Quick Reference for End-Users. Lambda Transmitter LT2 Lambda Probe LS2. Sensors and Systems for Combustion Engineering

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1 Quick Reference for End-Users Lambda Transmitter LT2 Lambda Probe LS2 Sensors and Systems for Combustion Engineering

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3 Table of Contents Table of Contents 1 GENERAL INFORMATION Validity of these Instructions SAFETY German Law on Device Safety For Your Safety Explanation of the Symbols in the Safety Notes Proper Use - Conditions of Use Authorised Users Safety Facilities / Safety Measures Protection Against Emissions from Gas-carrying Channels Important Notes on Shutdown/Return to Service Environmental Protection, Waste Disposal OVERVIEW System Overview Brief Description TECHNICAL DESCRIPTION System Overview - Necessary Components Advantages of the Measurement Principle LT2 Lambda Transmitter LT2 Lambda Transmitter in Wall Mounting Case Probe Connection Box (PCB) Cold-start Delay Device Configuration and Factory Setting Options Display and Operating Unit Type 657 R Remote-display-software Calculation of Combustion Efficiency Type 657 R 0895 / R Calculation of CO2 Concentration Load-dependent and Fuel-specific Limit Values/Limit Curves Draught Measurement (Available on Request) Type 657 R Analogue Output (0/ ma, V) Digital Outputs Analogue Inputs BUS interface LAMTEC SYSTEM BUS (LSB) Jumpers, LED, Fuses and Terminals Function

4 Table of Contents 5.3 Wiring Example COMMISSIONING / SHUTDOWN Factory Settings Device Configuration Preliminary Works The LT2 Lambda Transmitter's Display and Operating Elements Monitor Output Internal Display and Operating Elements Measurement Start-up Install the Probe in the PIF and Align the GED, See Illustration: Setting up Service Warnings Shutdown OPERATION Operation / Measurement Value Display Measurement Value Commands Status Signals Operating Parameters General Instructions for Operation Measurement During Pronounced Pressure Surges at the Measuring Site Operational Failure, Switching On and Off Liquid Purification SERVICE AND MAINTENANCE Checking the O2 Probe Checking the Air Voltage Checking by Counter-measurement Checking the LT Checking the LT2's Measuring Input Checking the Probe's Internal Resistance Measurement Servicing Consumable FAULTS / WARNINGS Faults Warnings Resetting Faults / Warnings Faults - Causes and Solutions Warnings - Causes and Solutions

5 Table of Contents LS2 Internal Resistance too High Offset Voltage to Air Invalid Analogue Inputs 1 / 2 / 3 / 4 Input Value too Large/too Small Configuration Error at Analogue Outputs Service Warning 1 / Service Warning SPARE PARTS APPENDIX Technical data LT2 Lambda Transmitter Technical Data LS2 Lambda Probe Electric Connections Device Side Jumpers DIP Switch Fuses LT2 Power Electronic Type 657 R Wet/Dry Measurement Deviations, Conversion Table DECLARATION OF CONFORMITY

6 1 General Information 1 General Information 1.1 Validity of these Instructions What does these operating instruction describe? These operating instructions describe the LT2 Lambda transmitter with all the components necessary for O 2 measurements such as the LS2 Lambda probe, probe installation fitting etc. Accessories and special applications The accompanying documentation applies to accessories and special applications. If necessary, please contact the Walldorf works for any information required. These operating instructions serve to understand the LT2 Lambda transmitter's functions, assembly, installation and maintenance works and its operation. Other documentation, such as e.g. product data sheets, may contain further information but should never be used as a substitute for these instructions. CAUTION! Always read the operating instructions before starting work! Carefully observe all warning notes! Certain works, such as electric installation, presuppose special expertise. These works may only be carried out by personnel with the appropriate qualifications. See the chapter Authorised Users. Validity Our products undergo constant development. Equally, we make every effort to ensure that the operating instructions are accurate and customised for the individual application. Previous editions become void as soon as a supplemented and amended new edition is issued. On the last page you will find the current version number of these operating instructions and the associated ordering number. 5

