Manual
Combustion Management System CMS
Sensors and Systems for Combustion Engineering
www.lamtec.de
Table of Contents
Table of Contents
1
Important Information about the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Validity of these Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 References to Other Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Standards, Directives and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Classification of the Safety Instructions and Warnings . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Target Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Product-specific Dangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1 Mounting Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3 Commissioning Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3.1 Electronic Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3.2 Basic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3.3 Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3.4 FFS/ION/Terminal - Flame Tolerance Time . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.4 Electrical Connection Flame Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.5 CO/O2 Measuring Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.6 Acceptance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.7 Components/Devices of External Manufacturers . . . . . . . . . . . . . . . . . . . . . .
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System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Brief Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Digital Input/Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3 Assignment of Input/Output Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4 Chain Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.5 Curve Set Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Analogue Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Analogue Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 Analogue outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Functional Description of the Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Life Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CMS Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 MCC – Master Control Component (burner module) . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.4 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.5 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.6 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.7 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 AEC-TPS – Actuator Extension Component Three-Point Step . . . . . . . . . . . . . . . . . .
4.2.1 For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.3 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents
4.3
4.4
4.5
4.6
4.7
4.8
4.2.4 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.5 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.6 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.7 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.8 Approved Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AEC-VS – Actuator Extension Component Variable Speed. . . . . . . . . . . . . . . . . . . . .
4.3.1 For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.3 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.4 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.5 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.6 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.7 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.8 Sensors Suitable for CMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SDI - Safe Digital Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.4 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.5 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.6 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.7 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SDO - Safe Digital Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.3 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.4 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.5 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.6 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.7 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAI - Safe Analogue Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.3 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.4 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.5 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.6 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.7 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UI400 - User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.1 For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.3 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.4 Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.5 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graphic User Interface - GUI607/GUI610/GUI615 . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.1 For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.2.1 GUI607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.2.2 GUI615 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Functional Description with Process Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Basic Burner Sequencer Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 Default Process Flow for Gas Modulating with Pilot Burner . . . . . . . . . . . . . .
5.1.2 Default Process Flow for Gas Modulating Without Pilot Burner . . . . . . . . . . .
5.1.3 Default Process Flow for Oil Modulating With Pilot Burner . . . . . . . . . . . . . . .
5.1.4 Default Process Flow for Oil Modulating Without Pilot Burner. . . . . . . . . . . . .
5.2 Additional Burner Sequencer Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Start Without Pre-Purge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1.2 Required Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1.3 Required Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1.4 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.2 Required Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.3 Required Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.4 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Purging the Fuel Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.2 Required Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.3 Required Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.4 Purging After Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.5 Purging with Digital Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.6 Purging Oil Gun during Standby Operation and Fuel Changeover by Pilot
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.7 Operating Modes for the 'Purging Fuel Train Function . . . . . . . . . . . . . . . . . .
5.2.4 Pilot Burner - Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4.2 Required Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4.3 Required Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4.4 Process Sequence Chart: Pilot Burner Continuous Operation . . . . . . . . . . . .
5.2.5 CPI/POC - Closed Position Indication/Proof of Closure . . . . . . . . . . . . . . . . .
5.2.5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.5.2 Required Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.5.3 Required Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.5.4 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6 Valve Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6.2 Required Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6.3 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6.4 Valve Leakage Test Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6.5 Process Sequence Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6.6 Calculation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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80
80
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82
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85
86
86
86
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86
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87
87
87
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88
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90
92
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93
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94
95
95
95
95
95
95
96
96
96
97
98
98
4.9
5
4.8.3
4.8.4
4.8.5
Router
4.9.1
4.9.2
4
Table of Contents
5.2.6.7 Suggested Circuit For Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Ratio Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.2 Required Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.3 Required Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.5 Physical actuator types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.5.1 Continuous Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.5.2 Actuators with TPS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.6 Logical Actuator Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner Firing Rate Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.2 Required Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3 Required Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3.2 I Term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3.3 Constant Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3.4 Controlled by Atmospheric Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3.5 Limiting the Firing Rate Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3.6 Burner Shut-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.4 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPS Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100
101
101
101
101
101
101
101
102
102
103
103
103
103
103
104
104
104
105
106
107
107
6
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Parameter and Password Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Commissioning Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Programming of Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.1 Programming Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.2 Configuring Special Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.3 Configuring the Range Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.4 Shut-off Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.4.1 Run to Shut-off Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.4.2 Checking the Shut-OFF Limits of the CMS with the CMS Remote Software .
6.3.4.3 Checking the O2 Effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108
108
108
108
109
110
112
113
113
114
115
7
Operating Control and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Operation, Controls and Display with UI400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3 Information Menu Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3.1 Burner Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3.2 Recalling Fault History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3.3 Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3.4 Display of Check Sums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3.5 Positions of Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3.6 Display IP Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.4 Manual Menu Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.5 Settings Menu Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.5.1 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.5.2 Program Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116
116
116
118
118
119
120
121
122
122
122
123
124
124
125
5.3
5.4
5.5
5
Table of Contents
7.2
7.3
8
7.1.5.3 Configuring the Servomotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.5.4 Setting Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.5.5 Deleting Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.5.6 Adjusting Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.5.7 Changing Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.5.8 UI400 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation, Controls and Display with GUI607/610/615 . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1 Process Diagram and Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.3 Burner Settings Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.4 Burner Firing-Rate Controller Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.5 CO/O2 Burner Optimisation Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.6 Flame Monitoring System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.7 System Functions Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.8 User Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation, Controls and Display with CMS Remote Software. . . . . . . . . . . . . . . . . . .
7.3.1 Remote Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1.1 Installation Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1.2 Installing the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 Offline/Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2.1 Offline Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2.2 Online Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2.3 Connecting the CMS to the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3 CMS Remote Software User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3.1 Dataset Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3.2 Connection Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3.3 Access Rights Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3.4 CMS Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3.5 Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3.6 Help Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
128
129
130
131
132
132
133
134
137
138
148
152
154
155
162
164
164
164
164
167
167
168
168
172
173
176
178
180
202
205
CO/O2 Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8.1 For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8.2 Safety Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8.3 Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8.4 Required Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8.5 Required Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8.6 Why Control CO?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8.6.1 Where Can CO Control be Used? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8.6.2 Overview of Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8.6.3 Optimisation Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.6.4 Advantages of CO Control over O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.7 Operating Control and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.7.1 Is CO Control or O2 Trim Activated? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.7.2 Display in the Case of Active CO/O2 Control . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.7.2.1 Display with Active CO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.7.2.2 Display for Active O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.7.2.3 Status Display in Case of O2 Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.7.2.4 Resetting Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
8.8 Electrical Connection - Connection via LSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
6
Table of Contents
8.8.1 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.2 LAMTEC SYSTEM BUS (LSB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9.1 Activating CO/O2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9.2 Access Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9.3 Password Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10 Installation and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.1 Guidelines for Commissioning CO/O2 Controller . . . . . . . . . . . . . . . . . . . . . .
8.10.2 Putting the Electronic Ratio Control System into Operation . . . . . . . . . . . . . .
8.10.3 Combined O2/CO/H2 Measurement LT3-F . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.3.1 Checking the Connection from LT3-F to BT300 by LAMTEC SYSTEM BUS.
8.10.3.2 Operating and Comparing O2 and COe Measurements . . . . . . . . . . . . . . . .
8.10.4 Setting the CMS Correction Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.5 CO Control: Start-up O2 Monitoring Shut-off Limits . . . . . . . . . . . . . . . . . . . .
8.10.6 Checking the Combustion-related Limit Values . . . . . . . . . . . . . . . . . . . . . . . .
8.10.7 Set and Optimise the CO Response Threshold on LT3-F . . . . . . . . . . . . . . . .
8.10.8 Commissioning the CO/O2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.8.1 Commissioning with UI400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.8.2 Operating with PC Remote Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11 Monitoring Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.1 Dynamic Monitoring Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.2 CO/O2 Controller Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.3 CO Controller Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.4 O2 Trim Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.5 Burner Fault Shut-down when Falling below the Absolute O2 Minimum . . . . .
