www.lamtec.de
Sensors and Systems for Combustion Engineering
User Manual
Lambda Transmitter LT2
Lambda Probe LS2
2
Table of Contents
Table of Contents
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Validity of these Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Explanation of the Symbols in the Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Proper Use - Conditions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Permissible Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Safety Equipment/Safety Measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Protection Against Emissions from Gas Carrying Channels . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Important Notes on Shutdown/Return to Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Environmental Protection, Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Brief Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Advantages of the Measurement Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 LT2 Lambda Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2.1 LT2 Lambda Transmitter in Wall Mounting Case. . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Cold-start Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4 Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4.1 Display and Operating Unit Type 657R0831 . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4.2 Remote Display Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4.3 Calculation of Combustion Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4.4 Calculation of the CO
2
Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4.5 Firing Rate Dependent and Fuel Specific Limit Values/Limit Curves. . . . . . . . . 18
4.4.6 1 ... 4 Analogue Output (0/4 ... 20 mA, 1 ... 10 V) . . . . . . . . . . . . . . . . . . . . . . . 18
5 LAMTEC SYSTEM BUS (LSB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Jumpers, LED, Fuses and Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Commissioning/Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1 Preliminary Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1.1 The LT2 Lambda Transmitter's Display and Operating Elements . . . . . . . . . . . 20
6.1.2 Monitor Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1.3 Internal Display and Operating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3 Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4 Measurement Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.4.1 Install the Probe in the PIF and Align the GED . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.4.2 Setting up Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.1 Operation/Measurement Value Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.1.1 Measurement Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.1.2 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.3 Status Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.4 Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3
Table of Contents
7.2 General Instructions for Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2.1 Measurement During Distinct Pressure Surges at the Measuring Site . . . . . . . 32
7.2.2 Operational Failure, Switching On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2.3 Liquid Purification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8 Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1 Checking the O2 Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.1 Checking the Air Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.2 Checking by Counter Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2 Checking the LT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2.1 Checking the LT2's Measuring Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.3.1 Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9 Faults/Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.1 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.3 Resetting Faults/Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.3.1 Faults - Causes and Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.3.1.1 Probe voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.3.1.2 Defective LS2 Probe Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.3.1.3 Broken Wire Probe/Defective Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.3.1.4 No Probe Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.3.1.5 Fault Analogue Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.3.1.6 O2 Value Is Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.4 Warnings - Causes and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.4.1 LS2 Internal Resistance too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.4.2 Offset Voltage to Air Invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.4.3 Analogue Inputs 1/2/3/4 Input Value too Large/too Small . . . . . . . . . . . . . . . . . 42
9.4.4 Configuration Error at Analogue Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.4.5 Service Warning 1/Service Warning 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.1 LT2 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.2 Spare Parts Lambda Probe LS2 in Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.3 Spare Parts LS2-HT Lambda Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.1 Technical Data LT2 Lambda Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.1.1 Technical Data LT2 in Wall Mounting Housing. . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.2 Technical Data LS2 Lambda Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.3 Technical Data LS2-HT Lambda Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.3.1 Terminal Assignment terminal socket for Probe HT. . . . . . . . . . . . . . . . . . . . . . 50
11.4 Electric Connections Device Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11.4.1 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11.4.2 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11.4.3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11.4.4 LT2 Power Electronic Type 657E1882. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
11.5 Wet/Dry Measurement Deviations, Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . 53
12 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4
1 General Information
1 General Information
1.1 Validity of these Instructions
Content of this Operating Manual
This Operating Manual describes the Lambda Transmitter LT2 with all components necessary
for O2 measurement, such as the Lambda Probe LS2, the probe installation fitting, etc.
Accessories and special applications
Information on accessories and special applications is provided in the booklets supplied with
the particular systems. This information can be obtained from the manufacturers, at the Walldorf address.
This Operating Manual explains the functioning, mounting, installation, maintenance and operation of the Lambda Transmitter LT2. Other booklets, such as Product Information for example, provide further information but must never be used as a substitute for this Operating
Manual.
CAUTION!
Always read the Operating Manual before starting work!
Please adhere strictly to all warnings/safety instructions!
For particular tasks, for example electrical installation, specialised knowledge is required.
These tasks may only be carried out by suitably qualified personnel. See chapter 2.3 Permis-
sible Users.
Validity
Our products undergo constant redevelopment. However, we make every effort to ensure that
the Operating Manual is accurate and relevant to individual applications.
All previous editions are rendered obsolete on publication of an updated and corrected new
edition.
On the last page you will find the current version number of this Operating Manual and the
corresponding order number.
5
2 Safety
2 Safety
2.1 Explanation of the Symbols in the Safety Notes
The following symbols are used in this document to draw the user's attention to important safety information. They are located at points where the information is required. It is essential that
the safety information is observed and followed, and that applies particularly to the warnings.
DANGER!
This draws the user's attention to imminent danger. If it is not avoided, it will result in death or
very serious injury. The plant including its surroundings could be damaged.
WARNING!
This draws the user's attention to the possibility of imminent danger. If it is not avoided, it may
result in death or very serious injury. The plant including its surroundings could be damaged.
CAUTION!
This draws the user's attention to the possibility of imminent danger. If it is not avoided, it may
result in minor injuries. The plant including its surroundings could be damaged.
NOTICE
This draws the user's attention to important additional information about the system or system
components and offers further tips.
The safety information described above is incorporated into the instructions.
Thus, the operator is requested to:
1 Comply with the accident prevention regulations whenever work is being carried out.
2 Do everything possible within his control to prevent personal injury and damage to prop-
erty.
6
2 Safety
2.2 Proper Use - Conditions of Use
Application
The LT2 Lambda Transmitter is an O2 measuring instrument for the continuous measurement
of O2 concentration in non-combustible gases in the super-stoichiometric domain, in conjunction with the LS2 Lambda Probe.
Suitable for gas measurements with a small proportion of combustible components
(< 10,000 ppm), for example in flue gases of combustions systems.
Admissible fuels:
• Non-interacting gaseous hydrocarbons
• Light oil
• Coal
• Biomass (wood)
NOTICE
Direct measurements in combustion gases are not possible.
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 au-
thorised 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 fol-
lowed.
– All steps necessary to protect the equipment, e.g. during transport, storage, maintenance
and inspection, should be carried out.
7
2 Safety
2.3 Permissible Users
Qualified personnel
The person responsible for safety absolutely must guarantee that
• only qualified personnel perform work on the system parts.
Due to their training, education, experience, or instruction and due to their knowledge of
pertinent standards, provisions, accident prevention regulations, and system conditions,
qualified personnel are authorized to perform these tasks by the person responsible for
the safety of people and the system. It is decisive that this personnel must be able to recognise and prevent risks on time.
Experts are considered to be people according to DIN VDE 0105 or IEC 364 or directly
comparable standards like DIN 0832.
• These persons must have access to the provided operating manual and any pertinent order-related documentation during all work and observe these documents within the scope
of preventing risks and damage.
User groups
For the handling of the Lambda Transmitter LT2, three user groups are required:
• Service technicians of LAMTEC or its OEM customers and/or trained customer personnel:
– Qualified technicians/engineers have very good knowledge of the device.
– SERVICE access level - password-protected
• Operators, customer fitters, technicians for instrumentation and control technology, electricians, and electronic engineers have introductory knowledge of the device.
– CUSTOMER access level - password-protected
• Operating personnel with basic knowledge
– OPERATION access level - no password
8
2 Safety
2.4 Safety Equipment/Safety Measures
Hazards from electrical equipment
The LT2 Lambda Transmitter and the Lambda Probe is equipment for use in industrial electrical power installations. Always switch off the power when working on mains connections or
mains voltage. If contact protection has been removed, reattach it before switching on the
power supply again. Damage to health or equipment may result from improper use or improper handling.