7 2 Safety 2 Safety 2.1 German Law on Device Safety The German Law on Device Safety regulates the following: Note the instructions for use! Use the device only in compliance with the instructions, which are contained in this document for LT2 (publication no. DLT aEN-034). If this document is a supplement, use it only in combination with the basic manuals. Use the devices only for the purpose described in this documentation. Used by trained personnel only. Only persons whose knowledge and training qualifies them to do so, are allowed to operate and service the device. Note the safety provisions of the burner manufacturer. To be used only in a grounded power line network! Electrical connection with devices that are not mentioned in this operating instructions - only after consultation with the manufactorers or an authorized expert. Liability for the function of the device shall be transferred to the owner or user. Liability for the function of the device shall be borne by the owner or user insofar as the device has been used by persons without the necessary knowledge, has been improperly used, serviced or repaired or has been handled in a manner that does not conform to proper use. Modifications to the device render the type approval null and void. Inputs and outputs of the device and associated modules may only be connected as indicated in this manual. LAMTEC GmbH & Co. KG is not liable for damages occurring as a result of non-compliance with the above instructions. Compliance with the above instructions shall not entail any extension to the warranty and liability provisions of LAMTEC GmbH & Co. KG's terms of sale and delivery. Insofar as reference is made to laws, regulations and standards, the basis for these shall be the law of the Federal Republic of Germany. 6

8 2 Safety 2.2 For Your Safety Explanation of the Symbols in the Safety Notes The following symbols are used in these operating instructions as important safety notes for the user. They appear within each chapter where the information is required. The safety notes, in particular the warnings, must always be observed and followed. DANGER! Identifies possible hazards to personnel, especially through electric power. WARNING! Indicates possible hazards to personnel caused by improper handling of system parts. CAUTION! Indicates risk to system parts or a possible adverse effect on functions. NOTICE! Contains important additional information for the user about the system or system parts, and offers further tips. Appears in texts containing instructions for carrying out an action. In this context the user is urged to observe the statutory accident prevention measures during all works, and to do everything in accordance with the situation to prevent damage to persons and property. 7

9 2 Safety Proper Use - Conditions of Use Authorised Users Application The LT2 Lambda transmitter is an O 2 measuring instrument for the continuous measurement of O 2 concentration in non-combustible gases in the super-stoichiometric domain, in conjunction with the LT2 Lambda probe. If the system is to be used in some other way, and if the instrument's functionality in this application cannot be unambiguously assessed, the manufacturer should be contacted in advance. Prerequisites It is assumed that facility planning, assembly, installation, commissioning, maintenance and service works are carried out by sufficiently trained personnel, and these works are supervised by qualified specialists. Correct handling Special attention must be paid to the following: The application must conform to the technical data and the specifications regarding authorised use, assembly, connection, environmental and operational conditions (derived from the job documentation, the instrument's user information, rating plates etc), and to the documentation supplied. The local regulations and facility-specific and technical hazards must be noted and followed. All steps necessary to protect the equipment, e.g. during transport, storage, maintenance and inspection, should be carried out. Qualified personnel Those responsible for safety must always ensure that only qualified personnel carry out work on system parts. Qualified personnel have been authorised by those responsible for maintaining the safety of employees and that of the facility, to perform such activities as a result of their training, experience or familiarity with the relevant Standards, regulations, accident prevention measures and local conditions. The important factor is that such personnel are able to identify and prevent possible hazards in good time. Specialist personnel are those meeting DIN VDE 0105 or IEC 364, or directly comparable Standards such as DIN these personnel have the supplied operating instructions and the associated, job-related documentation available to them during all works, and observe these documents in order to avoid hazards and damage. 8