214
214
215
215
215
216
216
216
217
218
218
219
219
222
223
223
224
224
225
245
245
245
246
250
253
9
Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Customer Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
11.1 Important Notes on Shutdown/Return to Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
11.2 Disposal Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
12
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1 CP Default Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.2 Acceptance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.3 Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4.1 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4.2 Servo Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.5 EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.6 Display Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.7 Indication Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
271
271
278
279
279
281
281
281
283
283
283
284
284
285
286
1
Important Information about the Manual
1
Important Information about the Manual
1.1
Validity of these Instructions
This manual is valid for the burner control system Combustion Management System CMS in
any configuration.
The information contained in this document refer to the software versions V1.0.3. If you use
any other software version as mentioned previously some of the described functions may not
be available or not all available functions work as described in this document.
1.2
References to Other Documents
Additional information is available for the CMS from the following documents:
1.3
•
Parameter list (DLT7202): Lists and explains the relevant parameters
•
Fault list (DLT7201): Lists potential faults and offers help and advice for remedying faults
•
Description of the Modbus TCP protocol (DLT6104)
•
Manual LT3-F with UI300 (DLT3140)
Standards, Directives and Approvals
The CMS complies with the following standards and directives:
Harmonised European standards:
EN 298: 2012-09
EN 12067-2: 2004-02
prEN 12067-2:2017
EN 13611: 2011-12
EN 60730-1: 2012-11
EN 60730-2-5:2011-02, parts 1–7
EN 60654-3:1996-08
EN 61508: 2011-02; parts 1–7
ISO 23552-1: 2007-10
USA and Canada:
UL 372
Edition 6
UL 1998
Edition 2
UL 840
Edition 3
UL 746C
Edition 6
UL 60730-2-5
The CMS can be used to control burners in accordance with:
EN 676: 2008-11
EN 267: 2011-11
The CMS can be used for combustion systems in accordance with:
EN 50156
8
1
Important Information about the Manual
EN 746-2
EN12952
EN12953
IEC 746-2
NFPA85
NFPA86
NOTICE
Respect the national safety regulations and standards.
9
1
1.4
Important Information about the Manual
Abbreviations
A/D converter
Analogue/Digital converter
AEC-ST
Actuator Extension Component - Stopper Motor
AEC TPS
Actuator Extension Component Three Point Step = module for DPS motors
with potentiometer feedback
AEC VS
Actuator Extension Module Variable Speed = module for frequency inverters or
servo motors with 4 ... 20 mA interface
BS
Burner sequencer
CMS
Combustion Management System
CPI
Closed Position Indication
DIN EN
German Institute for Standardisation European Standard
DLTxxxx
LAMTEC document number
EBM112
PROFINETmodule
ESD
Electro Static Discharge
FI
Frequency inverter
FFDT
Flame failure detection time of the flame scanner
FFRT
Flame failure response time = safety time during operation = sum of the parameter values of P 801 +P 816 + FFDT
GUI607
Graphical User Interface with 7" touch panel
GUI610
Graphical User Interface with 10" touch panel
GUI615
Graphical User Interface with 15" touch panel
HMI
Human Machine Interface
IACS
International Association of Classification Societies
ICOM
Internal communication of the module
IDLE
Open-circuit operation
iLSB
Failsafe LAMTEC SYSTEM BUS
IO
Input/Output
IP xx
Protection class according to EN60529, xx = protection class code
LAN
Local area network
LED
Light emitting electrode
LSB
LAMTEC System Bus
MCC
Master Control Component = burner module
Middleware
Software for data exchange between application programs working with different operating systems or in heterogeneous networks.
MTBF
Meantime between failure = average operating time between failures for repairable units
NTC
Negative temperature coefficient
P xxx
P = parameter, xxx = number of the parameter
PEC
Programmable electronic component = Module of the CMS system
PLC
Programmable logic control system
10
1
Important Information about the Manual
POC
Proof of closure = A device that provides feedback that a plant part is in the
"Closed" position.
Pt100
Board measurement resistance (Ro= 100 Ohm) Ro= nominal resistance at 0 °C
Pt1000
Board measurement resistance (Ro= 1000 Ohm) Ro= nominal resistance at
0 °C
PWR
Power
RAM
Random-access memory
RECI
Flue gas recirculation
Ri
Internal resistance
RJ45
Connector Registered Jack (standard socket/plug) - Standard for Ethernet connecting cable
RL-L
Lower range limits
RL-U
Upper range limits
rpm
Revolutions Per Minute
SAI
Safe Analogue Inputs = module for failsafe analogue inputs
SDI
Safe Digital Inputs = module for failsafe digital inputs
SDO
Safe Digital Outputs = module for failsafe digital outputs
SELV
Safe Extra Low Voltage = Voltage that does not exceed the limits for voltage
range I according to IEC 60449.
SIC
Safety interlock chain
STL
Safety temperature limiter
TFT
Thin Film Transistor (Liquid Crystal Display, LCD technology)
TPS
Three-point step
UI400
User interface = simple operating and display unit; display with symbols
VLT
Valve leakage test
WLAN
Wireless Local Area Network
11
2
Safety
2
Safety
2.1
Classification of the Safety Instructions and Warnings
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 property.
12
2
2.2
Safety
Target Group
These instructions must have been read carefully and completely before commencing with
any work. The basic prerequisite for working safely is compliance with all the specified safety
instructions.
NOTICE
 All assembly, commissioning, troubleshooting and maintenance work may only be carried
out by authorised and trained personnel.
 The device may be operated and maintained only by those who are capable of doing so
in terms of their level of knowledge and training.
 For safety reasons, access to parameter settings must be restricted to authorised and
trained personnel.
2.3
Product-specific Dangers
Please observe the safety instructions to avoid personal injury and damage to property and
the environment!
CMS 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!
•
Qualified specialist staff are required to carry out all activities (assembly, installation, servicing, etc.).
•
The person in charge will ensure that CMS 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.
•
Adjustment of an open actuator must only be carried out by specialists who are trained in
mains voltage operation.
•
To re-place or disconnect the plug connectors, all poles of the plant must be disconnected
from the mains. Check that there is no voltage!
•
After each activity (e.g. assembly, installation, servicing, etc.) check wiring and parameters 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.
•
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.
•
An electrical signal low or 0 V always corresponds to a logical 0 in the CMS and is evaluated as inactive/safe state. If corresponding signals are connected to the CMS in a system, it must be ensured that 0 is always the safe state.
•
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.
13
2
Safety
NOTICE
Recommendation: Use ESD equipment while working on electrics/electronics!
NOTICE
The optional ionisation monitoring system integrated into the MMC is suitable for continuous
operation.
•
During the continuous fan stopping time (post-purging) following normal shutdown, the external safety mechanisms are not monitored. As a result, the combustion air fan cannot be
switched off by actuating one of the hazard switches included as part of the burner’s safety
interlock chain. Additional precautions such as a emergency stop button, or control panel
OFF switch, hard-wired to the combustion air fan control circuit should be considered as
the case may be.
•
Access to the CMS and the network in which it is located may only be granted to authorised personnel.
The following optional measures must be guaranteed by the plant owner:
• Providing physical access protection to the system by:
Locking system
Alert system
Access protection to the electronics, e.g. lockable switch cabinet
• Providing technical access protection to the system by:
Password protection (restricting the group of people with access to passwords)
Firewall
• Respect IEC62443 regulations or comparable IT security standards.
