be accessed by pressing the up or down buttons. The parameter
will appear on the display, alternating with the value. The controller is supplied with the
following default settings:-
LEVEL%
64
SP%
50
CTL BAND%
20
AL1 HIGH%
85
AL1 HYST%
5
Process Variable - the level, shown as a percentage of the gauge
glass.
The Set Point - as shown in commissioning mode. Normally 50%
of the gauge glass.
Sets the Proportional Band. This is the upper and lower limit
over which the valve operates. The proportional band is set as
a percentage of the gauge glass, with the Set Point being in the
middle.
Alarm 1 can be set as a HIGH or LOW water alarm. Its value is a
percentage of the gauge glass.
Shows the hysteresis selected for alarm 1. Its value is a
percentage of the gauge glass.

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AL1 DEL S
0
AL2 LOW%
20
AL2 HYST%
5
AL2 DEL S
0
OFFSET%
0
The display will always revert to displaying the current level percentage if a button has not
been pressed for 5 minutes.
Shows the delay in seconds (damping effect for turbulent
conditions), chosen for ALARM 1.
Alarm 2 is set to a LOW or HIGH water alarm. Its value is a
percentage of the gauge glass.
Shows the hysteresis selected for alarm 2. Its value is a
percentage of the gauge glass.
Shows the delay in seconds (damping effect for turbulent
conditions), chosen for ALARM 2.
Only shows if steam meter selected, (two element control). Shows
% offset of steam meter. Its value is a percentage of the gauge
glass.

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2.7 Alarm / Error display messages
If an error occurs, the details of the error or alarm will appear on a message screen, which
can be accessed by scrolling through the run menu. Pressing and holding the OK button for
3 seconds can clear a message and re-energize the alarm relay(s). If the cause has not been
corrected, the same message will reappear. If the error or alarm is of a latching type, only
the message will disappear. The alarm relay will remain de-energised until the correct pass
code is entered in the commissioning menu. If more than one error or alarm has occurred,
the next message will appear (in priority order) after the previous one has been cleared.
See Section 9 - 'Fault finding'.
2.8 Equipment delivery, handling and storage
Factory shipment
Prior to shipment, the product is tested, calibrated and inspected to ensure proper operation.
Receipt of shipment.
Each carton should be inspected at the time of delivery for possible external damage. Any
visible damage should be recorded immediately on the carrier’s copy of the delivery slip.
Each carton should be unpacked carefully and its contents checked for damage. If it is found
that some items have been damaged or are missing, notify Spirax Sarco immediately and
provide full details. In addition, damage must be reported to the carrier with a request for
their on-site inspection of the damaged item and its shipping carton.
Storage
If the product is to be stored for a period prior to installation, the environmental storage
conditions should be at a temperature between 0 °C and 65 °C (32 °F and 149 °F), and
between 10% and 90% relative humidity (non-condensing).
Before installing and connecting the power ensure there is no condensation within the unit.
Operators instructions
An alternative operator instruction manual, in place of this manual, for operating the equipment
is required. This will avoid the commissioning menu passcode being disclosed to the operator.
The alarm reset passcode may optionally be disclosed if this is deemed necessary.

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3.1 Function
The product compares the input signals with the Set Point to control the water level in the
boiler tank, or vessel, by operating a pump, valve, or solenoid.
On / off control
- Pump control.
- Two alarm outputs.
- 4 - 20 mA level retransmission output (isolated).
Note: A solenoid valve may be used instead of a pump.
Modulating control
Modulating valve control using valve motor drive (VMD) or 4 - 20 mA control signals:
- Two alarm outputs.
- 4 - 20 mA level retransmission output (isolated).
Two or three element modulating control
Modulating valve control using valve motor drive or 4 - 20 mA control signals:
- Two alarm outputs.
- 4 - 20 mA level output (isolated).
- Feedback from steam meter.
- Feed forward from water meter.
3.2 Inputs
The product has three inputs to accept the following signals:
- Level probe or transmitter 1-6 V or 4-20 mA outputs.
Note: The level probe must be long enough to sense over the complete level range.
- Steam meter 4-20 mA output to compensate for the rise in water level due to increased
steam demand (Two element control).
- A signal from a water meter to compensate for variations in feedwater flow rate (Three
element control).
3.3 Outputs
The product control signal can be configured / wired to work with a pump or a modulating
control valve. It also provides relay outputs for high and low level alarms and can provide an
isolated 0-20 mA or 4-20 mA retransmission output.
Parameters can be remotely accessed via the RS485 / MODBUS communications.
3. System overview

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3.4 Other features
An additional filter can be selected to increase the damping effect for turbulent conditions.
A test function provides the operator with a diagnostic feature. Inputs can be measured
and outputs can be set from the front panel.
To prevent unwanted or inadvertent changes being made, all commissioning parameters
are protected with a pass code. The commissioning Engineer can change this.
The product can communicate via an infra-red link between adjacent controllers (Spirax Sarco
Products only) - see Section 7 'Communications'.
3.5 Typical applications
Two element control (Figures 9 and 10)
When a sudden increase in steam demand occurs, boiler pressure will drop, and the steam
bubbles in the water will expand. This causes the water level to rise, and the feedwater
valve to close. Although the measured level of water has increased, the mass of water will
be decreasing, requiring the feedwater valve to open. A two element control system (probe /
controller and steam flowmeter) uses the output from the steam flowmeter to alter the control
action and prevent the valve closing, by increasing the Set Point.
Fig. 9 Two element control - electric valve
OK
LC2650
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50
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SP PV AL
Steam meter
Level probe
Motorised KE / EL valve
(with feedback potentiometer)