10 2 Safety User groups Two user groups are assumed to handle the LT2 Lambda transmitter: a Operators, the customer's installers, measurement/control/electric/electronic technicians - have elementary knowledge of the instrument. b Service technicians of LAMTEC or their OEM customers, or the customer's trained personnel: qualified technicians/engineers - have very good knowledge of the instrument. c Operating personnel with basic knowledge access level "OPERATION SERVICE" - without password Safety Facilities / Safety Measures Hazards from electric equipment The LT2 s system parts are items of equipment designed to be used in industrial high-current facilities. When working on parts connected to the supply or carrying supply voltage, disconnect from the supply and ensure zero voltage. Re-install all machine guards before reconnecting to the supply. Damage to health or to property may result from improper use or incorrect handling. To prevent damage, observe the appropriate safety notes. Preventive measures for improving operating safety Where the LT2 is used as a sensor in conjunction with regulating or control systems, it is the operator's responsibility to ensure that LT2 failure or faults cannot lead to dangerous situations or those that cause unacceptable damage. In order to prevent faults, which in turn could cause direct or indirect damage to personnel or to property, the operator must ensure that the appointed maintenance personnel can be notified at any time and as soon as possible, the maintenance personnel are trained to respond correctly to LT2 faults and associated operational faults in the event of doubt, the affected equipment is immediately switched off switching off does not lead to direct consequential faults CAUTION! In risk of a shortfall below the dew point in the gas channel, you must heat the gas extraction device (MEV) and eventually the preliminary filter electrically. Prevention of consequential damage To prevent consequential damage in the event of instrument faults, which in turn could cause direct or indirect damage to personnel or property, ensure that qualified personnel assess the faults and initiate appropriate steps Protection Against Emissions from Gas-carrying Channels The LT2 Lambda transmitter is directly attached to the gas-carrying channel, via the probe installation fitting (SEA). If the LT2 Lambda probe or the SEA installation fitting are dismantled; then depending on the facility and particularly in the event of excess pressure, aggressive and/ or hot gas may be emitted from the channel and cause severe health damage to unprotected operatives, unless suitable protective measures have previously been put into place. 9

11 2 Safety WARNING! In the event of excess pressure and temperatures above 200 C in the gas channel, dismantling the LT2 Lambda probe or the installation fitting lead to the emission of gases. - Switch off the facility before opening. If this is not possible, wear protective clothing and a protective mask. - Put up appropriate warning signs near the installation site. - Close the aperture at once. You can get adequate sealing flanges, (blind flang) as an accessory Important Notes on Shutdown/Return to Service The LT2 Lambda transmitter and the LS2 Lambda probe form a high quality electronic measurement system. Treat them with care at all times, including during shutdown, transport and storage. Shutdown CAUTION! Do not switch the LT2 Lambda transmitter off as long as the LS2 Lambda probe is mounted; including when the relevant facility has been shut down. Residual gases cause corrosion and may damage system parts. Do not store the instruments outdoors without protection! Always store in a dry place, if possible in the original packaging. When dismantling, protect cable ends and plugs against corrosion and dirt. Corroded plugs may cause malfunction. If possible, transport in the original packaging. Return to service According to chapter 6 Commissioning / Shutdown Environmental Protection, Waste Disposal The LT2 Lambda transmitter's construction is also based on environmental considerations. The modules can easily be separated and sorted into distinct types, and recycled accordingly. 10

12 3 Overview 3 Overview 3.1 System Overview The LT2 Lambda Transmitter is a universal, microprocessor-based measuring device for directly measuring the O 2 concentration in the super-stoichiometric range (λ > 1) in combination with the proven Lambda probe LS2. The Combination Probe KS 1 can be connected for measuring combustible gas constituents (CO/H 2 ). Fig. 3-1 System overview LT2 Lambda Transmitter 11

13 3 Overview Fig. 3-2 System overview - LT2 Lambda Transmitter input / output modules 12

