Spirax Sarco LCR2250 User manual

IM-P693-01 EMM Issue 2 1
LCR2250 Level Controller
LCR2250
Level Controller
Installation and Maintenance Instructions
IM-P693-01
EMM Issue 2
850143-01
1. Safety information
2. General product information
3. Mechanical installation
4. Electrical installation
5. Commissioning
6. Fault finding
7. Technical information
8. Technical assistance
© Copyright 2020
Printed in Germany

IM-P693-01 EMM Issue 2
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LCR2250 Level Controller
The equipment may only be installed, electrically connected and commissioned by suitable persons
with the relevant instruction/training.
Maintenance and modification may only be performed by authorised staff who have undergone
specific instruction/training.
Danger
The terminal strips of the equipment are live during operation! There is a risk of
serious injury due to electric shock!
Always cut off the power supply to the equipment before installing, removing or
connecting terminal strips!
Important
The name plate specifies the features of the equipment. Do not commission or operate
any item of equipment that does not have its own specific name plate.
Directives and standards
VdTÜV Bulletin "Wasserstand 100" (Water Level 100)
The LCR2250 level controller, in combination with the LP20/LP21/PA420 level transmitter, is type
approved to the VdTÜV Bulletin "Water Level 100".
The VdTÜV "Wasserstand (=Water Level) 100" describes the requirements for water level control
and limiting equipment for boilers.
LV (Low Voltage Directive) and EMC (Electromagnetic Compatibility)
The equipment conforms to the requirements of the Low Voltage Directive 2014/35/EU and the
EMC Directive 2014/30/EU.
ATEX (Atmosphère Explosible)
The equipment must not be used in potentially explosive atmospheres, in accordance with European
Directive 2014/34/EU.
1. Safety information

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LCR2250 Level Controller
2.1 Intended use
The LCR2250 level controller is used in combination with a LP20/LP21/PA420 level transmitter as a limit
switch and water level controller, e.g. in steam and water boiler systems, or in condensate and feedwater
tanks. The level controller indicates when a MIN or MAX water level has been reached, and opens or closes
a control valve.
2.2 Function
The LCR2250 level controller processes the level-dependent current signal from the LP20/LP21/PA420 level
transmitter. This input signal is recognised by the controller as 0 and 100 % of the boiler measuring range,
and shown as an actual value on the 7-segment LED display.
The level controller works with an electrically actuated control valve as a 3-position stepping controller
with proportional-plus-integral control action (PI controller). If the actual value deviates from the setpoint,
the electric actuator is triggered by two output contacts and two flashing LEDs indicate whether the control
valve is opening or closing.
The controller can be configured for fill or discharge control.
A further output contact indicates when a MIN or MAX water level is reached (the desired function can be
selected by a switch). After the de-energizing time has elapsed, the output contact switches over and the
MIN or MAX LED lights up.
Faults in the level transmitter, the electrical connection or the settings are indicated as error codes on the
7-segment LED display. In the event of a malfunction, the MIN and MAX alarm is triggered.
If faults occur only in the LCR2250 level controller, the MIN and MAX alarm is triggered and the system is
restarted.
Parameters can be changed or the MIN/MAX alarm simulated by operating the push buttons. For external
level indication, the LCR2250 level controller has a 4 - 20 mA actual value output.
2. General product information
Fig. 1

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LCR2250 Level Controller
3. Mechanical installation
3.1 Dimensions (approximate) in mm
12046
74
Item
1Upper terminal strip
2Lower terminal strip
3Housing
4Support rail TH 35, EN 60715
Fig. 2
3.2 Installation in control cabinet
The LCR2250 level controller is clipped onto a type TH 35, EN 60715 support rail in the control cabinet.
Fig. 2, Item 4.
4
1
2
3

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LCR2250 Level Controller
3.3 Name plates
Fig. 3
M 0,5A
LP20/ LP21/ PA420
4 W
+ +
1 2 3 4 5 6 7 8
OUT 4-20mA actual value
24 V ±20%
IN 4-20mA
+12V
LOOP- LOOP+
+
Type
designation
Top
Bottom
Safety information
Manufacturer
Degree of protection
External fuse for output contacts
Ambient temperature
Output
contacts
Supply voltage
Connection
of level
transmitter
Approvals
Disposal
information
Actual value output
Fuse, provided on site
Power consumption
Serial number

