This manual is valid for the burner control system BurnerTronic BT300 in any configuration.
The information contained in this document refer to the software versions BT300 v 3.0.0.0 and
v 3.1 and UI300 v 3.1. If you use any other software version as mentioned previously some of
the described functions may not be available or some available functions are not described in
this manual.
1.2Life Cycle
BurnerTronic BT300 burner management system has a designed lifetime * of 250,000 burner
start-up cycles, which, under normal operating conditions in heating mode, correspond to approx. 10 years of usage (starting from the production date given on the type plate).
This lifetime is based on the endurance tests specified in standard EN230/EN298 and the table containing the relevant test documentation as published by the European Association of
Component Manufacturers (Afecor) (www.afecor.org).
The designed lifetime is based on use of BT300 according to the manufacturer’s basic documentation. After reaching designed lifetime in terms of number of burner start-up cycles, or
the respective time of usage, the BT300 must be replaced by authorized personnel.
1.3Disposal Notes
The unit contains electrical and electronic components and must not be disposed of
together with household waste. Observe local and currently valid legislation.
*
The designed lifetime is not the warranty time specified in the Terms of Delivery
4
2 Safety
2Safety
2.1German 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 BT300 (publication no. DLT1206-13-aEN-008).
Use the device 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 regulations of the burner manufacturer.
To be used in a grounded power line network only!
Electrical connection with devices not mentioned in this manual - only after direct inquiry to
the manufacturer 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 with type approval 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 ex-tension 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.
5
2 Safety
2.2Safety Instructions - Common Information
The following symbols are used in this document to draw the user's attention to important safety information. They are located within the chapter where the information is required. It is essential that the safety information is adhered to, and that applies, in particular, 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 or something in 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 or something in 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 or something in 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.
In this connection, the operator is requested to:
1Comply with the accident prevention regulations whenever work is being carried out.
2Do everything possible in the circumstances to prevent personal injury and damage to
property.
6
3 For Your Safety
3For Your Safety
Please observe the safety instructions to avoid personal injury and damage to property and
the environment!
The BT300 is a safety device! The device must not be opened, interfered with or modified.
LAMTEC assumes no liability for damages arising as a result of unauthorised interference!
•After commissioning and after each maintenance action check the exhaust gas values
across the entire power range.
•Qualified specialist staff are required to carry out all activities (assembly, installation, servicing, etc.).
•The burner or boiler manufacturer will ensure that the BT300 base unit is compliant with
protection class IP40 or IP54 for outdoor use in accordance with DIN EN 60 529.
•Before working in the connection area, switch off the power supply to the plant from all
poles. Ensure that it cannot be switched back on and that the plant is voltage-free. There
is a risk of electric shock when the plant is not switched off.
•Place and secure the protection against contact on the BT300 and on all connected electrical parts. The cover must fulfil the design, stability and protection requirements of
EN 60730.
•Plug connectors X30 - X34 have no protective separation from the mains voltage. To replace or disconnect the plug connectors, all poles of the plant must be disconnected from
the mains.
•After each activity (e.g. assembly, installation, servicing, etc.) check the wiring and
parameterisation to make sure it is in good working condition.
•If the equipment is dropped or suffers impact, you should no longer commission it. The
safety functions may also be impaired but fail to show any obvious external damage.
•When the ratio curves are being programmed, the adjuster will continually monitor the
quality of the plant's combustion (e.g. using an exhaust gas analysis station). In the event
that the combustion values are inadequate or the conditions are potentially harmful, the
adjuster will take suitable action, e.g. switch off the system manually.
•These operating instructions describe many possible applications and functions and
should be used as guidelines. Carry out functional tests on the test bench and/or in the
plant application to ensure correct functioning and document the results.
Follow additional instructions to guarantee safety and reliability while operating the BT300:
•Condensation and humidity are to be avoided. If necessary, make sure that the installation
is sufficiently dry before you switch it on.
•Avoid static charge having a destructive effect in case of touching the device's electronic
components.
NOTICE!
LAMTEC recommends that you use ESD equipment while working on electrics/electronics.
3.1Mounting Notes
•Please consider protection against contact when installing the BT300. Protection classes
as IP 40 - IP 54 are minimum requirements for outdoor use in accordance with EN 60529
and therefore obligatory.