14 3 Overview 3.2 Brief Description Universal O 2 measuring instrument, based on the LS2 Lambda probe (zirconium dioxide voltage probe), for the direct continuous measurement and monitoring of oil (EL) and gas combustion systems in the super-stoichiometric domain ( > 1)without special gas purification. Fig. 3-3 LT2 Lambda Transmitter wall-mounting housing IP x 300 x 150 mm (H x B x T) type 657 R 1025 Fig. 3-4 LT2 Lambda Transmitter on mounting plate 173 x 310 x 270 mm (H x B x T) type 657 R 1030 Fig. 3-5 Lambda Transmitter LT2 panel installation 3HE, 50HE 173 x 310 x 270 mm (H x B x T) type 657 R 1040 Fig. 3-6 Lambda Sonde LS2, Type 650 R 1000 with gas extraction device (MEV) type 655 R R 1003 and probe installation fitting (PIF) type 655 R

15 4 Technical Description 4 Technical Description 4.1 System Overview - Necessary Components The O 2 measurement system is available in various versions.it consists of the following components: LT2 Lambda probe Gas extraction device (GED) Probe installation fitting (PIF) Probe connection box (PCB) LT2 Lambda Transmitter in IP 54 wall-mounted housing alternatively - on mounting plate - panel installation housing including display and operating unit M measuring gas 300 C max. 1 plug 2 probe signal 3 Lambda Probe LS2, Type 6 50 R gas extraction device (GED) 5 half-collar R11/4, type 6 55 R probe installation fitting (PIF), Type 6 55 R probe heater 8 probe connection box (PCB), Type 6 55 R 1025 (optional) 9 display and operating unit, Type 6 57 R

16 4 Technical Description 10 LT2 Lambda Transmitter panel installation 3 HE, 50 TE 173 x 310 x 280 mm (h x w x d) type 657 R LT2 Lambda Transmitter in IP 54 wall-mounted housing type 657 R 1025, sheet steel, 400 x 300 x 150 mm (h x w x d) with display and operating unit 13 LT2 Lambda Transmitter on mounting plate 350x258x132 (HxBxT) type 657 R Advantages of the Measurement Principle No gas treatment needed, measurement directly in the humid flue gas Setting time at 90%-value (T 90 ) < 20 seconds measuring gas temperature up to 300 C low heating power Watt depending on the state of aging of the zirconium dioxid sensor universal applycable easy application low-maintenance 15

17 4 Technical Description 4.2 LT2 Lambda Transmitter LT2 Lambda Transmitter in Wall Mounting Case 1 Display and operating unit 2 Probe and electronics transformer 3 Connection for Remote-Display- Software (Option) 4 Connecting cable with plug for display and operating unit 5 Electrical connections 6 BUS-interface alternative LAMTEC SYSTEM BUS (CAN BUS) 7 Operating mode display multifunction push button maintenance switch 8 Protective earth terminal for cable screening 9 Monitor output 10 Mains connection (plug) 11 Terminal bar x 2 12 Relay module type 660 R 0017 Fig. 4-1 LT2 Lambda Transmitter in wall-mounting housing type 657 R 1025 with display and operating unit type 657 R 0831 Accessible after removing the front panel with the main switch ("POWER ) Fig. 4-2 Change over power supply voltage 16

18 4 Technical Description Probe Connection Box (PCB) For use at large distances between probe and analyser, where no customised cable is employed. Input: Probe plug Output: Terminal strip The PCB contains a terminal strip and conversion to the probe and heating plugs. Fig. 4-3 PCB-Dimension diagram high: 40 mm protection class: IP55 Fig. 4-4 PCB-Connection diagram 33 Probe signal - 34 Probe signal + 35 Probe heater 13V DC 36 Probe heater 13V DC NOTICE! Keep the distance to the PCB as short as possible. Avoid distances of more than 450 mm if possible. 4.3 Cold-start Delay Serves to suppress false measurements while the probe warms up to operating temperature. Cold-start delay is always activated after "Power off and probe replacement. The cold-start delay can be aborted at any time via the multifunction key via the optional display and operating unit, see separate publication via Remote-Display-Software, see separate publication During the cold-start delay, either a substitute value (factory setting), O 2 0 Vol.% (P361) You can set the type of the substitute value for O 2 in P362: OFF: No output of the substitute value ON: Output of the substitute value of the preceding parameter. 17