NOTICE
To avoid damage, always observe the respective security notices.
Preventive measures for improving operating safety
If the LT2 is used in conjunction with control and steering technology, the operator must ensure
that any breakdown or failure of the LT2 device does not cause inadmissible damage or dangerous operating states. To avoid faults which could cause direct or indirect personal or material damage, the operator must ensure that:
• the responsible maintenance personnel can be reached at any time and as quickly as possible
• the maintenance personnel are trained to correctly respond to faults with the LT2 Lambda
Transmitter and the associated malfunctions
• in the case of doubt, the faulty equipment can be switched off immediately
• A switch-off does not lead to direct follow-up problems.
Avoiding consequential damages
To avoid consequential damages in the event of failure, which could cause direct or indirect
personal or material damage, the owner must ensure that qualified personnel can assess the
faults and initiate appropriate measures to tackle them.
2.5 Protection Against Emissions from Gas Carrying Channels
The Lambda Transmitter LT2 is attached directly to the gas-carrying duct by the probe installation fitting (PIF) and the mating flange. If the LS2Lambda Probe or the probe installation fitting (PIF) is removed, the operating system, especially if pressurised, can cause corrosive
and/or hot gas to escape from the duct through the flange, causing severe injury to the operator if the operator is unprotected and if appropriate safety precautions have not first been taken.
WARNING!
Discharge of hot, corrosive gases!
With pressurised gas, corrosive gases and/or temperatures higher than 200 °C in the gas-carrying duct, gases can escape if the Lambda Probe LS2 or the probe installation fitting (PIF) is
removed
Before opening, switch off the installation. If this is not possible, put on protective clothing
and masks
Place appropriate warning signs in the vicinity of the unit
Reseal the opening immediately. Appropriate sealing flanges (blind flanges) are available
as accessories
9
2 Safety
2.6 Important Notes on Shutdown/Return to Service
The Lambda Transmitter and the Lambda Probe form a high quality electronic system. Treat
them with care at all times, including during shut-down, transport and storage.
Shut-down
NOTICE
Do not switch the Lambda Transmitter off as long as the 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.
WARNING!
Danger of burns!
Probe becomes hot during operation.
If the probe is operated when removed, there is a danger of burns on the probe housing.
Never lay the probe on flammable material and heat it up.
Wear protective gloves
Return to service
According to chapter 6 Commissioning/Decommissioning.
2.7 Environmental Protection, Waste Disposal
The design of Lambda Transmitter and LS2 is also based on environmental considerations.
The modules can easily be separated and sorted into distinct types, and recycled accordingly.
10
3 Overview
3 Overview
3.1 System Overview
The LT2 Lambda Transmitter is an all-purpose O2 measuring device based on microprocessor
for direct measurement of the O2 concentration under super-stoichiometric range (λ > 1) used
together with LS2 Lambda Probe.
Fig. 3-1 System overview LT2 Lambda Transmitter
11
3 Overview
3.2 Brief Description
Universal O2 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. 3-2 LT2 Lambda Transmitter wall-mounting housing IP65
400x300x150 mm (HxWxD) type 657R102-...
Fig. 3-3 LS2 Lambda Probe, type 650R1000 with gas extraction device (GED) type 655R1001 - R1003
and probe installation fitting (PIF) type 655R1010
12
4 Technical Description
4 Technical Description
4.1 Advantages of the Measurement Principle
• No gas treatment needed, measurement directly in the humid flue gas
• Setting time at 90 %-value (T90) < 20 s
• Measuring gas temperature depending on the design up to 300 °C (572 °F)/up to 1200 °C
(2192 °F)
• Low heating power 15 ... 25 W
depending on the state of aging of the zirconium dioxide sensor
• Universal applicable
• Easy application
• Low-maintenance
13
4 Technical Description
4.2 LT2 Lambda Transmitter
4.2.1 LT2 Lambda Transmitter in Wall Mounting Case
NOTICE
Fuse replacement F1/F3 when changeover 230/115 VAC necessary !
Fig. 4-1 LT2 Lambda Transmitter in wall-mounting housing type 657R1025 with display and operating unit type 657R0831
1 Display and operating unit
2 Probe and electronics trans-
former
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 660R0017
Fig. 4-2 Change over power supply voltage
Accessible after removing the front panel with the main
switch (POWER)
14
4 Technical Description
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)
• set the type of the substitute value for O2 in P362:
OFF: No output of the substitute value
ON: Output of the substitute value of the preceding parameter.
+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
0 ... 20 mV and the AC inner resistance to a value below 100 .
15
4 Technical Description
4.4 Options
4.4.1 Display and Operating Unit Type 657R0831
Fig. 4-3 Optional with LT2 in wall-mounting housing type 657R102
16
4 Technical Description
4.4.2 Remote Display Software
The Remote Display Software is a PC software to configure the LT2. Use it instead of the display and operating unit, and to store and restore the data set.
• Remote Display Software including interface RS 232 module for PC type 657R1101
• Other licences for the Remote Display Software type 657R1102
• Suitable with windows-based computers
• Connection with LT2 via RS 232 interface.
Refer to special documentation DLT1004.
Fig. 4-4 Remote Display Software
17
4 Technical Description
4.4.3 Calculation of Combustion Efficiency
The calculation follows the formula:
Calculation of exhaust gas losses is based on the following mean fuel values:
It is assumed that the combustion is CO and soot-free.
Exhaust gas losses through bound heat are not taken into account.
Measurement accuracy:
Temperature - better than 2 K
Efficiency/exhaust gas losses - better than 0.2 %
Electric connections:
depending on configuration/components
4.4.4 Calculation of the CO2 Concentration
Calculated by referring to the fuel from the measured O2 value and the CO2 maximum
value type 657R0910
The calculation follows the formula:
CO2 = CO2 max – (21 % -O2 / 21 %)
The calculation is based on the following max. CO2-contents at = 1 O2 = 0 % vol.
referenced to dry exhaust gas.
Individual specification of CO2 max. is possible via the parameters 846, 862, 878 and 894.
hF= 100 (qAf + qAg) %
qAf= Exhaust gas loss through free heat
qAg= Exhaust gas loss through bounded heat
qAf=(tA - tL) * [A2/21 - O2 + B]
Oil
Gas
A2 = 0.68;
A2 = 0.66;
B = 0.007
B = 0.009
Display:
Efficiency
Exhaust gas losses
Exhaust gas temperature
Intake air temperature
Other ranges on request
0 ... 100 %
0 ... 100 %
0 ... 320 °C
0 ... 320 °C
Light fuel oil
Natural gas
Heavy fuel oil
Natural gas
EL 15.4 Vol. %
H 12.0 Vol. %
HFO 15.9 Vol.%
L 11.7 Vol. %
18
4 Technical Description
4.4.5 Firing Rate Dependent and Fuel Specific Limit Values/Limit Curves
The burner firing-rate value or some other measured quantity is supplied via analogue input 4
or via LAMTEC SYSTEM BUS. Instead of fixed limit values you can enter fuel-specific curves
with 2 up to a maximum of 8 checkpoints.