•The protective cover of the BurnerTronic may only be opened by trained, qualified personnel.
•Make sure that settings for safety-relevant parameters are set in line with the requirements
applicable to each type of combustion requiring monitoring and conform to the applicable
7
3 For Your Safety
standards (by checking device parameters via operating elements or using remote-control
software after commissioning). To verify settings you should also refer to manufacturer’s
documentation of the combustion plant. Protecting the parameters in level 1 by setting a
password will prevent any unauthorised change.
•Save setting values for the actuating elements across the power range of the burner as
follows:
–Quantity of fuel
–Quantity of air
–All additional, safety-relevant actuating variables of the combustion
–While burner is modulating with at least five different firing-rate points
•Make sure that the combustion equipment operates stably and safely throughout the power range and in all combustion modes. For this purpose you should adjust the following
values correctly:
–Actuating elements
–Parameter settings of the CO/O
–Combustion chamber pressure
–Fuel pressure
–Temperature
–Pressure of combustion air
–Heating value of fuel
•Ensure the connection between the actuators and control valves is form-fit throughout,
gearing this towards the maximum controlling torques of the actuators.
•Only use external flame monitors compliant with DIN EN 298 or DIN EN 230 and authorised for continuous operation. Safety time of flame monitor must not extend 1 s.
•If the valve testing system is activated, connect the supply-side solenoid valve to terminal
X01 and the burner-side solenoid valve to terminal X02. Connect the pressure monitor of
the valve testing system to terminal X05. Adjust the gas pressure monitor and the dimensions of the test section in order to make sure that the valve testing system is detecting a
maximum leakage gas volume of 0.1 % in relation to the gas flow rate (minimum 50 dm³/
h) at maximum combustion heat output.
•Consider the potential danger depending on installation situation and position where thepressure equipment is being installed. Bear in mind the risk of external fire and the impact
from traffic, wind and earthquake.
•When fixing duomodul plug-in connectors to insulation displacement technology (IDT) use
HZ-M35 a modular crimping tool from Lumberg (see www.lumberg.com).
controller
2
3.2Security Advice - Mounting
•Compliance with national safety regulations and standards is obligatory at all times.
•During the assembly and installation process, you must meet the requirements of standards DIN VDE 0100, 0550 and DIN VDE 0722
•To mount the BT300 basic unit, use screw fittings with an M4 thread (UNC32) or an M5
thread (UNC24) and a maximum tightening torque of 1.8 Nm for fastening at all four fixing
points. Keep in mind that housings have improved mechanical stability when connected
on surrounding contact surfaces.
Connect generally to an even mounting surface.
8
3 For Your Safety
3.3Installation Notes
•Lay high-voltage ignition cable always separately and in safe distance from device and
other cables.
•Only trained, qualified personnel may open the BurnerTronic’s cover.
•Observe local and national regulations when wiring the electric cables inside the burner.
•Tighten the screw terminals of the BT300 using a tightening torque of > 0.5 Nm.
•Supply the feed cable with L, N and PE only. The N neutral conductor must not have potential difference to the PE protective conductor.
•The pre-fuse for the BT300 should be max.10 A slow-blow.
•Phase, neutral and central point conductors must not be interchanged (this would lead to
dangerous malfunctioning, loss of protection against contact, etc.).
•The strain relief for the connected cables must comply with standards (e.g. DIN EN 60730
and DIN EN 60335).
•Make sure that no spliced strands can come into contact with any of the adjacent connections. Use appropriate end sleeves.
•The burner manufacturer is obligated to supply unused connections on the BT300 with
dummy plugs.
•To replace or disconnect the plug connectors, all poles of the plant must be disconnected
from the mains.
•Make a form-fit connection between the actuators and actuating elements for fuel and
combustion air, as well as a form-fit connection for any additional actuator element.
•Optional components with safety extra low voltage (SELV) must be safely separated from
the mains. Otherwise this can cause an electrical shock or damage the device due to a
short-circuit.
•You may connect only passive devices or devices without feedback effects at the 230V
outputs of the BT300 (like relays without additional voltage connection). In case of error it
must be guaranteed that BT300 is not feeded with 230 V by this terminals.