14
2
2.3.1
Safety
Mounting Notes
•
Observe national safety regulations, as well as guidelines given in national and international standards.
•
Safety extra low voltage (SELV) signal cables to and from the CMS must be physically
separated from line voltage/power cabling.
Frequency converter cables and switches or contactors that switch high, inductive or capacitive load are particularly relevant P.ex. spark igniter).
NOTICE
No parallel laying of control cables of solenoid valves, spark igniters, large servomotors or
similar devices.
Shielded cables from the field are connected directly, without using intermediate terminals. If
intermediate terminals are necessary, the shielding must be connected to an earth terminal
directly next to the terminal.
NOTICE
Avoid long distances without shielding!
•
Only use the actuators with integrated feedback mentioned in the operating instructions.
Other actuators may only be used after consultation with LAMTEC and a supplementary
test.
•
The connection between the actuators and the control valves must be positively connected throughout and designed for the maximum torque of the actuators.
15
2
2.3.2
Safety
Installation Notes
•
Always lay the high-voltage ignition conductor separately and as far away as possible from
the device and the other conductors.
•
Observe the relevant local and national regulations when wiring the electrical cables within
the burner.
•
Tighten the screw terminals using a tightening torque >0.5Nm.
•
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 on CMS is permitted to be max. 8 A fast-acting per output module (MCC and
output module).
•
Ensure that strain relief of the connected conductors complies with relevant standards
(e.g. DIN EN 60730 and DIN EN 60 335).
•
Ensure that no spliced strands can come into contact with any of the adjacent connections. Use suitable end splices.
•
To replace or disconnect the plug-in connectors, all poles of the plant must be disconnected from the mains.
•
The connection between the actuating drives and actuator devices for the fuel and combustion air, as well as to any additional actuator devices that may be in use, must be positive locking.
•
When wiring components with protective extra low voltage (SELV), and in connected devices, make sure there is a safe separation to the mains voltage.
•
Only connect passive or non-interacting devices to the CMS firing rate outputs (e.g. relay
without additional power supply). In the event of a fault, a supply of 230 V must be excluded to the CMS via these terminals.
•
Use gold-plated silver contacts on 24 VDC inputs.
•
To avoid faults on the LSB, the termination via P 1010 must be switched to active on the
first and last device connected to the bus.
•
Via installation of the CMS modules, the flame sensor and all additional equipment, the
minimum protection class IP40 – or IP54 for use outdoors – must be ensured in accordance with EN 60529.
•
The analogue inputs connected to the modules must have the same potential as the power supply of the CMS system.
16
2
2.3.3
Safety
Commissioning Notes
•
During commissioning it is essential to observe all safety accessory.
•
There is no way to completely rule out the connection plugs being connected incorrectly.
For this reason, check the correct assignment of the plugs before commissioning the
plant.
•
The person responsible for the plant/commissioning engineer must document the following values after installing and commissioning a plant:
– Settings/changes to the parameters
– Setting values across the burner firing-rate range (e.g. curve progressions),
– corresponding exhaust gas values where applicable
– media pressure levels where applicable
You can partly use CMS Remote Software to print this data or alternatively keep a handwritten note of it.
If tests are to be required by third parties in the application area of the device, these documents must be retained for presentation on request.
NOTICE
In CMS, parameter settings deviating from the application standards can be made.
 The parameter settings must correspond to the relevant application standards as applicable (e.g. EN 298, EN 676, EN 267, etc.) The documented evidence of conformity can be
managed via the LSB remote software.
NOTICE
Safety times can be called up via the HMIs UI400 and GUI607/GUI610/GUI615 and the CMS
Remote Software.
2.3.3.1 Electronic Ratio Control
•
Guarantee proper operation by ensuring adequate excess air.
In order to do this, set the values for fuel and combustion air in such a way that
– combustion chamber pressure
– fuel pressure
– temperature and pressure of the combustion air
can ensure proper, stable 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.
17
2
Safety
2.3.3.2 Basic Device
Check the following items prior to commissioning:
•
Valves must be assigned correctly to valve outputs on CMS.
•
Correct setting of time parameters (especially safety and pre-purge times).
•
Flame sensor functioning well in case of:
• flame blow-off during operation (incl. flame-out response time)
• ambient light is present during pre-purge period
• at a missing flame formation while end of safety period starts
•
Whether an ionisation or approved self-checking flame sensor is used as only these types
allow continuous operation.
•
Functioning of flame sensor
– in case of flame blow-off during operation
– parasitic light being present during pre-purge period
– missing flame formation at the end of the safety-period
•
Activated valve leakage control function for gas valves if required for application purposes.
– Ensure a correct leakage quantification.
2.3.3.3 Parameter Settings
Check the following:
•
Correct setting of time parameters (especially safety and pre-purge periods).
•
Activated valve leakage control function for gas valves if required for application purposes.
– If necessary, ensure the correct valve leakage quantification/monitoring time.
2.3.3.4 FFS/ION/Terminal - Flame Tolerance Time
The software processes the flame tolerance time* configurable in P801 and the pilot flame tolerance time** configurable in P816 in the same way.
To calculate the total response time in case of flame failure, the delay time of the related flame
scanner at terminal must be added. The following must be observed for each Flame sensor/
flame scanner:
•
The overall time in accordance with the standard is from flame failure to safety shutdown
→ must be checked in the plant context.
•
External flame scanner at terminal:
– Time starts as soon as the external digital input signal drops out.
– The time of the external flame scanner must also be taken into account.
•
Internal flame scanner as an add on FFS or ION:
– Time starts with drop of the internally formed flame signal.
– The time of the sensor (FFS07/08) and the internal flame scanner (flame card) must
also be considered.
*
**
Response time of the main flame at flame OFF
Response time of the pilot flame at flame OFF
18
2
Safety
Used flame input
Flame failure detection
time (FFDT)
Recommended parameter setting for a flame failure response
time (FFRT) of 1 s (P801, P816)
Terminal
Depending on the used
flame scanner (z.B: F300K)
0,2 s
FFS 07/08
500 ms
0,5 s
ION
800 ms
0,2 s
P801 and P816 describe the switch-off time of the digital, physical input to the digital, physical
output of the CMS. The system's safety time therefore depends on the sensor/scanner/ used
at the flame input.
The flame failure response time (FFRT) is the total of the parameter values and the flame detection time of the sensor/scanner used.
2.3.4
Electrical Connection Flame Sensor
•
CMS may only operate with appropriate approved flame sensors.
LAMTEC FFS07 and FFS08 sensors can be interfaced directly to the MCC or using an
F152 flame relay unit. Ionisation sensors may be interfaced using a LAMTEC F130i flame
relay. LAMTEC F200K and F300K flame sensors are also approved.
Alternatively, CMS can also be used with other flame detectors that are approved according to DIN EN 298. In this case it must be noted that the switch-off times of the flame monitor and the corresponding digital input are cumulative.
•
If a flame monitor without continuous operation approval is connected, the continuous operation approval for the entire system expires.
•
In combustion systems with only one flame sensor, it must be ensured that the main flame
is always ignited at the pilot flame.
•
Burners used in continuous operation must have dedicated flame monitors for pilot flame
and main flame.The main flame monitor may not respond to the flame of the pilot burner.
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 7-pole 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.
•
Ground the burner according to instructions – grounding the boiler itself is not sufficient!
•
Position ignition electrode and ionisation flame sensor where spark cannot hit ionisation
flame sensor (risk of electrical overloading).
•
The supply cable for connecting an ionisation electrode must have reinforced insulation in
accordance with DIN EN 60730-2-5 Section 20 to ensure protection against accidental
contact.