Possible combinations:
either
• 2 fuels with 4 limit curves / limit values per fuel
• 4 fuels with 2 limit curves / limit values per fuel
For details see supplement to the operating instructions for the optional "Display and operating unit”
4.4.6 1 ... 4 Analogue Output (0/4 ... 20 mA, 1 ... 10 V)
Max. 2 floating (output 1 and 2), max. potential difference 20 V, configurable in any order
Direct current 0/4 ... 20 mA, load 0 ... 600
Direct voltage 0 ... 10 V, load ≥ 10 k
Analogue output card 0/4 ... 20 mA, 0 ... 10 V type 657R0050
Analogue output card 0/4 ... 20 mA, 0 ... 10 V, floating, max. potential difference 20 V
type 657R0051
Fig. 4-5 Limit curves (factory settings), parameters adjusted to values
below threshold.
1 limit curve 1
fuel (curve 5)
2 limit curve 2
fuel 1 (curve 7)
3 burner firing rate [%]
4 regular firing rate input
[mA]
19
5 LAMTEC SYSTEM BUS (LSB)
5 LAMTEC SYSTEM BUS (LSB)
5.1 Jumpers, LED, Fuses and Terminals
5.2 Function
NOTICE
The data of the LT2 is only transferred by LAMTEC SYSTEM BUS if the device is set to MEASURING and not to MAINTENANCE or ERROR.
If the communication works properly LED 1 and LED 2 are flashing.
Fig. 5-1 LT2 assignment
1 F6 - T315 mA 5 VDC - LSB
2 BR12, BR13 → position ’C’ - CAN
3 BR105 → position 2-3 (left)
4 LED1 – green → RxD from LSB *
LED2 – yellow → TxD from LSB *
5 BR102 – BR104 position 1-2 (left)
base board V.03 and higher
6 BR101–120 termination resistor LSB,
→ position 1-2 (right)
without terminating resistor
→ position 2-3 (left)
with terminating resistor
7 terminal 71 → CAN-GND
terminal 74 → CAN-H
terminal → CAN-L
* LED flickering
20
6 Commissioning/Decommissioning
6 Commissioning/Decommissioning
6.1 Preliminary Works
6.1.1 The LT2 Lambda Transmitter's Display and Operating Elements
The LT2's operation and the display of measured values, operational and error messages take
place by the (optional) display and operating unit, or by a PC in combination with the Remote
Display Software. The LT2 itself has only limited operating capabilities, which do not allow LT2
to display or process all the functions necessary for operation, maintenance and servicing.
6.1.2 Monitor Output
The monitor output (terminals 31 (-) and 32 (+)) makes it possible to connect a multimeter for
example. The device indicates the following values by the monitor output:
–O2 measured value
– Probe voltage [U]
– The measuring cell's AC internal resistor [Ri]
DIP switch processor card
Input resistance of the connected measuring device greater than 10 k.
Fig. 6-1 Internal display and operating elements on the processor
board
1 Display of operating
mode
2 Warning /
Fault display
3 Maintenance switch
4 Multifunction key
SW 1 SW 2 Monitor output function
OFF OFF O2 measured value 0 ... 2.5 V = 0 ... 25 % vol O
2
ON OFF O2 probe voltage (U-O2) 0 ... 2.5 V = 0 ... 250 mV
OFF ON O2 cell’s internal resistance 0 ... 2.5 V = 0 ... 250
21
6 Commissioning/Decommissioning
6.1.3 Internal Display and Operating Elements
NOTICE
Legend: LED
is off
flashes
lights up
Multifunction key T 2
Maintenance switch S 1
Operation (green) LED 6 Operating mode (green) LED 5
Operation Measurement
Calibration
Offset compensation (flashes slowly)
With test gas/comparative measurement (flashes quickly)
Maintenance mode off
Maintenance mode on
Maintenance (orange) LED 1 Warning/fault (red) LED 12
Maintenance mode active
Normal operation
No warning / fault
At least one warning present
At least one fault present
Function Key operation
Toggle the displayed warning/ fault Press briefly
Reset the displayed warning/fault Press for longer than 3 sec*
Abort cold-start Press for longer than 3 sec**
Trigger an offset calibration to ambient air Press key for longer than 3 sec
during measurement**
* Some warnings and faults cannot be reset if the error is still present or the routine is
still running.
** If at least one warning or fault is still present, the key must be pressed for longer than
6 seconds.
22
6 Commissioning/Decommissioning
6.2 Decommissioning
In order to be sure to avoid damaging the probe’s ZrO2 measuring element, the probe must
be dismantled before the system is shut down or immediately after the supply voltage is
switched off.
NOTICE
Dismantle the probe before shutting down the measurement system.
CAUTION!
Hot probe!
The probe may be hot during mounting/demounting! Risk of burns!
Wear appropriate protective clothing.
Be careful.
Do not place the hot probe on flammable material.
NOTICE
Once dismantled, the probe can be stored indefinitely. The zirconium element is only con-
sumed during operation (measuring cell at operating temperature). This also applies where a
probe has already been used previously.
6.3 Return to Service
NOTICE
Outdoor mounting:
The measurement site should be protected on site against direct contact with rainwater,
through a sufficient large roof.
NOTICE
The connecting cable of the probe has a length of 2 m. The LT2 or the PCB must be installed
in the vicinity of the probe.
WARNING!
Escape of hot, explosive, and harmful gases!
Hot, explosive, and harmful gases can escape during work on the flue gas channel.
Take suitable protective measures to protect you and your environment from escaping
gases.
NOTICE
When making the apertures, any parts falling into the channel may cause damage.
Secure parts to be separated with wires!
23
6 Commissioning/Decommissioning
Mounting steps
1. Drill or burn out a hole in the flue channel, with diameter G 1¼ “.
2. Firmly weld a half-collar, interior thread G 1¼ “tight” at the measurement site.
NOTICE
Apply the collar’s thread, the PIF’s thread and the clamping ring with anti-size-paste type
650R1090. This avoids the seizing and guaranties a smooth dismounting of the LT2 probe.
3. Screw in the PIF without probe, and tighten.
4. Seal the PIF aperture with a blank plug if necessary.
5. Insert GED into probe and tighten
NOTICE
Install the probe just before commissioning. In a built-in state, the probe should always be
heated.
This prevents moisture from settling on the measuring cell, which, among other things, can
cause measuring errors and could destroy the probe.
NOTICE
During the installation of the probe and later operation, ensure that the probe does not come
into contact with oils, greases, or boiler cleaning agents.
Poisoned and/or dirty probes can be detected by an air voltage of -20 ... -30 mV.
6. Install, position and tighten probe in PIF after commissioning.
Fig. 6-2 Correct Probe installation with GED
1 Union nut
2 Threaded connection (position 1+2 = Probe
installation fitting (PIF) type 655R1010)
3 Welding socket
4 Probe
5 Flue gas
6 Gas extraction device
7 Welded
8 Rating plate
24
6 Commissioning/Decommissioning
CAUTION!
Hot probe!
The probe may be hot during mounting/demounting! Risk of burns!
Wear appropriate protective clothing.
Be careful.
Do not place the hot probe on flammable material.
NOTICE
To ensure that there is enough air circulation, the probe must be freely insulated from its en-
vironment in a radius of 5 cm.
Fig. 6-5 Installation position, any from horizontal to vertical
Fig. 6-3 Correct probe installation in flue gas duct
Fig. 6-4 Wrong probe installation
25
6 Commissioning/Decommissioning
6.4 Measurement Start-up
NOTICE
The maintenance switch always has priority.
NOTICE
During cold start the display and operating unit or the monitor output indicate the cell’s inner
resistance RI.
The measurement function is ready for operation after 10 minutes.