3.4Electrical Connection Flame Sensor
Interruptions and losses in signal transmission need to be minimised:
•Do not wire the sensor cable with other cables.
Flame signal is reduced through line capacities. Use a separate cable.
•Consider the permitted length of sensor cables.
•The ionisation flame sensor supplied from the mains is not protected against contact. Protection against accidental contact is therefore obligatory.
•Earth the burner according to instructions – earthing the boiler itself is not sufficient!
•Position ignition electrode and ionisation flame sensor where spark cannot hit ionisation
flame sensor (risk of electrical overloading).
9
3 For Your Safety
3.5Commissioning Notes
•Check all safety functions during commissioning!
•There is no feature to prevent RASTx connector plugs being transposed. Therefore ensure the correct assignment of the plant's plugs prior to commissioning.
•Check electromagnetic emissions specific to the application.
•While installing and commissioning the plant, the person in charge of the plant/heating
technician needs to document the following:
–Parameterised values
–Setting values (e.g. curve progressions)
–Values describing the fuel/air ratio control.
This data can be printed using LSB remote software or alternatively being kept as a hand-
written note.
Retain this documentation and have it checked by the "authority on the subject".
WARNING!
For BT300 parameterisations which deviate from the application standards can be carried out
in access level 2. For this reason, check whether the parameterisation is consistent with the
corresponding application standards (e.g. EN 298, EN 230, EN 676, EN 267, etc.) or the respective plant has to be approved separately.
WARNING!
While unlocking the safety interlock chain in the mode "BURNER OFF" BT300does not lock
the system. BT300 prevents a burner start-up until safety interlock chains are locked.
In case your application needs an interlock of the plant while unlocking the safety interlock
chain also in "BURNER OFF" mode you must take suitable measures at the plant.
3.5.1Fuel/Air Ratio Control
•Guarantee proper operation by ensuring adequate excess air.
In order to do this, set values for fuel and combustion air in such as
–combustion chamber pressure
–fuel pressure
–temperature and the pressure of the combustion air
to ensure proper operation through the entire range of burner firing-rate until next periodic
inspection.
•Pay attention to wear and tear of actuators and actuator elements.
•Measure characteristic values of combustion process to document proper operation.
10
3 For Your Safety
3.5.2Basic Device
Check the following items prior to commissioning:
•Valves must be assigned correctly to valve outputs on BT300.
•Correct setting of time parameters (especially safety and pre-ventilation times).
•Flame sensor functioning well in case of flame blow-off during operation (incl. flame-out
response time) or when parasitic light is present during pre-ventilation period and also at
a missing flame formation while end of safety period starts.
•Activated leakage control function of gas valves and correct leakage measurement, when
required by an application.
3.6Tasks fulfilled by "authority on the subject" during Approval Test
By specifying the assigned DIN registration number and product ID number the manufacturer
confirms that model BT300 burner control system is consistent with type-tested system.
The connection between actuators and actuator elements for fuel and combustion air and also
to any additional actuator elements used must be form-fit.
3.6.1Checking for Correct Parameterisation in System
While installating and commissioning the plant the person in charge of the plant/heating technician needs to document the following:
•Parameterised values
•Setting values (e.g. curve progressions)
•Values describing fuel/air ratio control.
This data can be printed using LSB remote software or alternatively being kept as a handwritten note.
Retain this documentation and have it checked by the "authority on the subject".
NOTICE!
For BT300 parameterisations which deviate from application standards can be carried out in
access level 2. For this reason, check whether the parameterisation is consistent with the corresponding application standards (e.g. EN 298, EN 230, EN 676, EN 267, etc.) or the respective plant has to be approved separately.
3.6.2Checking the Fuel/Air Ratio Control System
Save setting values (curve parameters) for actuator elements, fuel and combustion air through
the complete range of burner firing-rate in sufficient number.
Select setting values of fuel and combustion air considering combustion chamber pressure,
fuel pressure, temperature and pressure of the combustion air in order to guarantee proper
operation with adequate excess air through the entire range of burner firing-rate.
The burner/boiler manufacturer has to document this by measuring reference values of the
combustion process.
11
3 For Your Safety
3.6.3Checking Burner Sequencer Part
Check the following:
•Correct setting of time parameters (especially safety and pre-ventilation periods).