19
2
2.3.5
Safety
CO/O2 Measuring Systems
The following systems for CO control and O2 trim may be connected to the CMS:
CO Control – Lambda Transmitter in
Combination with Combination Probe
O2 Trim – Lambda Transmitter in
Combination with Lambda Probe
LT2 KS1
in combination with LT2 LS2 or LT1 LS1
LT1 LS1
LT2-K KS1-K
in combination with LT2-K LS2-K or LT1 LS1
LT2 LS2
LT3-F KS1D
LT2-K LS2-K
LT3 LS2
LT3 KS1D
2.3.6
Acceptance and Inspection
•
Check the following details as given on the label affixed to the side of the device:
• Configuration number
• Software version number
•
Confirm that parameters relevant for safety have been configured in accordance with
standards and the applicable requirements for each combustion system to be monitored.
The parameters at access level 1 must be protected against unauthorised reconfiguration
by changing the default password ’000000’.
•
When activating a curve set or a fuel changeover, the inspection must obtain proof that
safe, stable combustion is guaranteed during the changeover procedure.
During an on-the-fly changeover or loss of power, the inspection must also obtain proof
that the permitted combustion heat output is not exceeded during the changeover, and
that the combustion characteristics remain within limits that are acceptable in terms of device safety.
•
The values configured for the actuators for the control of the fuel quantity, air quantity, recirculation gas quantity and all other controllable variables for the combustion system
must be stored in sufficient numbers (i.e. at a minimum of five separate points) across the
burner’s entire output range.
•
The values configured for the respective actuators must be assigned in such a way that
ensures safe and stable operation of the combustion system across its entire output range
and during all modes of operation. This applies not only to the actuators for controlling the
fuel quantity, air quantity and recirculation gas quantity, and to all other safety-relevant
controllable variables for the combustion system, but also to the configuration of parameters for correctional intervention (e.g. when using a CO or O2 trim device). The combustion
chamber pressure, fuel pressure, temperature and pressure or the combustion air, and the
calorific value of the fuel must also be taken into account.
•
Proof of this must be obtained by measuring the combustion characteristics when operating the combustion system at the shut-down thresholds of the electronic ratio control device, and at the limits configured for the correction connection (e.g. to an O2 trim device).
To determine the shut-down thresholds applicable in each case, see the chapter 8.10.5
CO Control: Start-up O2 Monitoring Shut-off Limits’. Follow the specified procedure set out
in chapter 8.10.6 Checking the Combustion-related Limit Values
If the combustion system is equipped with a failsafe CO/O2 control device, the performance of a test at the shut-down thresholds is not required. Instead, a test must be per20
2
Safety
formed at the shut-off limit of the CO/O2 control device, see chapter 8.10.5 CO Control:
Start-up O2 Monitoring Shut-off Limits.
2.3.7
•
Testing at the shut-down thresholds is also not required if the parameter setting for the
tolerance at the air deficiency side is 0 digits. Proof must be obtained of the correct setting
of this parameter during commissioning.
•
In cases where mixed combustion is activated (simultaneous combustion of more than
one fuel), the precomputed setpoint curves must be verified during commissioning by
checking the combustion characteristics.
The operating modes must be analysed in terms of excess air and the combustion characteristics must be measured during the operating mode in which the lowest excess air
value has been configured.
Safe and stable combustion must be ensured during the activation and deactivation of a
fuel feed.
Components/Devices of External Manufacturers
Requirements for third-party manufacturers whose devices are connected to the communication interface of the CMS.
All bus nodes connected directly to the CMS (Ethernet devices, e.g. switches) must guarantee
insulation in accordance with DIN EN 60950-1
All devices connected to SELV terminals (sensors, converters, frequency inverters) must
guarantee/maintain insulation in accordance with DIN EN 60730-1 SELV.
21
3
3
System Description
System Description
The CMS is a failsafe modular burner control system that can be customised to control combustion systems from simple single fuel burners to complex multi-fuel burners with up to four
fuels. The minimum possible configuration is a single MCC which cam provide the functionality
of a burner sequencer with bus interface.
The burner sequencer is equipped with:
•
1 input for a flame sensor
•
12 failsafe digital inputs
•
9 failsafe digital outputs
•
1 non-failsafe analogue input
•
1 non-failsafe analogue output
With the help of configuration software, the inputs and outputs can be assigned required to
predefined functions for a gas burner (e.g. air pressure monitor, gas pressure monitor for valve
leakage test, minimum gas input pressure, etc.). With an oil burner, the terminal assignment
may differ from that for a gas burner.
The input for the flame sensor can be configured as appropriate for optical flame sensors
FFS07 and FFS08 or for ionisation monitoring.
In the full configuration, the following can be integrated within the CMS:
•
1 flame sensor
•
60 failsafe digital inputs
•
41 failsafe digital outputs
•
10 control channels for the electronic ratio control
•
9 failsafe analogue inputs or 18 non-failsafe analogue inputs
CO/O2 control for the burner is also possible using a suitable LAMTEC flue gas analyser/
probe combination.
Devices available for configuring parameters and operating the system include the graphical
user interface UI400 as well as the touch screen panels GUI607, GUI610 and GUI615 (in
three separate sizes).
CMS Remote Software is also available.
3.1
Brief Description
The CMS can adjust up to 10 control output channels defined in user-programmable curve
sets to modulate the burner through the firing range. The firing rate can be defined using internal PID control or can be set from an external tracking signal (4-20 mA or Fieldbus).
In the standard configuration, 2 curve sets (e.g. for oil or gas) can be stored. In addition, up to
16 curve sets are optionally available.
Up to 4 fuels can be defined.
Up to 10 control element outputs can be defined, e.g.
•
Fuel valve
•
Flue gas fan
•
Flue gas damper
•
Recirculation fan
•
Combustion air damper
•
Combustion air fan
•
Atomiser steam
22
3
System Description
For each channel up to 20 points can be programmed across the firing range. These are represented by values (digits) 0 ... 999 to indicate their relative positions.
Inputs/outputs
The CMS is equipped with both digital and analogue inputs and outputs, see chapter 3.2 Digital Input/Output Functions. and chapter 3.3 Analogue Inputs/Outputs.
Integrated burner control unit
A burner control unit with a sequential program is integrated into the CMS. The following outputs are possible:
•
Activation of the gas valves
•
Activation of the oil valves
•
Activation of the pilot valve and the spark igniter
•
Activation of the combustion air fan
•
Signal outputs for oil and gas operation
•
Oil pre-heating
•
Fault status signal
•
Other logical signals possible
External digital signals are hard-wired to the control unit via volt-free digital signals (either single digital contacts or chained contacts). The following signals can be predefined, for example:
•
System safety interlock chain
•
4 Discrete fuel safety interlock chains
•
Burner on
•
Fuel selection
•
Flame signal (main and pilot flame monitor), up to 2 main flame monitors
•
Fuel pressure monitor
•
Air pressure monitor
•
Control release (LFH - low)
•
Recirculation enable
•
Fault release
•
Pre-purge and ignition release
•
Pre-purge suppression
For Details refer to chapter 3.2.1 Digital Inputs.
Electronic ratio control system
The integrated electronic ratio control unit ensures that the control element outputs are corrected and precisely positioned at their pre-programmed curve set positions at each point in
the firing range.
Each of the control elements has a feedback position mechanism that enables the controller
to verify its actual position in relation to the programmed position; the feedback is either potentiometer or 4-20mA.
If the verified position deviates from the programmed position for too long a period or by too
may 'digits' a safety shut-down is initiated together with an alarm indicating the nature of the
fault
•
The controller stops actuators in order to prevent these actuators from leaving the control
system.
•
It ensures that the actuator activity stays within the control system.