Measurement is shown
LED 6 OPERATION is ON
LED 5 MEASUREMENT is ON
NOTICE
The cold-start delay can be activated from the display and operating unit → [cal] key. Proceed
as prompted by the menu, or interrupt by pressing the multifunction key T2 (for longer than 3
seconds, or if a warning or a fault is still present, for longer than 6 seconds).
• Observe the cell’s inner resistance and read the probe voltage alternatively via display and
operating unit (if available) or at the monitor output.
NOTICE
To read the probe voltage --> confirm with [meas] and choose probe voltage US.
Fig. 6-6 Maintenance (orange) LED 1
• Connect the probe but do not install it
Switch to MAINTENANCE
either via the display and operating unit in menu
[diag] or with the maintenance switch S1
– MAINTENANCE mode
active
– Normal OPERATION
• Switch on voltage
• LED 1 shows MAINTENANCE
• Probe warms up
• COLD START is shown
LED 6 OPERATION ON
LED 5 MEASUREMENT OFF
– MAINTENANCE mode OFF
– MAINTENANCE mode ON
26
6 Commissioning/Decommissioning
NOTICE
Calibration is displayed
LED 6 OPERATION is ON
LED 5 MEASUREMENT is flashing
• Wait for offset calibration to be finished.
Flashing has stopped.
• Enter probe temperature from the test protocol, parameter 141 ’customer access level’;
alternatively see separate manual in
– Display and operating unit (optional)
– Remote display software (optional)
• Exit MAINTENANCE
NOTICE
"Probe temperature T"
The LT2 Lambda Transmitter and LS2 Lambda Probe are not adjusted to each other. The LS2
Lambda Probe is subject to production dispersion, which can be compensated by offset calibration and probe temperature. A probe calibration with test gas is not necessary.
The probe temperatures determined by the end test can be found in the test protocol (which
is part of the delivery).
• Install probe as descriped in chapter 6.3 Return to Service.
NOTICE
When installing or operating the probe, ensure that the probe does not get into contact with
oil, grease or boiler cleaning materials.
This does not apply only to the cell, but also to the connector region!
The thread and the clamping ring should be treated with mounting paste type 655R1090 to
prevent for seizing.
Poisoned or contaminated probes can be identified by an air voltage of -20 …- 30 mV.
The probe must always be in operation when it is installed. This avoids the precipitation of
moisture on the measuring cell, which in certain cases can lead to erroneous measurements
and to the probe's destruction!
Fig. 6-7 Multifunction key T2
After a 10 minutes heating phase, the probe voltage
would be stabilised to values between -5 and -15 mV
and the measuring cell (Ri probe) internal resistance
would be stabilised to values below 100, for new
probe below 20 . Are positive values displayed in
air, the probe’s polarity is reversed. Swap probe connection on terminals 33/34.
Proceed with offset calibration alternatively by using
display and operating unit in [cal] or the multifunctional key T2 (hold for more than 3 seconds in
MEASURING mode).
27
6 Commissioning/Decommissioning
6.4.1 Install the Probe in the PIF and Align the GED
The LS2 Lambda Probe is the transducer. It is located directly in the exhaust gas stream. The
gas to be measured is fed to the probe via the gas extraction device (GED)/flue gas bypass
tube. Measurement takes place directly in the probe. The LS2 probe is connected to the probe
connection box (PCB) or LT2 via a 4 strand cable with two plugs.
Fig. 6-8 Probe installation with GED
1 Union nut
2 Threaded connection
(Position 1 + 2 = Probe installation fitting
(PIF) type 655R1010
3 Welding socket
4 Probe
5 Flue gas
6 Gas extraction device (GED) type
655R001 ... 1004
7 Welded
8 Rating Plate
Fig. 6-9 Correct probe installation with GED in flue gas duct
Fig. 6-10 Wrong probe installation
28
6 Commissioning/Decommissioning
NOTICE
To ensure that there is enough air circulation, the probe must be freely insulated from its environment in a radius of 5 cm.
NOTICE
To ensure that there is enough air circulation, the probe must be freely insulated from its environment in a radius of 5 cm.
Wiring between SAK and LT2 Lambda Transmitter via conventional cable and terminals, see
wiring diagram in chapter 11.4 Electric Connections Device Side until chapter 11.4 Electric
Connections Device Side
Alternatively, direct connection LS2 LT2 without SAK is possible via a customised cable (2 m,
5 m, 10 m and 20 m), see wiring diagram chapter 11.4 Electric Connections Device Side.
• Start up combustion
• Measured value plausible?
Check if necessary via comparative measurement
NOTICE
Almost all extractive O2-meters measure ’dry’, in contrast to the in-situ ZrO2-meters; i.e. moisture is extracted from the flue gas through a purification process (cooler) or a chemical absorber (silica gel). This reduces the volume of the measured gas, and thus the proportion of O2
increases. This fact must be taken into account during comparative measurement. A diagram
for converting wet into dry measurements can be found in chapter 11.5 Wet/Dry Measurement
Deviations, Conversion Table
• If large deviations are present, it is possible to compensate for the values obtained via
– the display and operating unit, in [cal]
– the service and diagnostic software
– as follows, using the multifunction key:
Measure the O2 value at the monitor output or analogue output. Start calibration with the multifunction key. LED 5 should flash rapidly
Briefly pressing the multifunction key increases the output O2 value by 0.1 %
Pressing for a longer (time s)
The modification direction is inverted.
NOTICE
Calibration should only be carried out if it was previously ascertained that the comparison instrument is measuring correctly (e.g. by using test gases).
In any event, offset calibration should previously have been carried out in operational (warm)
conditions.
It is necessary to ensure that ambient air is present at the measurement site. If this is not ensured, the probe must be dismantled again for the offset
29
6 Commissioning/Decommissioning
6.4.2 Setting up Service Warnings
Service warnings 1 and 2 are designed to draw attention to regular servicing.
The service warnings can be freely defined by the operator, e.g.
Service warning 1 check probe
Service warning 2 dismantle and clean probe
The appropriate cycle times can be specified via the parameters 1260 and 1261 in the range
1 to 65535 hours.
30
7 Operation
7 Operation
7.1 Operation/Measurement Value Display
• Display and operating unit (optional) is included as a
standard in LT2 19” for panel installation.
• Service and diagnostic software (optional)
• Limited by multifunction key and monitor output
7.1.1 Measurement Value
•O2 actual value 0 … 30 % vol O
2
Resolution: 0.1 % vol O2
up to 18 % vol O2
1.0 % vol O2
above 18 % vol O
2
• Probe voltage -30 ... +150 mV
Resolution: 0.1 mV
• AC internal resistance of the ZrO2 cell 0 … 750
Resolution: better than 0.2
Displayed up to 999.9
• Exhaust gas temperature (optional) 0 … 320 °C/32 °F ... 608 °F
Resolution:
Alternatively:
Resolution:
1 °C/33.8 °F
0 ... 850 °C/
32 °F ... 1562 °F
better than 2 °C/
35.6 °F
• Combustion efficiency (optional) 0 … 100 %
Resolution:
0.1 %
• Calculated CO2-concentration (optional) 0 … 20 % vol
Resolution:
0.1 % vol
• CO/H2 concentration, shown as
COe [CO
equivalent
]
0 … 10,000 ppm
Resolution:
Alternatively:
variable 1 ... 100 ppm
depending on measured value
1 % of measured
value,
not better than 1 ppm
• Customised values Can be freely configured, e.g. exhaust
gas, temperature, efficiency, CO2 concentration etc.