19 4 Technical Description +Maintenance: (factory setting): Output of the substitute value of the preceding parameter, even in maintenance mode. +Maint.freeze: Output of the substitute value of the preceding parameter in the case of cold start or error as hitherto. Additionally the preceding measurement value is freezed, as long as maintenance mode is active. The substitute value during cold start/error takes priority over the freezing of the measurement value during maintenance.frozen After a pre-heating period of 10 minutes the probe voltage stabilises to a value between mV and the AC inner resistance to a value below Device Configuration and Factory Setting You can derive the device's variant from the variant number. You will find the variant number on the type plate. The variant number is constructed according to the following key: Serial Number Example: LT2 in variant No.: LS2 1S a1 b0 c11 c21 c31 c40 d15 d25 d30 d40 e00 f4 g1 i0 k0 m1 n0 oe z0 LT2: LS2 1S a1 b0 c11 c21 c31 c40 d15 d25 d30 d40 e00 f4 g1 i0 k0 m1 n0 oe z : For probe KS1 configurated for CO-probe KS1 KS1D configurated for Combination probe KS1D LS2 configurated for Lambda probe LS2 2: Type 1S Standard type 2OEM OEM type 3a For probe with bypass and purge unit 3K For probe type "K - semi automatic calibration" 4KA For probe type "KA - semi automatic calibration and purge" 5KV For probe type "KV - full automatic calibration" 6KVA For probe type "KVA - full automatic calibration and purge" 6KVZ For probe type "KV-full automatic calibration and regeneration cyclic" 7EX1 For probe type "EX-area 1" 8EX2 For probe type "EX-area 2" 9E For probe type "HT - ejector extraction" 18

20 4 Technical Description 3: Display a0 without a1 with Display and operating unit 657R0831/33 a2 with Display and operating unit 657R0833RBT 4: Pressure sensor b1 with absolute pressure and differential pressure b2 with differential pressure sensor b3 with pressure sensor for draught measurement 5: Analogue output 1 c11 Analogue output 1 currrent mA 657R0050 c12 Analogue output 1 currrent mA 657R0050 c13 Analogue output 1 voltage V 657R0050 c14 Analogue output 1 currrent mA floating 657R0054 c15 Analogue output 1 currrent mA floating 657R0054REG c16 Analogue output 1 currrent mA floating 657R0054 c17 Analogue output 1 voltage V floating 657R0054 c18 Analogue output 1 ejector control 657R0050E c19 Analogue output 1 currrent mA electrically isolated 657R0053 6: Analogue output 2 c21 Analogue output 2 currrent mA 657R0050 c22 Analogue output 2 currrent mA 657R0050 c23 Analogue output 2 voltage V 657R0050 c24 Analogue output 2 currrent mA floating 657R0051 c25 Analogue output 2 currrent mA floating 657R0051REG c26 Analogue output 2 currrent mA floating 657R0051 c27 Analogue output 2 voltage V floating 657R0051 c28 Analogue output 2 ejector control 657R0050E c29 Analogue output 2 currrent mA electrically isolated 657R0053 7: Analogue output 3 c31 Analogue output 3 currrent mA 657R0050 c32 Analogue output 3 currrent mA 657R0050 c33 Analogue output 3 voltage V 657R0050 c34 Analogue output 3 currrent mA floating 657R0051 c35 Analogue output 3 currrent mA floating 657R0051REG c36 Analogue output 3 currrent mA floating 657R0051 c37 Analogue output 3 voltage V floating 657R0051 c38 Analogue output 3 ejector control 657R0050E c39 Analogue output 3 currrent mA electrically isolated 657R