23
3
System Description
Range monitoring is used to check the actual positions reported by the actuators. If these positions deviate too far and too long from the internally calculated setpoints, a safety shut-down
is initiated.
The following values are used to calculate the setpoints:
•
Curve sets stored in the EEPROM
•
Correction values received
•
External firing rate received
•
Internal firing rate - actual value
•
Parameters
•
Recirculation channel release
Internal validation requires that the feedback from each active control element must change
by a minimum amount at least once every 24 hours. If there has been no change within a 24
hour period then a change of output is initiated and the feedback checked. If the feedback
does not reflect the change of the output then an internal fault shutdown is initiated and corresponding alarm generated.
Fault history
The fault history shows the last 10 faults with fault number, fault text, affected module, curve
set, date, time of day, operating conditions, firing rate, setpoints and actual values. In addition,
the state of the existing inputs and outputs is shown as a time sequence. A detailed description of the CMS remote software is provided in the chapter 7.3 Operation, Controls and Display with CMS Remote Software
Interfaces
The CMS is equipped with an Ethernet interface for PC communication. Windows-based software can be supplied optionally.
A Modbus TCP protocol can also be operated over the same hardware interface.
The CMS is compatible with other LAMTEC system components such as the range of LT oxygen and COe flue gas analysers for oxygen trim and CO Control. Communications with these
devices is via the LAMTEC SYSTEM BUS (LSB).
Optional interface modules for PROFIBUS DP, PROFINET and Modbus RTU are available
(partly under development), further modules on request.
3.2
Digital Input/Output Functions
3.2.1
Digital Inputs
List of digital inputs (logic signals), version V1.0.3
Input
Description
System safety interlock chain
Fault shut-down signal of the combustion system
Air pressure main air 1 > min.
Combustion air pressure switch position; the dynamics are checked during start-up.
Main flame 1
Main flame signal present *
Main flame 2
Main flame signal present *
Main flame 3 (in development)
Main flame signal present *
24
3
System Description
Input
Description
High fire acknowledgement
If this signal is absent, the burner sequencer stops at
high fire. The pre-purge time does not count down.
This signal can be used as a condition for pre-purging.
Ignition position acknowledgement
If this signal is absent, the burner sequencer stops at
the ignition position. Ignition does not start.
This signal can be used as a condition for ignition.
Also called 'ignition hold'
Fault reset
This signal resets faults in the CMS.
A fault reset can also be initiated via the HMIs (UI400
and GUI6xx) as well as via the bus interfaces.
In the case of a remote reset, the guidelines specified
in EN 1361 must be respected.
Pre-purge suppression
If the signal is present during ’burner on’, CMS starts
without pre-purge.
Recirculation ON
If this signal is absent, the recirculation channel
remains at the lower range limit in burner operation.
Cooling air operation
(in development)
The signal activates cooling operation after ’Burner
OFF’
Pilot flame
The signal can be used if the main flame monitor does
not monitor the pilot flame.
Air pressure ignition air >min.
Air pressure monitor for ignition air
Air pressure main air 2 > min.
Standby operation
Signal to activate and deactivate standby operation,
see chapter 5.2.2 Standby Mode.
Flue gas damper OPEN
Recirculation gas pressure
monitor
Atomiser medium pressure
monitor
Burner ON
This signal switches the burner on. Removing the signal switches the burner off.
Control release
If the ’control release’ signal is absent, the control
system stays at low fire (LFH).
Burner OFF
The signal switches the burner off or prevents the
burner starting up. It overrides the ’Burner ON’ signal.
CPI input
This signal checks whether the valve is closed. A total
of 8 signals are possible:
CPI 1 for fuel trains 1 … 4
CPI 2 for fuel trains 1 … 4
Fuel safety interlock chain
Signal to switch off in the event of absent fuel-relevant
monitoring signals.
4 Signals for the chains 1 ... 4 are possible.
Pressure between the valves
in the fuel train > min.
This signal monitors the minimum pressure between
the valves with active valve leakage testing.
4 Signals for the chains 1 ... 4 are possible.
Fuel pressure < max.
This signal monitors the maximum pressure.
4 Signals for the chains 1 ... 4 are possible.
25
3
System Description
*
3.2.2
Input
Description
Pressure before valves > min.
Signal to switch off if pressure < min.
If the pressure drops below the minimum value, a
fault shut-down is initiated.
4 Signals for the chains 1 ... 4 are possible.
Safety chain input
User-configurable input for a safety chain function,
see chapter 3.2.4 Chain Functions.
Curve set selection
Signal for curve set pre-selection (max. 16 possible),
see chapter 3.2.5 Curve Set Selection.
Firing rate+/firing rate−
These signals increase or reduce the burner firing
rate if the regular firing rate input is configured to TPS.
Soft PLC input signal
User-programmable input via PLC
The signals "Main flame present" are logically connected in series (AND operation).
Digital Outputs
List of digital outputs, version V1.0.3:
3.2.3
Output
Description
Pilot valve 1+2
Activates the pilot valves
Fuel train 1–4
valves 1+2
Activates valve 1 and valve 2 in fuel
trains 1–4
Spark igniter per fuel train
1–4
Activates the spark igniter for fuel trains 1–4
Purge valve 1–4
Activates purge valves 1–4
Fault status signal
Indicates that CMS is in fault state.
Fan
Activates the fan
Fuel pump
Activates the fuel pump
Atomiser steam 1–4
Activates atomiser steam valves 1–4
Pilot fan 1–4
Activates the motor for pilot fans 1–4
Activation of the mechanic
ratio control
Provides floating contacts for controlling a servo
motor in combination with a mechanic ratio control.
Assignment of Input/Output Functions
(logic signals to the input/output terminals)
The input and output functions (logic signals) of the physical terminals in the CMS are assigned using the I/O matrix in the CMS remote software. Among these, there are signals
whose use is mandatory and those whose use is optional. To help with this assignment, the
CMS remote software provides a link matrix and a link table.
See chapter 7.3.3.4, section Configuration
26
3
3.2.4
System Description
Chain Functions
A total of 10 signal chains are available for linking together various input signals. These chains
are assigned to any logic signal as required and can consist of up to 16 links. These links must
be assigned to a physical input via the I/O matrix in the CMS remote software package.
Input functions/logic signals already assigned (e.g. main flame 1 and main flame 2) can also
be assigned to a signal chain.
See chapter Configuration
3.2.5
Curve Set Selection
3.3
Analogue Inputs/Outputs
3.3.1
Analogue Inputs
Analogue inputs can be any of the following physical signals:
– 0/4 - 20 mA
– Pt100
– NAMUR pulses/3-wire, inductive
– 0/2 - 10 V
– Pt1000
– Potentiometer
Examples of functions that can be
3.3.2
predefined:***
•
Regular firing rate input
•
Correction 1–4
•
Actuator pressure control
•
Burner firing rate controller actual value
•
Setpoint shift
•
Fuel meter
Analogue outputs
Analogue outputs can be assigned to any of the following physical signals:
– 0/ - 20 mA
– 0/ - 10 V
Examples of functions that can be output:
•
Monitor output
•
Servo motor
•
More functions possible
***
This is not an exhaustive list. Other functions are possible.
27
3
3.4
System Description
Functional Description of the Modules
MCC
Burner module: This module is equipped with the burner control with flame monitoring system,
valve leakage test as well as the complete communication interfaces.
The following variants of the inputs and outputs are available:
Inputs
24 VDC
Outputs
24 VDC
Type 668R0100 -05
Inputs
24 VDC
Outputs
120 VAC
Type 668R0100 -04
Inputs
24 VDC
Outputs
230 VAC
Type 668R0100 -03
Inputs
120 VAC
Outputs
120 VAC
Type 668R0100 -02
Inputs
230 VAC
Outputs
230 VAC
Type 668R0100 -01
AEC-TPS
Module for controlling and monitoring 2 three-point step servomotors with potentiometer for
position acknowledgement.