31
7 Operation
7.1.2 Commands
7.1.3 Status Signals
• Measurement
• Calibration offset [Cal - offs]
• Calibration [Cal - gas]
• Maintenance
• Cold-start
• Probe heating active
• Measurement/no measurement
• At least one warning active
• At least one fault active
Status message during calibration
• Offset
• Cal-Gas
7.1.4 Operating Parameters
• Downward counter, cold-start delay
• Time, date
• Operating hours counter
• Abort ’Cold-start delay’ Directly during measurement
• Offset compensation Compensate probe to ambient air, 21 % vol O
2
• Calibration Perform measured value compensation by comparative measurement. Test calibration only in connection
with a special testing device or with LS2-HT possible.
• Fault/warning Reset
• Limit values Reset
32
7 Operation
7.2 General Instructions for Operation
7.2.1 Measurement During Distinct Pressure Surges at the Measuring Site
If the display jumps badly, damping can be increased via the (optional) display and operating
unit and the service and diagnostic software (i.e. by increasing the integration's time-constant); this steadies the display: parameter 360 - Operational release level. However, this
slows down the display in terms of reaching an end state.
NOTICE
Large damping simultaneously leads to an artificial slowing down of the measurement signal.
7.2.2 Operational Failure, Switching On and Off
In the event of long interruptions during operation, which are lasting for longer than approx. 3
months, it is recommended to switch off the measuring system. The probe should be dismantled to avoid damage (see chapters 6.4.2 Setting up Service Warnings, 6.2 Decommission-
ing6.3 Return to Service).
NOTICE
Recommendation: Continue with the measurement in case of short service interruptions.
7.2.3 Liquid Purification
To perform a liquid purification of the boiler is possible, if the probe is dismantled before. Performing a liquid purification to an installed probe, can damage the probe. An error free operation is no longer possible.
NOTICE
For the liquid purification, the probe must be dismantled by all means. A liquid purification of
an installed probe will damage the probe.
33
8 Service and Maintenance
8 Service and Maintenance
To perform a liquid purification note the following:
Only perform a liquid purification, if the probe is dismounted.Performing the liquid purification
without dismounting the probe will damage the probe. The probe will not function properly after
that.
NOTICE
Always dismount the probe before liquid purification. Liquid purification without dismounting
the probe will damage the probe.
8.1 Checking the O2 Probe
8.1.1 Checking the Air Voltage
NOTICE
If probe voltage is outside the permissible range, the warning ’Offset calibration to air invalid’
is indicated.
• Read out probe voltage at LT2 either by
– the display and operating unit (option)
– the service and diagnostic software (option)
– measure probe voltage with a multimeter;
Connect a digital voltmeter in parallel to the probe at terminal 33 (-) and 34 (+).
Compare the measured voltage with the displayed voltage (US).
• Valid range: 5 mV … -30 mV
• If the probe’s voltage is above/below this range → replace probe
Fig. 8-1 T2 multifunction key
• Switch off the facility
• Pre purge, until no more flue gas is present at the
measurement site (approx. 1 minute).
• Turn off the pre purge.
• Carry out offset calibration either by
• the (optional) display and operating unit in
[cal] - menu-driven
• the (optional) service and diagnostic software
• T2 multifunction key
Functions Handling of the Keys
Toggle the displayed warning/fault
Reset the displayed warning/fault
Quick start of the measuring gas pump - abort of
the cold start
Trigger an offset calibration
Press shortly
Press for longer than 3 sec.*
Press for longer than 3sec.**
Press key for longer than 3 sec.
during measurement **
* Some warnings and faults cannot be reset if the error is still present or the routine is
still running.
** If at least one warning or fault is still present, the key must be pressed for longer than
6 seconds.
34
8 Service and Maintenance
NOTICE
Do not forget!
Perform a new offset-calibration in ambient air and enter the probe’s new temperature value
after replacing the probe.
Limit value 4 is set at the factory: An automatic check of the probe is possible at downtime and
at pre-purge of the plant. No response of the limit values!
An intact probe does not cause fault no. 1.
If fault no. 1 ’probe voltage < -30 mV’ occurs reset it manually.
NOTICE
After the loss of the power supply (and therefore the heating of the probe) the probe voltage
may decrease for a moment to -30 mV in the heating period.
Recommendation: Retain the factory-set limit value 4 for safety reasons.
If the facility cannot be switched off, the probe must be dismantled for examination.
Limit value 4 → 5 mV shortfall, automatic reset
Delay time of the trigger 3 seconds
-30 mV shortfall is monitored by fault no. 1
35
8 Service and Maintenance
8.1.2 Checking by Counter Measurement
Precise checking of the measurements is only possible through counter measurement with a
second probe, or by comparing the measured values after probe replacement.
NOTICE
During counter measurement, check whether the instrument being used measures wet or dry.
Those with an advance gas cooler are always used for dry measurement. This also applies to
instruments that extract moisture via a chemical compound. The LS2 Lambda Probe measures wet. The difference between wet and dry measurements can be obtained from the diagram in the Appendix (see chapter 11.5 Wet/Dry Measurement Deviations, Conversion Table).
• If large deviations are present, it is possible to compensate for the values obtained via
– the display and operating unit, in [cal]
NOTICE
Confirm the new calibration value with ENTER or OK during the calibration of the measurement value with the display and operating unit → [cal]. If not, the menu will be quit automatically after 15 sec. and the new calibration value is discarded.
• the service and diagnostic software
• as follows, using the multifunction key:
– Measure the O2 value at the monitor output or analogue output.
– Start calibration with the multifunction key.
– LED 5 should flash rapidly (see chapter 6.1.3 Internal Display and Operating Ele-
ments).
– Press briefly: The O2 value is changed by 0.1 %
– Press long (> 3 seconds): The direction of change is reversed.
NOTICE
Which instrument measures correctly?
Compensation should only be carried out if it was previously ascertained, e.g. by using test
gases, that the comparison instrument is measuring correctly.
36
8 Service and Maintenance
8.2 Checking the LT2
8.2.1 Checking the LT2's Measuring Input
Connect a digital voltmeter between terminals 33 (-) and 34 (+), in parallel to the probe. Compare the measured voltage with the probe voltage displayed (US).
Range: -30 mV … +300 mV.
If the difference is less than 1 mV, the LT2 is operating correctly.
If the difference exceeds 1 mV, repeat the above step with another digital voltmeter.
NOTICE
Check the accuracy of the digital voltmeter used.
If the difference persists → exchange the instrument.
8.3 Maintenance
Check the measurement system on a monthly, quarterly or semi-annual basis, depending on
the application.
8.3.1 Consumables
Lambda Probe Average lifetime
– natural gas and light fuel oil: 3 ... 5 years
– with heavy fuel oil, coal and biogas: 1 ... 3 years
37
9 Faults/Warnings
9 Faults/Warnings
Messages in plain text (see chapter 7.1.3 Status Signals).
• by (optional) display and operating unit, in menu [diag]
• by Remote-display software (optional)
• by LED row, LED 7 to 12, on LT2's processor board
If several faults/warnings are present, they can be called up in sequence by activating the T2
multifunction key.
9.1 Faults
Message by LED line, LED 7 to 12, LED 12 flashes
Faults (flashing)
Legend LED
is off
flashes
lights up
12 11 10 9 8 7 Fault No.:
Display of active faults (red), flashes
No warnings/faults active
1 Probe voltage < -30 mV
2 Probe heater faulty
5 Probe broken wire/probe faulty
9 Dynamic response missing
11 Fault analogue outputs
38
9 Faults/Warnings
9.2 Warnings
Message by LED row, LED 7 to 12, LED 12 lights up.