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LCR2250 Level Controller
1E
2
4. Electrical installation
4.1 Wiring diagram
0.5 A (semi- delay)
1 2
3 4
5
6
7
Item
1Output contact for control valve actuation
2MIN/MAX output contact, de-energizing delay 3 seconds
3Supply voltage connection 24 Vdc with semi-delay fuse 0.5 A provided on site
4Actual value output 4-20 mA
5Central earthing point (CEP) in control cabinet
6Earthing point at auxilliary equipment (e.g.PA420/LP20/LP21).
7Level transmitter LP20/LP21/PA420 4-20 mA.
Fig. 4
MIN/MAX
6

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LCR2250 Level Controller
4.2 Supply voltage connection
The equipment must be supplied with 24 Vdc from a SELV (Safety Extra Low Voltage ) power supply. An
external 0.5A semi-delay fuse must also be fitted.
This power supply unit must be electrically isolated from dangerous live voltages and meet the requirements
for double or reinforced insulation in accordance with one of the following standards:
EN 50178, EN 61010-1, EN 60730-1, EN 60950-1 or EN 62368-1.
4.3 Connection of output contacts
Wire the upper terminal strip 1 (terminals 16-23), shown in Figure 1, according to the desired switching
functions. Provide an external slow-blow 2.5 A fuse for the output contacts.
When inductive loads are switched off, voltage spikes are produced that may have a major adverse effect on
the operation of control and measuring systems. Connected inductive loads must therefore have interference
suppression (RC combination) as per the manufacturer's specifications.
4.4 Connecting the level transmitter
For connecting the equipment, please use a screened, multi-core control cable with a minimum conductor
size of 0.5 mm2, e.g. LiYCY 2 x 0.5 mm2, maximum length 100 m.
Wire the terminal strip as shown in the wiring diagram (Fig. 4).
Connect the screen as shown in the wiring diagram.
Route the connecting cable between items of equipment separately from power lines.
4.5 Connection of actual value output
For connection, please use a screened, multi-core control cable with a minimum conductor size of 0.5 mm2,
e.g. LiYCY 2 x 0.5 mm2, maximum length 100 m. Please note the load of max. 500 ohms.
Wire the terminal strip as shown in the wiring diagram (Fig. 4).
Connect the screen as shown in the wiring diagram (Fig. 4). Route the connecting cable between items of
equipment separately from power lines.
Any item of equipment that you wish to connect to the terminals for the actual value output 4-20 mA must be
certified to have at least double or reinforced insulation to EN 50178, EN 61010-1, EN 60730-1, EN 60950-1
or EN 62368-1 between the current loop and live parts of the equipment that are not supplied with safety
extra-low voltage (SELV).
Important
Do not use unused terminals as support point terminals.
4.6 Tools
Screwdriver size 3.5 x 100 mm, fully insulated to VDE 0680-1.

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LCR2250 Level Controller
4.7 Connection of level transmitter
The LCR2250 level controller can be combined with the LP20/LP21/PA420 level transmitter.
For connecting the equipment, please use a screened, multi-core control cable with a minimum conductor
size of 0.5 mm2, e.g. LiYCY 2 x 0.5 mm2, maximum length 100 m.
Connect the screen as shown in the wiring diagram (Fig. 4).
Important
-Please commission the equipment as described in the LP20/LP21/PA420
installation & operating manuals.
-Route the connecting cable between items of equipment separately from power
lines.

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LCR2250 Level Controller
5. Commissioning
5.1 Factory settings
-De-energizing delay: 3 sec. (factory set)
-Current input for the connection of an LP20/LP21/PA420 level transmitter.
-MAX switchpoint AL.Hi = 80 % or MIN switchpoint AL.Lo = 20 %
-Setpoint SP = 50 %
-Proportional band Pb = 20 % of setpoint
-Integral action time ti = 0 s
-Dead band = +/– 5 % of setpoint
-Valve travel time tt = 40 s
-Filter = 2 s
-Fill control function
-MIN/MAX output contact set as MAX alarm
Code switch C: S1 = OFF, S2 = OFF, S3 = ON, S4 = ON See Figure 5
5.2 Changing factory settings
Danger
The upper terminal strip of the equipment is live during operation. There is a risk of
serious injury due to electric shock!
Always cut off the power supply to the equipment before installing, removing or
connecting the terminal strip!