The module is available in the following voltage variants:
120 VAC
Type 668R0200-120VAC
230 VAC
Type 668R0200-230VAC
AEC-VS
Module for controlling and monitoring frequency inverters or actuators with 4 ... 20 mA input
and 4 ... 20 mA acknowledgement. For the control of frequency inverters, the speed is recorded with pulse, Namur or three wire sensors. In addition, the module provides a non-failsafe
output for activating the frequency inverter and a non-failsafe input for importing the frequency
inverter’s fault status signals
.
The module is available in the following voltage variants:
24 VDC
Type 668R0230-24VDC
120 VAC
Type 668R0230-120VAC
230 VAC
Type 668R0230-230VAC
SDI
Module with 8 safe digital inputs.
The module is available in the following voltage variants:
24 VDC
Type 668R0400-24VDC
120 VAC
Type 668R0400-120VAC
230 VAC
Type 668R0400-230VAC
SDO
Module with 8 safe digital inputs.
The module is available in the following voltage variants:
24 VDC
Type 668R0500-24VDC
120 VAC
Type 668R0500-120VAC
230 VAC
Type 668R0500-230VAC
28
3
System Description
SAI
Module with 6 non-safe, analogue inputs or 3 safe, analogue inputs and 2 pulse inputs for fuel
meters. The following can be processed as analogue input signals: 4 ... 20 mA, Pt100 and
Pt1000.
UI400
Compact HMI for fault status signals, curve programming, simple parameter setting and system queries.
GUI6xx
Touch panel with graphical menus for convenient curve programming, advanced parameter
setting and all system queries. The touch panel is available in the following sizes:
3.5
GUI607
7"
Type 668R1000
GUI610
10"
Type 668R1002
GUI615
15"
Type 668R1004
Life Cycle
CMS has a designed lifetime of 250,000 burner start-up cycles.**** In normal operating conditions in heating mode, this corresponds to a usage of approx. 10 years (starting from the production date given on the type plate).
Other values may result from the operating conditions of the respective plant.
The basis for this is formed by the stress tests specified in the EN 298 standard and referenced standards.
The design lifetime applies when using the base system according to the specifications given
in the documentation. If the designed lifetime is reached, the device must be replaced by authorised and trained personnel.
**** The
design lifetime is not the same as the lifetime as described in the terms of delivery.
29
4
CMS Components
4
CMS Components
4.1
MCC – Master Control Component (burner module)
4.1.1
For Your Safety
4.1.2
•
Use password entry to protect parameters from unauthorised modification.
•
Use external flame sensors only when these have been tested and approved according to
applicable local regulations see chapter 2.3.3.4 FFS/ION/Terminal - Flame Tolerance
Time.
•
When connecting flame sensors approved for intermittent operation only, the MCC must
also be configured for intermittent operation (settings in P 301).
•
The safety times can be accessed via the HMIs (UI400, GUI607/GUI610/GUI615).
Technical Data
Fig. 4-1 Figure of MCC
Fig. 4-2 MCC dimensional drawing
30
4
CMS Components
Part number
Type 668R1000-XX*
MCC – Master Control Component
*
XX = depends on configuration
Function
Supply voltage
MCC
24 VDC +/−20%, SELV
Inputs
230 V/120 V +10/−15%, 47–63 Hz, 24 VDC ±20%
Outputs
230 V/120 V +10/−15%, 47–63 Hz, 24 VDC ±20%
Maximum backup fuse/outputs
8 A fast-acting
Current draw
Min: 200 mA
Max: 335 mA
Power consumption max.
10 W
Digital inputs
Nominal
current:
2.3 mA (230 VAC), impedance 100 kΩ
2.1 mA (120 VAC), impedance 100 kΩ
2.1 mA (24 VDC), impedance 100 kΩ
Since the inrush currents on the are low, use gold-plated silver
contacts.
Digital outputs
Signal ON:
0.78 mA (230 VAC) 77 VAC
0.97 mA (120 VAC) 56 VAC
0.55 mA (24 VDC) 6.9 VDC
Signal OFF:
0.35 mA (230 VAC) 36 VAC
0.35 mA (120 VAC) 21 VAC
0.27 mA (24 VDC) 4 VDC
Imax = 2 A per output, but not to exceed 8 A in total
cos  0.2
Residual voltage possible due to self-test function.
Flame sensor input
Optical: Flame sensor connection FFS07 or FFS08
Unom = 27 V ±1 V
Ionisation: 230 VAC (120 VAC) supply voltage
Imin = 1 A
Imax = 50 A
Cable length max: 300 m, shielded.
Current output
0 - 20 mA ±2%
Output current max: 25 mA
Load max: 1 kΩ
Use shielded cables only!
Analogue input
Multifunctional input for the connection of:
– Potentiometer (2 kΩ … 10 MΩ)
– TPS (see wiring diagram chapter)
– Power input 0/4 - 20 mA, Ri = 150 Ω – Voltage input 0 - 10 V, Ri = 100
MΩ
Reference voltage 10 V, short-circuit proof
Tolerance ±2%
Use shielded cables only!
Fieldbus
MODBUS TCP
LAMTEC SYSTEM BUS
Other Fieldbus protocols using separate modules
31
4
CMS Components
Function
Housing
Dimensions (H × W × D) [mm]
120 x 67.8 x 121
Weight [kg]
0,505
Flammability
UL94 V-0
Environmental conditions
Operation
Transportation
Storage
Electrical safety
Climatic conditions
Class 3K5 according to DIN EN 60721-3-3, 5-95%
Mechanical conditions
Class 3M5 according to DIN EN 60721-3-3
Temperature range
−30 … +70°C (non-condensing)
Climatic conditions
Class 2K4 according to DIN EN 60721-3-2,  95%
Mechanical conditions
Class 2M2 according to DIN EN 60721-3-2
Temperature range
−40 … +80°C (non-condensing)
Climatic conditions
Class 1K3 according to DIN EN 60721-3-1, 5-95%
Mechanical conditions
Class 1M2 according to DIN EN 60721-3-1
Temperature range
−40 … +80°C (non-condensing)
IP rating according to DIN EN 60529
IP20 ( as long as all terminals are mounted)
NOTICE
The limits of the technical data must be strictly adhered to.
4.1.3
Functional Description
The MCC can be used independently, without any expansion modules, as a standalone burner
sequencer for gaseous and liquid fuels. The on-board I/O is sufficient for basic burner control
components such as fuel isolation valves, air pressure switch etc. Burner control components
are defined in the CMS I/O matrix. In addition to standard digital inputs and outputs an input
is provided for LAMTEC dedicated FFS07 and FFS08 flame sensors as well as the option for
ionisation input - all without the need for a separate continuous pilot burner flame relay. There
is an analogue input to accept a 4-20mA firing rate signal from an external source and an analogue output to drive a 4-20mA third-party motor for burner modulation using standard mechanical linkages. A three-point step motor, with potentiometer feedback is also available as
an control output option. The MCC can be configured and commissioned for each application
using either one of the CMS HMI touch screen panel options or using the PC-based CMS configuration software.
The analogue inputs of the CMS (MCC or SAI) can be used as digital signals. To do so, the
IO configuration must be set as in chapter 4.6.4 Functional Description.
32
4
CMS Components
4.1.4
LEDs
LED
Colour
Explanation
PWR
Gree
n
LED is active as soon as the device is supplied with voltage.