•Whether an ionisation flame sensor or a corresponding flame scanner is used since only
these are capable of running in continuous operation.
•Functioning of flame sensor in case of flame blow-off during operation, parasitic light being
present during pre-ventilation period and missing flame formation at the end of the safetyperiod.
•Check the performance of all available and/or essential incomming signals, such as for:
–Air pressure
–Gas pressure - min/oil pressure - min
–Safety interlock chain (e.g. STB)
•Activated Leakage control function for gas valves if required for application purposes.
–If necessary, ensure a correct leakage quantification.
12
4 Functional Description
4Functional Description
BT300 combines the benefits of an electronic fuel/air ratio control system with up to three motorised actuator elements and optional modules like an analogue output for speed control of
the combustion air fan with an electronic burner control unit. The leakage test, flame monitoring system, power control unit and (optional) CO/O2 controller for control and optimisation of
an oil or gas-fired forced-draught burner are all integrated.
BT300 is suitable for virtually all combustion plants. Safety interlock chains, monitors (e.g. gas
and air pressure) and sensors are wired directly to the BT300. This greatly reduces the cost
of additional relays and wiring. The BT300 is designed to be attached to the burner. The short
wiring paths also save money. As a result, BT300 is particularly suitable as standard equipment for monoblock burners.
The compact design of BT300 burner control system also has its advantages during commissioning. Standardisation of wiring and operator interface minimises sources of errors right
from the start. Moreover, intelligent display information is making search for errors much easier.
The BT300 is available in five designs:
•BT3202 motorised control outputs
1 continuous output 0 ... 10 V, 0/4 ... 20 mA for speed control of the
combustion air fan using VSM100 (optional)
intermittent operation
•BT3303 motorised control outputs
1 continuous output 0 ... 10 V, 0/4 ... 20 mA for speed control of the
combustion air fan using VSM100 (optional)
Approved for continuous operation only in combination with
flame sensors capable of running continuously
•BT331Same range of functions as BT330 but including following certificates:
DIN EN 61508:2002 parts 1-7 for SIL 3
Performance Level PLE according DIN EN ISO 13849-1
•BT340 3 motorised control outputs
Oil-gas dual-fuel operation via DFM300
1 continuous output 0 ... 10 V, 0/4 ... 20 mA for speed control of the
combustion air fan using VSM100 (optional)
approved for continuous operation only in combination with
flame sensors capable of running continuously
•BT341Same range of functions as BT340 but also including following certificates:
DIN EN 61508:2002 parts 1-7 for SIL 3
Performance Level PLE according DIN EN ISO 13849-1
Burner sequencer and fuel/air ratio control can be adjusted for a wide range of combustion
conditions by setting parameters. The BT300 for oil and gas can be set to start with and without pilot burner. The integrated leakage test can be run before ignition or after shutting down
the burner.
Starting without pre-ventilation using gas is available in accordance with EN676.
The setting of fuel/air ratio curves can be optimised using optional CO/O
eration. This helps to counteract conditions that interfere with combustion. This ensures a permanent burner operation at the greatest possible efficiency.
Operating and fault messages are displayed by symbols and numbers on UI300 User Interface. Plant-specific configurations and settings of fuel/air ratio control curves are operated via
menu of UI300 User Interface.
An operating and start-up counter is integrated.
The optional LCM100 power control unit with two setpoints, external setpoint shift (control by
atmospheric condition) and start-up control is also available.
13
control during op-
2
5 Operating Control and Displays
5Operating Control and Displays
5.1UI300 User Interface
Fig. 5-1 User Interface
Display
The display shows in pictograms:
•the menu structure
•operating status
•parameters
•error messages
1Display
2BACK key
3Cursor keys
4ENTER key
Back key
Jump to previous window.
Cursor keys
ENTER keys
Press ENTER to call up a menu on the start screen. Select a sub-menu in the menu
window. Transfer setting values by pressing ENTER key in a parameter window.
You navigate in the menu using cursor keys.
You use "left'' and ''right'' keys to move step by step in a selected row. At
the end of the selected row the cursor jumps down to the next row, if possible.
In a multiline menu use "up" and "down" keys to switch to other rows.
To display parameters, switch between various fields.
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