21 4 Technical Description 8: Analogue output 4 c41 Analogue output 4 currrent mA 657R0050 c42 Analogue output 4 currrent mA 657R0050 c43 Analogue output 4 voltage V 657R0050 c44 Analogue output 4 currrent mA floating 657R0051 c45 Analogue output 4 currrent mA floating 657R0051REG c46 Analogue output 4 currrent mA floating 657R0051 c47 Analogue output 4 voltage V floating 657R0051 c48 Analogue output 4 ejector control 657R0050E c49 Analogue output 4 currrent mA electrically isolated 657R0053 9: Analogue input 1 d11 Analogue input 1 potentiometer kohm d12 Analogue input 1 currrent 0/4...20mA passive d13 Analogue input 1 voltage mV (EX1) d14 Analogue input 1 pulse (RPM) d15 Analogue input 1 temperature PT C d16 Analogue input 1 temperature PT C d17 Analogue input 1 currrent 0/4...20mA active (24V supply) d18 Analogue input 1 differential pressure d19 Analogue input 1 voltage mV (KS1-D) 10: Analogue input 2 d21 Analogue input 2 potentiometer kohm d22 Analogue input 2 currrent 0/4...20mA passive d23 Analogue input 2 voltage mv (EX1) d24 Analogue input 2 pulse (RPM) d25 Analogue input 2 temperature PT C d26 Analogue input 2 temperature PT C d27 Analogue input 2 currrent 0/4...20mA active (24V supply) d28 Analogue input 2 absolute pressure d29 Analogue input 2 voltage V 11: Analogue input 3 d31 Analogue input 3 potentiometer kohm d32 Analogue input 3 current 0/4...20mA passive d33 Analogue input 3 voltage mV EX1 d34 Analogue input 3 pulse (RPM) d35 Analogue input 3 temperature PT C d36 Analogue input 3 temperature PT C d37 Analogue input 3 current 0/4...20mA active (24V supply) d38 Analogue input 3 differential pressure d39 Analogue input 3 voltage V 20

22 4 Technical Description 12: Analogue input 4 d41 Analogue input 4 potentiometer kohm d42 Analogue input 4 current 0/ ma passive d43 Analogue input 4 voltage mV EX1 d44 Analogue input 4 pulse (RPM) d45 Analogue input 4 temperature PT C d46 Analogue input 4 temperature PT C d47 Analogue input 4current 0/4...20mA Active (24V supply) d48 Analogue input 4 absolute pressure d49 Analogue input 4 voltage V 13: RM/LI/Controller/Load e30 Relay module 657R0857 e31 Load dep. limit values, load def. LSB and relay module 657R0922 e32 Load dep. limit values, load def. poti and relay module 657R0922/PO e33 Load dep. limit values, load def. current. and relay module 657R0922/ST e34 O 2 -controller (PID), load def. LSB and relay module 657R1120 e35 O 2 -controller PID, load def. poti and relay module 657R1120/PO e36 O 2 -controllerr PID, load def. current. and relay module 657R1120/ST e37 Speed depended O 2 -controller, load def. LSB and relay module 657R1123 e38 Speed depended O 2 -controller, load def. LSB and relay module 657R1123/ PO e39 Speed depended O 2 -controller, load def. current and relay module 657R1123/ST e40 Output of "burner-firing rate" at analogue output 657R : Efficiency calculation f1 Efficiency calculation (fixed ambient temperature) 657R0896 f2 Efficiency calculation 657R0895 f3 Temperature measurement / 850 C f4 Efficiency calculation incl. 2x PT100-sensors and analogue output 657R0917 f5 Efficiency calculation incl. 2x PT100-sensors 699R0895 f6 Efficiency calculation incl. 1x PT100-sensors 699R : Supply voltage g1 Supply voltage 230VAC g2 Supply voltage 115VAC 16: Reference air pump i1 Pump unit for reference air 230VAC 657R1060 i3 Pump unit for reference air 115VAC 657R : Case heating k1 Housing heating 230VAC / 120W 657R

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