ERR
*
Burner firing-rate
In operation
– ON: There is a fault
– Flashing at 2 Hz:
Device initialising
– ON: There is a fault.
– OFF: No fault
iLSB
Yellow
– Flashing at 2 Hz:
iLSB initialising
– Permanent light:
iLSB successfully initialised
– OFF and ERR-LED OFF:Passive mode*
– OFF and ERR-LED ON:
Fault during system layer initialisation
– Permanent light: iLSB communication OK,
Module is in operation
– Short flashing (60 ms on/140 ms off): Synchronisation
– Short flashing (140 ms on/60 ms off): IDLE
– Short flashing (50 ms on/50 ms off): Middleware fault
S1
Yellow
– Flashing at 2 Hz:
EEPROM initialising
– Permanent light:
EEPROM successfully
initialised
– OFF: There are no indications/messages from the
middleware.
– ON: There are indications/messages from the
middleware
S2
Yellow
– Flashing at 2 Hz:
ICOM initialising
– Permanent light: ICOM successfullyinitialised
– Flashing at 2 Hz:
PEC identification activated.
Passive mode = PEC not taught-in
LED
Colour
Description
SPS
Green
Initialising
– Permanent ON, 1 time per second OFF:
Operation
– ON: SPS in operation
– OFF: SPS in stop
– Flashing: SPS in single step operation
Fault
– 5 s ON - Fault code - 5 s ON - Fault code - ...
Initialising/
operation
– ON: LSB active
– OFF: LSB inactive
– Flashing: Fault code
Fault
– 5 s ON - fault code - 5 s ONN - fault code - ...
LSB
Yellow
LEDs at RJ45 Plug
ACT
Yellow
– OFF: No activity at the Ethernet connection
– Flashing: The module transfers/receives data
Link
Green
– ON: The Ethernet connection is established
– OFF: Establishing the Ethernet failed
NOTICE
Report the fault codes to the support (p. ex. by video transmission).
33
4
CMS Components
4.1.5
Terminal Assignment
Fig. 4-3 MCC 230 VAC or 120 VAC terminal assignment
Fig. 4-4 MCC 24 VDC terminal assignment
Fig. 4-5 Alternative terminal assignment for ionisation
34
4
CMS Components
4.1.6
Connection Diagram
Fig. 4-6 Connection diagram for MCC for 220 VAC/120 VAC (for 24 VDC) inputs and outputs
Terminal assignment: Safe input for FFS07/FFS08
X25-1
pi
X26-1
bk
X25-2
–
X26-2
gn
X25-3
ye
X26-3
bl
X25-4
we
X26-4
rd
35
4
4.1.7
CMS Components
Interfaces
Ethernet/Modbus TCP
The Ethernet interface enables communication between the CMS and a remote PC. The connection cable must conform to the Ethernet specifications.
This interface is also used to connect the GUI6xx.
An Ethernet switch can be used to deploy multiple nodes simultaneously.
LAMTEC SYSTEM BUS
The CMS uses both the failsafe LAMTEC SYSTEM BUS (iLSB), for the interconnection of
CMS modules, and the non-failsafe LAMTEC SYSTEM BUS (LSB) to communicate with other
system components such as a LAMTEC LT series flue gas analyser for oxygen trim and/or CO
Control.
Even when LT3-F is connected with 2 LT2/LT1 for CO control, the safe transmission of the relevant signals is ensured by protocol adaptation, despite the unsafe LSB hardware.
The cable length of the ILSB system must not exceed 100 m.
The cable length of the LBS system is about 500 m. The cable must be shielded and use twisted-pair cabling. For more information about LSB, see ’LAMTEC SYSTEM BUS Technical
Documentation’, publication no. DLT6095.
Consult the CAN specification!
PROFINET
Optional module EBM112: The connection requirements match those of the PROFINET
specification. The cable length must not exceed 100 m (Ethernet without repeater). Minimum
specification = CAT-5.
For more information about EBM112, see ’Commissioning supplement for fieldbus module
EBM112’ (DLT1226).
PROFIBUS
In the pipeline
Modbus RTU
In the pipeline
36
4
4.2
CMS Components
AEC-TPS – Actuator Extension Component Three Point Step
Extension Module for Three Point Step Actuators
4.2.1
4.2.2
For Your Safety
•
As an option, the AEC-TPS has 2 position acknowledgement inputs per motor. When using failsafe, single-channel feedback according to EN 12067-2, one input has one potentiometer.
•
Feedback potentiometer used to verify the position of TPS motors must be of an approved
type in order to comply with the CMS certification.
•
The connection between the actuator drives and the actuator units must be positive-locking throughout and designed to operate with the maximum torque from the drive systems.
•
Via induction, motor movements create generator-like voltages in the open, inactive control circuit of the motor up to a maximum of double the supply voltage.
•
An inactive output has a residual voltage that can cause electric shock if touched.
Technical Data
Fig. 4-7 AEC-TPS photo
37
4
CMS Components
Fig. 4-8 AEC-TPS dimensional drawing
Item number
Type 668R0200-XX*
AEC-TPS Actuator Extension Component - DPS-Motor
*
XX = dependent on the configuration
Function
Power supply
AEC-TPS
24 VDC ± 20 % (via plug-in connection from MCC)
Motor outputs
230 VAC +10/-15 %, 47 - 63 Hz, 0.5 A max
120 VAC +10/-15 %, 47 - 63 Hz, 0.5 A max
Caution! Semiconductor switching element: A minimum residual voltage is present even when the device is switched off.
Maximum pre-fuse
1.6 A slow-blow for each output module
Current consumption
Min: 50 mA
Max: 60 mA
Power consumption
2W
Analogue signal inputs
Potentiometer 1:
Potentiometer, conductive plastic 1 kΩ ... 10 kΩ
qualified according to EN 12067-2 when using a
single-channel position feedback signal
Reference voltage 6.6 V
Potentiometer 2:
optional
Potentiometer, conductive plastic 1 kΩ ... 10 kΩ
Reference voltage 6.6 V
Resolution
0.1 % from angle of rotation
Repeating precision
Electronic ratio control accuracy:
– for annual check ±1.5 %
– across the entire life cycle of 10 years ±5.3 %
Running time motor to TPS module
Not less than 30 s to 90°
Potentiometer connection
Max. conductor length = 100 m, shielded conductor
38
4
CMS Components
Housing
Dimensions (h x w x d)
120 mm x 45.3 mm x 121 mm
Weight
0.244
kg
Flammability
UL94 V-0
Environmental conditions
Operation
Transport
Storage
Electrical safety
Climatic condition
Class 3K5 as per DIN EN 60721-3-3, 5 % ... 95 %
Mechanical condition
Class 3M5 as per DIN EN 60721-3-3
Temperature range
-30...+70 °C (no condensation permitted)
Climatic condition
Class 2K4 as per DIN EN 60721-3-2,  95 %
Mechanical condition
Class 2M2 as per DIN EN 60721-3-2
Temperature range
-40...+80 °C (no condensation permitted)
Climatic condition
Class 1K3 as per DIN EN 60721-3-1, 5 % ... 95 %
Mechanical condition
Class 1M2 as per DIN EN 60721-3-1
Temperature range
-40...+80 °C (no condensation permitted)
Protection class as per DIN EN60529
IP20 (when all terminals are fitted)
NOTICE
The limits of the technical data must be strictly adhered to.
4.2.3
Functional Description
Via AEC-TPS, CMS controls up to 2 DPS servomotors for positioning air and fuel valves, for
example, as part of electronic ratio control.
AEC-TPS has the following:
•
Outputs for activating 2 DPS AC motors (OPEN/CLOSED)
•
Inputs for connecting a potentiometer for read back the motor position
•
Input for connecting a redundant potentiometer (option).