Warnings (LED ON)
* Only relevant in conjunction with an integrated O2 control system.
Without an integrated O2control system the dynamic test should remain OFF
parameter 1330 = 0.
Legend: LED
is off
flashes
lights up
12 11 10 9 8 7 Warning No.:
Display of active warnings (red),
LED(s) permanently on.
No warnings/faults active
1 Internal resistance too high
2 Offset voltage to air invalid
19
Analogue input 1: input value too
high/low
20
Analogue input 2: input value too
high/low
21
Analogue input 3: input value too
high/low
22
Analogue input 4: input value too
high/low
23
Configuration error analogue
output
24 Service warning 1
25 Service warning 2
26 No probe dynamics *
27 Dynamic test triggered *
39
9 Faults/Warnings
9.3 Resetting Faults/Warnings
• by (optional) display and operating unit, in [diag], menu-driven
• by service and diagnostic software in [status], menu-driven
• by digital inputs – input 1
• by pressing the T2 multifunction key (for longer than 3 seconds per fault).
If several faults are present simultaneously, press the multifunction key several times.
Press the key [diag] to switch to warnings and faults. Select the single warnings, faults or limit
values with the cursor keys (up/down).
NOTICE
Limit values are displayed only if they are activated in parameters 930/940/950/960 (access
level ’Service’).
NOTICE
Reset all warnings or faults by quitting them. If necessary eliminate the cause of the warning/
fault.
See chapter 6.1.1 The LT2 Lambda Transmitter's Display and Operating Elements.
40
9 Faults/Warnings
9.3.1 Faults - Causes and Solutions
9.3.1.1 Probe voltage too low
• Probe + / - reversed probe connection terminal 33-34 change
• Probe poisoned replace
NOTICE
Probe voltage to air +5 to –30 mV
9.3.1.2 Defective LS2 Probe Heating
NOTICE
In 99 % of all cases, the LS2 Lambda Probe was disconnected during operation. Reset fault
either by the multifunction key or by the display and operating unit etc.
1. Reset fault either by the multifunction key or by the display and operating unit etc.
2. A defect only exists if the fault cannot be reset.
Possible causes:
• Check fuse F 5 (see chapter 11.4.4 LT2 Power Electronic Type 657E1882
• Check the probe heater. In an intact heater, ca.10 (9 ... 11 ) can be measured
between terminal 35 and 36. If not (R ) heater faulty. Replace probe.
• If intact, check the supply voltage: The probe heater must be supplied with about 13 VDC,
cyclically reversed. If not, check the wiring and the terminals and tighten if necessary.
NOTICE
The probe is heated with direct current at approx. 13 V, cyclically reversed. Therefore the use
of a multimeter to measure it is somewhat difficult.
NOTICE
The current heating data can be read out from LT2 operating parameters 41/42/43.
9.3.1.3 Broken Wire Probe/Defective Probe
This message is indicated if the AC internal resistance (Ri) or the ZrO2 cell exceeds the permissible limit of 300 . Before or after this message you normally will get the warning ’Inner
resistance [probe] too high’.
Possible reasons:
• The probe is disconnected (measuring signal on terminals 33 to 34)
• Loose connection check the terminals, re-tighten
• Probe too cold, possibly enhance the heating power gradually (0.5 W)
• Check wiring, if OK replace probe
41
9 Faults/Warnings
9.3.1.4 No Probe Dynamics
No probe dynamic detected. Check the probe.
NOTICE
Testing is shut off on delivery.
Activate testing in parameter group 1330 to 1334.
The testing checks, if the measuring value changes more than the parameter set threshold
value during a specified time.
Only valid in combination with an integrated O2 control.
9.3.1.5 Fault Analogue Output
Check the parameters of the analogue outputs.
• Parameter 530 … 539 analogue output 1
• Parameter 540 … 549 analogue output 2
• Parameter 550 … 559 analogue output 3
• Parameter 560 … 569 analogue output 4
Check the analogue outputs on the processor electronic and replace them if necessary. An
analogue output might be activated, but is not assembled˜
Check assembly.
(see chapter11.4.3 Fuses)
The parameters can only be viewed via the display and control unit or remote display software.
Without these options, the computer electronics must be sent in.
9.3.1.6 O2 Value Is Incorrect
If a control measurement results in a different O2 value than the one displayed:
• Has the relationship between wet/dry measurement been taken into account?
see chapter 11.5 Wet/Dry Measurement Deviations, Conversion Table
• Check LT2 and probe, see chapter 8.2 Checking the LT2
• Commission the new probe as described in chapter 6 Commissioning/Decommissioning
• Measuring value too high? Secondary air, check sealing and hose connections if they are
tight.
NOTICE
During counter measurement, check whether the instrument being used measures wet or dry.
Those with an advance gas cooler are always used for dry measurement. This also applies to
instruments that extract moisture via a chemical compound. The LS2 Lambda Probe measures wet. The difference between wet and dry measurements can be obtained from the diagram in the Appendix, see chapter 11.5 Wet/Dry Measurement Deviations, Conversion Table
42
9 Faults/Warnings
9.4 Warnings - Causes and Solutions
In general: Warnings do not affect the measurement functions.
9.4.1 LS2 Internal Resistance too High
This message is output if the AC internal resistance (RI) of the ZrO2 cell exceeds the permissible limit of 200 during operation.
Possible cause:
Probe aged (worn out) Obtain a spare probe and replace.
Measurement can continue, using caution. Check accuracy by counter-measurement,
see chapter 7 Operation
– Check fuses F2, see chapter11.4.3 Fuses
– Fault in supply section electronics replace
Check the Lambda Transmitter’s electronic:
Measure the AC voltage across LT2 terminals 33 and 34, using a multimeter.
The result in mV corresponds approx. to half the AC internal resistance.
9.4.2 Offset Voltage to Air Invalid
The voltage determined during offset compensation is not permissible.
Check whether probe is in air.
If yes - check probe voltage to air.
Permissible voltage range +5 … -30 mV.
9.4.3 Analogue Inputs 1/2/3/4 Input Value too Large/too Small
The input value at the relevant analogue input is outside the permissible range.
• Check parameters 574/584/594/604 (minimum) and parameters 578/585/595/605 (maximum). Parameters 570/580/590/600 indicate the current value.
• Check wiring poles reversed?
• Check source (connected instrument).
• Analogue input card defective? Replace it.
Access to the parameters is only possible with the display and control unit or the remote display software.
9.4.4 Configuration Error at Analogue Outputs
Parameters have been set for analogue outputs not physically found. Check parameters 539,
549, 559, 569 and 530, 540, 550, 560 and compare with the fitted cards.
If necessary, replace the analogue output cards and/or processor card.
9.4.5 Service Warning 1/Service Warning 2
See chapter 6.4.2 Setting up Service Warnings.
43
10 Spare Parts
10 Spare Parts
10.1 LT2 Spare Parts
The following is a list of relevant spare parts. It is recommended to maintain a stock of the
spares marked
(1)
.
Spares marked with the footnote
(2)
should be kept if considered appropriate.
Spares marked with the footnote
(3)
should be kept only if the system is equipped with the rel-
evant option.