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LCR2250 Level Controller
5.3 Changing the function and input of the level transmitter
The input and function are determined by the setting of code switch c. To make changes, you can access
the code switch as follows:
-Switch off the supply voltage.
-Remove the lower terminal strip (Fig. 5).
-Insert a screwdriver between the terminal strip and the front frame, to the right and left of the arrow
markings.
-Release the terminal strip on the right and left sides, by turning the screwdriver in the direction of the arrow.
-Remove the terminal strip.
Fig. 5
When your changes are complete:
-Refit the lower terminal strip.
-Switch the supply voltage back on. The equipment restarts
C
C

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LCR2250 Level Controller
If you wish to change the input or the function, set code switch CS1 to S4 in accordance with Table 1 below.
Table 1
Code switch C
Toggle switch, white
Level controller LCR2250 S 1 S 2 S 3 S 4
Output contact set for MAX alarm OFF
Output contact set for MIN alarm ON
Not used. OFF
Input for connection of level transmitter LP20/LP21/PA420 * ON
Fill control OFF
Discharge control ON
Not used OFF
Not used ON
grey = factory setting
Important
* Set the upper and lower ends of the measuring range only in the transmitter.
Here, please pay attention to the LP20/LP21/PA420 Installation and Maintenance
Instructions.
Do not change the code switch C settings of S4!

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LCR2250 Level Controller
5.4 Meaning of codes on the 7-segment display
Valve open LED Amber Valve closes LED Amber
MIN LED red
7-segment display
MAX LED red
Push buttons
Fig. 6
Code Meaning
Indicated when up and down buttons are pressed:
AL.Hi Alarm High MAX switchpoint
adjustable between 0 and 100% measuring
range (see figure 7 opposite)
AL.Lo Alarm Low MIN switchpoint
SP Setpoint Setpoint
Pb Proportional band adjustable between 10 and 100 %
ti Time integral Integral action time, adjustable between 0 and 120 seconds
tt Motor travel time Valve travel time, adjustable between 10 and 600 seconds
tESt Test Tests output relays
FiLt Filter Used to dampen the effects of turbulent water level.
Indicated in parameterization mode
quit Confirm Input is not confirmed
done Done Input is confirmed
Indicated if malfunctions occur
E.005 Error Faulty level transmitter, measuring current too low
E.006 Error Faulty level transmitter, measuring current too high
E.013 Error MIN switchpoint higher than MAX switchpoint

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LCR2250 Level Controller
B
A
5.5 Setting the measuring range
Fig. 7 LP20/21 with a PA420 level transmitter.
Important
Set the upper and lower end of the measuring range only in the transmitter.
5.6 Additional information on control parameters
Parameter Control deviation Control valve
Proportional
band
Pb
Larger Large remaining deviation Responds slowly
Smaller Small remaining deviation Responds quickly and may continually
open/ close
Example
Measuring range 100% = 200 mm of sightglass
Setpoint SP = 80 % of measuring range = 160 mm
Proportional band Pb = +/- 20% of setpoint = +/- 16% = +/- 32 mm
If the measuring range is 100% (200 mm) and the setpoint is 80% (160 mm), the
proportional range will be +/- 16% (+/- 32 mm) or in the range of 128 to 192 mm.
Integral
action time
ti
Larger Slow correction of deviations Responds slowly
Smaller Fast correction of deviations, control
loop may tend to overshoot Responds quickly
A Lower end of measuring range, adjustable
B Upper end of measuring range, adjustable
C Measuring range [mm] = xxx %
D Maximum installed length at 238 °C
Set the lower and upper ends of the measuring range for your fill level
measurement. The result is the measuring range C.
There is always a 0-100% measuring range and these correspond to
a measuring range of xxx mm.
C
D
25 mm