10.2 Spare Parts Lambda Probe LS2 in Housing
Spare parts
Display and Operation Unit LT2 657R0833
(3)
1 Replacement main board for LT2, without connector set 657E1882
(2)
1 Processor electronic board for LT2 657R1874 LT2
(2)
1 Replacement power supply transformer for LT2 657P0342
(2)
1 Analogue output module 0/4 ... 20 mA; 0 ... 10 V 657R0050
(2)
1 Analogue output module0/4 ... 20 mA; 0 ... 10 V floating, Max. potential difference 20 V 657R0051
(3)
1 Analogue input module LT1/LT2 Potentiometer 1 ... 5 657P6000
(3)
1 Analogue input module 0/4 ... 20 mA 663P6001
(3)
1 Analogue input module 0/4 ... 20 mA with supply 24 VDC for transmitter 663P6002
(3)
1 Analogue input module 0/2 ... 10 V 657P6005
(3)
1 Temperature input for Pt100 657R0890
(3)
1 Temperature sensor Pt100, 250 mm (9.843" in) long 657R0891
(3)
1 Relay card for digital outputs, 6 relays, 1 switcher each 660R0017
(3)
Wear parts
1 LS2 Lambda Probe average lifetime ca. 10.000 - 20.000 operating hours (depending on fuel)
(without gas extraction device (GED))
650R1000
(1)
Spare parts
1 Gas extraction device (GED),e.g. 300 mm (11.81" in) long, for standard lengths see price lists
1 Gas extraction device (GED) 150 mm (5.91" in)
1 Gas extraction device (GED) 450 mm (17.72" in)
1 Gas extraction device (GED) 1000 mm (39.37" in)
655R1002
(3)
655R1001
(3)
655R1003
(3)
655R1004
(3)
1 Anti-size-paste (package of 5) 650R1090
(1)
1 Probe installation fitting (PIF) 655R1010
(1)
1 Clamping ring for PIF655R1010 (package of 5) 650R1013
(1)
(1)
Recommendation: Add these spare parts into stock
44
10 Spare Parts
10.3 Spare Parts LS2-HT Lambda Probe
Spare parts Type
1 Replacement probe average lifetime ca. 2 ... 5 years (depending on fuel) with PTFE-connecting cable, in
housing, in connection with flue gas bypass tube for measuring temperature up to 1200 °C (2192 °F),
650R1515
1 Replacement sensor, consists of sensor, seal for connecting head, filter discs and metal c-ring 650R1520
(1)
1 Mounting compound - Anti-seize-paste (5 pcs. per pack) 650R1090
1 Flange seal between counter flange/ flue gas bypass tube 655P4211
1 Flange seal between probe High temperature /flue gas bypass tube 656P0263
(1)
Recommendation: Add these spare parts into stock
45
11 Appendix
11 Appendix
11.1 Technical Data LT2 Lambda Transmitter
11.1.1 Technical Data LT2 in Wall Mounting Housing
LT2 in wall mounting housing
Housing Housing in sheet steel, powder-coated
Dimensions (HxWxD) 400x300x150 mm/15.75"x11.81"x5.91" in - without reference
gas pump
500x300x200 mm/19.69"x11.81"x7.87" in - with reference
gas pump
Colour Light grey RAL 7035
Weight 10 kg/22.05 lb
with display and operating unit +0,5 kg/1.10 lb
Control elements Display and operating unit with LCD graphic display (option)
LSB Remote Software (option)
Characteristics
Power supply 230 VAC and 115 VA C
+10 % / -15 %, 48 Hz ... 62 Hz
Use only in earthed networks!
Power consumption max. 50 VA short-term 150 VA (heating phase probe)
Display LCD graphic display 100x80 mm (WxH)/3.94"in.x3.15" in
in panel installation housing = standard
in wall mounting housing = optional
Resolution O2: 0,1 Vol. % O2 in range 0 ... 18 Vol. % O2
1,0 Vol. % O2 in range 18 ... 30 Vol. % O2
CO: 1 ppm in CO range
Measurement accuracy (standard value)
– other Measurement accuracies can be
achieved depending on the design
With Lambda Probe LS2:
0,1 Vol. % O2 in range 0 ... 18 Vol. % O2
1,0 Vol. % O2 in range 18 ... 30 Vol. % O
2
With Combination Probe KS1 or KS1D:
O2:10 % of the measured value, no more precise than
0,3 Vol. % O2
CO: 25 % of the measured value, no more precise than
10 ppm on natural gas combustion, after previous calibration
under operating plant conditions with a CO-reference
measurement in measuring range 0 ... 100 ppm
Time for operational readiness approx. 10 minutes after MAINS ON
Cold start delay automatically cold start delay, 10 min.
Analogue outputs
Monitor output 0 ... 2,55 VDC, load >10 k, 100 nF
1 ... 4 current/voltage outputs 1 (LS2, KS1) or 2 (KS1D) standard – up to 4 options
direct current 0/4 ... 20 mA load 0 ... 600
direct voltage 0 ... 10 V load 10 k non floating (potential
isolation optional)
46
11 Appendix
Analogue inputs
Analogue inputs: 1 ... 4 via plug-in card on LT2 power pack electronic
– Analogue input module potentiometer 1 ... 5 k
type 657P6000
– Analogue input module 0/4 ... 20 mA type 663P6001
– Analogue input module 0/4 ... 20 mA with supply 24 VDC
for transducer type 663P6002
– Temperature input for Pt100 sensor type 657R0890
temperature range 0 ... 320 °C/32 °F ... 608 °F/
0 ... 850 °C/32 °F ... 1562 °F resolution 1 °C/33.8 °F
Digital output
Digital output 1 standard + 6 optional
– 1 relay output 0 ... 230 VAC, 2 A – 0 ... 42 VDC, 3 A
collective fault indicator
– relay card with 6 relays (1 changeover switch)
0 ... 230 VAC, 2 A – 0 ... 42 VDC, 3 A
Digital input
Digital input 8 inputs - configurable (any)
Factory settings: 24 VDC referenced to instrument potential,
Can be switched via jumper to floating, for external voltage
source.