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LCR2250 Level Controller
5.6 Setting parameters
Fig. 8
Start
Action Display Function
Switch on supply voltage.
Water level between MIN and MAX.
7-segment display shows software and
type of equimpent System test, takes approx. 3 sec.
7-segment display shows actual value System switches to operating mode
Setting parameters
Action 7-segment display Function
Press the up or down button until
desired parameter is shown
Display toggles between parameter
and saved value. Selecting the parameter
Press and hold the ok button First digit (0000) flashes. Parameterization mode active. You can
change the first digit.
Press the up or down button A new value is displayed.
Pressing the up button increases
the value, pressing the down button
reduces the value.
Briefly press ok button 2nd, 3rd or 4th digit flashes. (from right
to left)
2nd, 3rd or 4th digit can now be
changed using the up and down
buttons. Pressing the up button
increases the value, pressing the down
button reduces the value.
When your entries are complete:
press and hold the ok button within
3 sec.
done is displayed.
Next, the display toggles between the
parameter and the new saved value.
Input is confirmed. System switches
back to the parameter.
If you do not confirm your entry
within 3 sec. or you do not make any
further entries:
quit is briefly displayed.
After this, the display toggles between
the parameter and the old value.
If you do not confirm, your entries
will not be applied. Please repeat the
procedure. If you do not confirm, the
system switches back to the parameter.
Press the up or down button until the next parameter is shown.
Or press the up or down button until the actual value is displayed.
Or after 30s, the actual value is displayed automatically.
Valve open LED Amber Valve closes LED Amber
MIN LED red
7-segment display
MAX LED red
Push buttons

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LCR2250 Level Controller
5.7 Setting switchpoints and control parameters
Fig. 9
Setting the MIN/MAX switchpoints
Select parameter AL.Lo, enter and save the desired percentage. MIN switchpoint setting between 0-100 %
Select parameter AL.Hi, enter and save the desired percentage. MAX switchpoint setting between 0-100 %
Setting the setpoint
Select parameter SP, enter and save the desired percentage.
Setpoint setting between 0-100 %
Please take the settings for MIN/MAX switchpoints into
consideration.
Setting the proportional band
Select parameter Pb, enter and save the desired percentage. Proportional band setting between 10-100 %
Setting the integral action time
Select parameter ti, enter and save the desired percentage. Integral action time settings between 0-120 s.
Setting the valve travel time
Select parameter tt, enter and save the desired percentage. Integral action time settings between 10-600 s.
Setting the filter time
Select parameter FiLt, enter and save the desired time. Filter time. Select either 2, 4, 8 or 16 s.
Note
-The LCR2250 level controller is only equipped with one output contact for limit indications.
Therefore, please define its function (MAX or MIN alarm) using the code switch C.
(Fig. 5 and Table 1).
-The actual value is shown on the 7-segment display.
Valve open LED Amber Valve closes LED Amber
MIN LED red
7-segment display
MAX LED red
Push buttons

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LCR2250 Level Controller
5.8 Displays
Operation
Action Display Function
Actual value = setpoint Valve and MIN/ MAX LEDs do not
light up
Valve output contact 16/17/19 open.
MIN/MAX output contacts 21/23 open,
22/23 closed.
Value above or below setpoint
Value above or below setpoint.
Valve OPEN LED flashes amber Control valve opens, valve output
contact 16/19 closed.
or
Valve CLOSED LED flashes amber Control valve closes, valve output
Contact 17/19 closed.
MAX alarm
Switchpoint for MAX water level
reached or exceeded.
MAX LED flashes red De-energizing delay in progress.
MAX LED lights up red De-energizing delay elapsed, output
contacts 21/23 closed, 22/23 open.
or
MIN alarm
Switchpoint for MIN water level reached
or exceeded.
MIN LED flashes red De-energizing delay in progress.
MIN LED lights up red De-energizing delay elapsed, output
contacts 21/23 closed, 22/23 open.

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LCR2250 Level Controller
5.9 Check function of MIN/MAX output contacts
Test of MIN alarm and MAX alarm
Action Display Function
In operating mode:
Water level between MIN and MAX
Select parameter test. Press and hold
the ok button.
MAX LED flashes red De-energizing delay in progress.
MAX LED lights up red for 3 seconds MAX output contact 21/23 closed,
22/23 open, if selected.
The MIN and MAX LED do not light up
for 1 second
MIN/MAX output contact 21/23 open,
22/23 closed.
MIN LED flashes red De-energizing delay in progress.
MIN LED lights up red for 3 seconds MIN output contact 21/23 closed, 22/23
open, if selected
Test complete, release ok button.
Device switches to operating mode.
Note: If you continue holding the ok button, the test sequence will start again. You
can interrupt the test sequence at any time by releasing the ok button.
Press the up or down button until the actual value is displayed.
Or after 30 s, the actual value is displayed automatically.
Note
The actual value is shown on the 7-segment display.

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LCR2250 Level Controller
6. Fault finding
6.1 Display, diagnosis and troubleshooting
Important
Please check the following before fault diagnosis:
Supply voltage:
Is the level switch supplied with the voltage specified on the name plate?
Wiring:
Does the wiring conform to the wiring diagram?
Faults indicated by the 7-segment display
Fault code Fault Remedy
E.005 Faulty level transmitter, measuring current
< 4 mA
Check level transmitter and replace if necessary.
Check electrical connection.
E.006 Faulty level transmitter, measuring current
> 20 mA
Check level transmitter and replace if necessary.
Check electrical connection.
E.013 MIN switchpoint higher than MAX switch- point Re-adjust switching points
In the event of a malfunction, the MIN and MAX alarm is triggered.
Important
For further diagnosis, please refer to the LP20, LP21, and PA420 installation &
operating manual.
Note
In the event of a level controller malfunction, the MIN or MAX alarm is triggered and the
equipment restarts.
If the process is continually repeated, the equipment must be replaced.

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LCR2250 Level Controller
6.2 Action against high-frequency interference
High-frequency interference can be caused by out-of-phase switching operations. If such interference
occurs and results in sporadic failure, we recommend taking the following action to suppress interference:
-Provide inductive loads with RC combinations as per manufacturer's specifications.
-Route the connecting cable to the level transmitter separately from power lines.
-Increase the distance from sources of interference.
-Check the connection of the screen to the central earthing point (CEP) in the control cabinet and
auxilliary equipment.
-Suppress HF interference using hinged-shell ferrite rings.
6.3 Replacing/taking the equipment out of service
-Switch off the power supply and cut off power to the equipment.
-Remove the upper and lower terminal strips (Fig. 10).
-Insert a screwdriver between the terminal strip and the front frame, to the right and left of the arrow
markings.
-Release the terminal strip on the right and left sides, by turning the screwdriver in the direction of the
arrow.
-Remove the terminal strips.
-Release the white sliding fixture at the bottom of the housing and take the device off the support rail
Fig. 10
6.4 Disposal
The equipment must be disposed of in accordance with statutory waste disposal provisions.
In the event of faults that cannot be remedied with the aid of this
manual, please contact our Technical Customer Service.
C
C

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LCR2250 Level Controller
7. Technical information
Supply voltage 24 Vdc +/– 20%
Fuse External 0.5 A (semi-delay)
Power consumption 4 W
Connection of level transmitter 1 analogue input 4-20 mA, e.g. for LP20/LP21/PA420 level transmitter, 2 poles and
screen.
Supply voltage to level transmitter 12 Vdc/max. 20 mA
Outputs:
2 floating changeover contacts, 8 A 250 Vac/30 Vdc cos f= 1 (control valve open/
closed).
1 floating changeover contact, 8 A 250 Vac/30 Vdc cos f= 1.
De-energizing delay 3 seconds (MIN/MAX alarm, can be switched)
Inductive loads must have interference suppression (RC combination) as per the
manufacturer's specification.
1 analogue output 4-20 mA, max. load 500 ohms, e.g. for an actual value display.
Displays and controls
3 push-buttons for MIN/MAX alarm test and parameter setting,
1 4-digit 7-segment LED display, green
2 red LEDs for MIN/MAX alarm,
2 amber LEDs for control valve opening/closing
1 4-pole code switch for configuration.
Housing
Housing material, base: black polycarbonate; front: grey polycarbonate
Conductor size: 1 x 4.0 mm2solid, per wire, or
1 x 2.5 mm2per lead with sleeve to DIN 46228, or
2 x 1.5 mm2per lead with sleeve to DIN 46228 (min. 0.1 mm)
Terminal strips can be removed separately
Housing attachment: Mounting clip on support rail TH 35, EN 60715
Electrical safety Degree of contamination 2 for installation in control cabinet with degree of protection
IP 54, fully insulated
Degree of protection Housing: IP 40 to EN 60529 Terminal strip: IP 20 to EN 60529
Weight approx. 0.2 kg
Ambient temperature At moment of switch-on 0 ° to 55 °C
In operation –10 to 55 °C
Transport temperature –20 to +80 °C (<100 hours), only switch on after a defrosting period of 24 hours.
Storage temperature –20 to +70 °C, only switch on after a defrosting period of 24 hours.
Relative humidity max. 95%, no moisture condensation
Approvals:
TÜV Certificate VdTÜV Bulletin "Wasserstand 100" (Water Level 100):
Requirements for water level control and limiting equipment.
Type approval no.: TÜV · WR · XX-XXX (see name plate)
Contents of package
1 x Level controller LCR2250
1 x Installation and Maintenance Instructions