Interface
Interface LAMTEC SYSTEM BUS
RS 232 only in combination with PC Remote Software
BUS connection PROFIBUS DP
Modbus RTU
Operating condition
ambient temperature Operation: -20 °C ... +60 °C/-4 °F ... 140 °F
Transport and storage: -40 °C ... +85 °C/-40 °F ... 185 °F
Protection class to DIN 40050 IP65
CE Declaration of Conformity 2014/30/EU – EMC Directive
2014/35/EU – Low Voltage Directive
2011/65/EU – RoHS Directive
47
11 Appendix
11.2 Technical Data LS2 Lambda Probe
Fig. 11-1 Lambda Probe LS2 in housing with gas extraction device (GED) and probe installation fitting
(PIF)
Fig. 11-2 Lambda Probe LS2 in housing with gas extraction device (GED) and probe installation fitting
(PIF)
1 Probe in housing 650R1000
2 Probe heat
3 Probe installation fitting type 655R1010 655R1010
4 Gas extraction device length X = 150 mm/5.91" in
Gas extraction device length X = 300 mm/11.81" in
Gas extraction device length X = 450 mm/17.72" in
Gas extraction device length X = 1,000 mm/39.37" in
655R1001
655R1002
655R1003
655R1004
Characteristics
Measurement range 0 ... 18 by Vol. %
with restriction 0 ... 21 Vol. % O
2
Measurement accuracy 10 % of measured value
not more than 0,3 by Vol. %
Effect of measured gas pressure -1,6 mV / 100 mbar change
Response time t60 (60% of final value) 10 seconds
Error influences Temperature change of the measuring gas depending on the
accuracy of temperature control of the ZrO2 measuring cell
Permissible fuels Non-interacting gaseous hydrocarbons and light heating oil
direct measurement in combustion gas are not possible
Permissible continuous exhaust gas temperature 300 °C (572 °F)
Probe output voltage 0,01 ... 21 by Vol. % O
2
150 ... -15 mV
48
11 Appendix
Probe internal resistance RI in air at 20°C (68 °F)
and 17 W heat output
15 ... 30
Probe voltage in air 20° C (68 °F) and 17 W heat
output (new probe)
0 ... -15 mV
Heat output at room temperature 16 ... 22 W - depending on version
Supply voltage of heating in plug Polarity is changed cyclically if PH 18 VA 11,4 V
if PH 20 VA 12,34 V
if PH 25 VA 14,8 V
Heat output for T = 350 °C (662 °F) ca.17 W
Heating current if PH 20 VA approx. 1,4 A
approx. 5A briefly during heating
PTC characteristic
Electrical connection Plug
Isolation resistance between heating and probe
connections
> 30 M
Weight [g] [oz] 600 (21.2) (with housing),
290 (10.2) (without housing)
Material probe housing 1.4751/1.4301
Material connecting pipework cooper strand nickel-plated
Insulation FEP
Characteristics
Environmental conditions
Operating temperature Connecting cable 150 °C (302 °F)
Useful life 2 years with heating oil and natural gas
Mounting position horizontal via vertical to horizontal
Protection class DIN 40050; IP42
49
11 Appendix
11.3 Technical Data LS2-HT Lambda Probe
Fig. 11-3 Dimensional drawing Lambda Probe LS2-HT (high temperature) with flue gas bypass tube
1 Lambda Probe LS2-HT high temperature type 650R1515
2 Connection head max. 100 °C (212 °F)
3 Flange seal Novaphit type 656P0263
4 Flange seal graphite type 655P4211
5 Counter flange with tube socket KTL coated type 655R0179 or
Counter flange with tube socket stainless steel 1.4571 type
6 Flue gas temperature at the probe head max. 450 °C (842 °F)
7 Abgasumlenkrohr
8 Diameter/diagonal maximum. 70 mm
9 Gas velocity:
> 1 < 10 m/s (32.81 ft/s) at a length of > 1,000 mm (39.370" in)
> 1 < 30 m/s (98.425 ft) at a length of 1,000 mm (39.370" in)
From 16 m/s (52.493 ft/s) on with increasing accuracy !
10 Length: 500 ... 2.000 mm (19.68 ... 78.74" in)
11 Hose connection 4/6 mm (0.02 in.) for calibration gas
12 Connecting cable with plug, length 2 m (6.6 ft.)
50
11 Appendix
Fig. 11-4 Flue gas bypass tube delay time as function of the velocity in the exhaust air channel depending
on the varying lengths of the flue gas bypass tube
The figure shows the delay time t
EGDT
[s] resulting from the length of the flue gas bypass
tube L
EGDT
[mm] as a function of a flow velocity in the middle of the flue air channel v [m/s].
51
11 Appendix
11.3.1 Terminal Assignment terminal socket for Probe HT
Fig. 11-5 Terminal socket
LS2-HT up to 6/2015
1 (-) Probe signal (grey)
3 (+) Probe signal (black)
4 without configuration
5 Probe heating (white)
6 Probe heating (white)
Fig. 11-6 Terminal socket LS2-HT from 6/
2015
1 (+) Probe signal (black)
2 without configuration
3 Probe heating (white)
4 Probe heating (white)
5 not equipped
6 (-) Signal (grey)
52
11 Appendix
11.4 Electric Connections Device Side
11.4.1 Jumpers
LAMTEC SYSTEM BUS
Digital inputs
11.4.2 DIP Switch
See chapter 6.1.2 Monitor Output.
11.4.3 Fuses
BR101:
BR105:
Selection of connection resistance: 1-2 off, 2-3 on.
Position 2-3
The new processor card must also be set up for the LAMTEC SYSTEM BUS (BR12 and
BR13 in position “C“).
BR106, 107: Position 1-2:
Position 2-3:
Digital inputs referenced to instrument potential.
Digital inputs, galvanic isolation.
Designation Value Function
F1 1A inertial for 230 V (IEC60127-2/5)
2A inertial for 115 V (IEC60127-2/5)
Primary fuse
F2 0.4 A inertial (IEC60127-2/3 or /5) Probe measuring electronics
F3 1 A inertial (IEC60127-2/3 or /5) 12 V for display background illumination
F4 1.25 A inertial (IEC60127-2/3 or /5) 5 V supply for processor card
F5 4 A inertial
from 11/2016 3,15A ultra slow fuse
Probe heating and 24 V supply
F6 0.315 A inertial (IEC60127-2/3 or /5) LAMTEC SYSTEM BUS
53
11 Appendix
11.4.4 LT2 Power Electronic Type 657E1882
Fig. 11-7 LT2 Power electronic type 657E1882
CAUTION!
Different fuse figures F1 for 230 V and 115 V supply voltage.
Guard against supply voltage toggling!
1 Transformer LT2 230/115 V change over 10 BR 106, BR 107
2 Module 1-4 Analogue outputs 11 Analogue outputs
3 Plug connector for interface modules, 12 Probe connection
e.g. RS232 in combination with interface module 13 Monitor output
4 DIP-switch 14 Analogue inputs
5 Maintenance switch 15 Relay output 1 e.g. for combined fault indication.
6 Multifunction push button switch 16 Power supply connection 230/115 V, 50/60 Hz
7 Row of LED’s for operating and status messages
(fault/warning)
17 Module 1-4
Analogue inputs (voltage, current, potentiometer)
8 LAMTEC SYSTEM BUS 18 Power supply switch
9 Digital inputs (open collector) 19 Electrical connection X211 for relay module
54
11 Appendix
11.5 Wet/Dry Measurement Deviations, Conversion Table
NOTICE
The LT2 carries out measurements directly in the humid flue gases (wet measurement). When
extractive devices are used, flue gases are removed and prepared. "Dry Measurements" are
normally used here, since the humidity has been extracted from the flue gas. As a result, O
2
measurement values vary (see diagrams below).
Alternatively, the H2O share can be automatically calculated via a fixed factor.
To perform a liquid purification of the boiler is possible, if the probe is dismantled before. Performing a liquid purification to an installed probe, can damage the probe. An error free operation is no longer possible.
NOTICE
For the liquid purification, the probe must be dismantled by all means. A liquid purification of
an installed probe will damage the probe.
Theoretical maximum deviations between wet and
dry measurement of the O2 concentration with
natural gas (CH4) or oil (CH2)X as fuel
Calibration diagram and conversion table of the concentration values of wet (O
2(n)
) and dry (O
2(tr)
) measured oxygen
O2 concentration range Constant K Gas/CH
4
Constant K oil/(CH2)
X
0 - 6% O
2
1.18 1.115
6 - 12% O
2
1.12 1.08
0 - 12% O
2
1.15 1.10
55
12 Declaration of Conformity
12 Declaration of Conformity
56
12 Declaration of Conformity
LAMTEC Meß- und Regeltechnik
für Feuerungen GmbH & Co. KG
Wiesenstraße 6
D-69190 Walldorf
Telefon: +49 (0) 6227 6052-0
Telefax: +49 (0) 6227 6052-57
info@lamtec.de
www.lamtec.de
Print-No. DLT6080-18-aEN-039
The information in this publication is subject to technical changes.
Printed in Germany | Copyright 2018
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