•
Wear-free TRIACs for 230 VAC or 120 VAC for power switching
Resolution:
•
Representation of the position: 0 ... 999 digits
Channel configuration per channel
Parameters are scaling the channel feedback.
•
AEC-TPS configuration lower range (P 48, P 50)
•
AEC-TPS configuration upper range (P 49, P 51)
Setting the parameters, requires a reboot of the system.
Factory setting: 0 ... 65360
39
4
CMS Components
4.2.4
LEDs
LED
Colour
Explanation
PWR
Gree
n
LED is active as soon as the device is supplied with voltage.
ERR
*
Burner firing-rate
In operation
– ON: There is a fault
– Flashing at 2 Hz:
Device initialising
– ON: There is a fault.
– OFF: No fault
iLSB
Yellow
– Flashing at 2 Hz:
iLSB initialising
– Permanent light:
iLSB successfully initialised
– OFF and ERR-LED OFF:
Passive mode*
– OFF and ERR-LED ON:
Fault during system layer
initialisation
– Permanent light: iLSB communication OK,
Module is in operation
– Short flashing (60 ms on/140 ms off):
Synchronisation
– Short flashing (140 ms on/60 ms off): IDLE
– Short flashing (50 ms on/50 ms off):
Middleware fault
S1
Yellow
– Flashing at 2 Hz:
EEPROM initialising
– Permanent light:
EEPROM successfully
initialised
– OFF: There are no indications/messages from the
middleware.
– ON: There are indications/messages from the
middleware
S2
Yellow
– Flashing at 2 Hz:
ICOM initialising
– Permanent light:
ICOM successfully
initialised
– Flashing at 2 Hz:
PEC identification activated.
Passive mode = PEC not taught-in
LED
Colour
Description
 M1
Yellow
Motor 1 - Control OPEN
M1
Yellow
Motor 1 - Control CLOSE
M2
Yellow
Motor 2 - Control OPEN
 M2
Yellow
Motor 2 - Control CLOSE
40
4
CMS Components
4.2.5
Terminal Assignment
Fig. 4-9 AEC-TPS 230 VAC or 120 VAC terminal assignment
41
4
CMS Components
4.2.6
Connection Diagram
Fig. 4-10 AEC-TPS connection diagram
4.2.7
Interfaces
Failsafe communication via iLSB.
42
4
4.2.8
CMS Components
Approved Actuators
662R2127
6 Nm
662R2111
20 Nm
662R2121
40 Nm
662R2123
90 Nm
662R2125
180 Nm
668M2006
6 Nm
668M2020
20 Nm
668M2040
40 Nm
Further servo motors are in the pipeline.
4.3
AEC-VS – Actuator Extension Component Variable Speed
Extension Module for Frequency Inverters
4.3.1
For Your Safety
•
When using the module to provide speed feedback for a frequency-controlled fan, it must
be ensured that values cannot exceed or drop below the selected measurement range.
Check the parameter settings!
•
For motors with 0/4 - 20 mA position preset, the position feedback must be independent
of and non-interacting with the preset.
•
When using a frequency controlled fan, the actual speed of the fan must be used as feedback - either by connecting the speed sensor directly to the AEC-VS or by interconnecting
a converter to 4 ... 20 mA
•
A 4 ... 20 mA feedback signal that comes directly from the FI or a signal that does not
directly represent the fan speed is invalid must not be processed.
•
The digital input 1 and the digital output of the AEC-VS must not be used for safety-relevant functions.
DANGER!
Warning! Risk of short circuit and electric shock!
Incorrect wiring can lead to a short circuit and irreversible damage to the connected equipment
or may cause an electric shock.
 For connections with SELV, always ensure a safe isolation from the supply voltage in the
wiring and with the connected equipment!
43
4
CMS Components
4.3.2
Technical Data
Fig. 4-11 AEC-VS photo
Fig. 4-12 AEC-VS dimensional drawing
Item number
AEC-VS Actuator Extension Component - Variable Speed
*
Type 668R2030-XX*
XX = dependent on the configuration
Function
Power supply
24 VDC ± 20 % (via plug-in connection from MCC)
Current consumption
Min: 50 mA
Max: 60 mA
Power consumption
2W
44
4
CMS Components
Signal inputs
Namur
Sensor supply: 8.2 V, max. 8.2 mA
Pulse input for connecting inductive
sensors with Namur interface according to
EN 60947-5-6
Conversion of the sensor recording into digital information:
– Inactive: >2.1 mA  Digital signal ON
– Active/pulse: <1.2 mA  Digital signal OFF
– Hysteresis: ≥ 0.5 mA
Frequency range: 5 ... 9400 pulses/min (0.25 ... 157 Hz)
Pulse length: min. 200 s,
Use shielded connection cable for cable lengths >10 m.
Pulse input 3-wire
Sensor supply: 24 V
Pulse input for connecting inductive
sensors with
3-wire interface
Conversion of the input voltage into digital information:
– Inactive: 0 V/High-Z  Digital signal OFF
– Active/pulse: 24 V  Digital signal ON
– Hysteresis: ≥ ¼ Umax
Frequency range: 5 ... 9400 pulses/min. (0.25 ... 157 Hz)
Pulse length: min. 200 s,
Use shielded connection cable for cable lengths >10 m.
Analogue input 0/4 ... 20 mA
Range: 0/4 ... 20 mA, load 150 Ω, accuracy ±1 %
for connecting speed transmitter 4 ...
20 mA or position detectors from servomotors with power interface 4 ... 20
mA.
Overcurrent limitation: approx. 25 ... 28 mA
Digital inputs*
Nominal current:
Use shielded connecting pipework
2.3 mA (230 VAC), impedance 100 kΩ
2.1 mA (120 VAC), impedance 75 kΩ
2.1 mA (24 VDC), impedance 11 kΩ
Due to low currents on the contacts, use gold-plated silver contacts.
Signal ON:
0.78 mA (230 VAC) 77 VAC
0.97 mA (120 VAC) 56 VAC
0.55 mA (24 VDC) 6.9 VDC
Signal OFF:
0.35 mA (230 VAC) 36 VAC
0.35 mA (120 VAC) 21 VAC
0.27 mA (24 VDC) 4 VDC
Electrically safe separation between the input and electronics,
floating
*
Do not use for safety-relevant signals
Outputs
Analogue output
0/4 ... 20 mA or 0/2 ... 10 V
Same setpoint for both outputs
Can be set via parameters
Current output 0/4 ... 20 mA
Accuracy ±1.5 %
Use shielded connecting pipework
Voltage output 0/2 ... 10 V
Voltage ripple ≤50 mVpp
max. current 10 mA
Short circuit proof
Accuracy ±2 % of the maximum value
Use shielded connecting pipework
45
4
CMS Components
Outputs
Digital output
Non-safe, digital output
Relay output, floating
Voltage up to 230 VAC/50 Hz
Rated current: 2 A, cos  = 0.2
Fuse protection:
Resettable/electronic 4.1 A max. (voltage-dependent)
Not resettable 5 A fast-acting
Electrically safe separation from SELV power supply voltage of the
CMS system
Environmental conditions
Operation
Transport
Storage
Electrical safety
Climatic condition
Class 3K5 as per DIN EN 60721-3-3, 5% ... 95 %
Mechanical condition
Class 3M5 as per DIN EN 60721-3-3
Temperature range
-30...+70 °C (no condensation permitted)
Climatic condition
Class 2K4 as per DIN EN 60721-3-2,  95 %
Mechanical condition
Class 2M2 as per DIN EN 60721-3-2
Temperature range
-40...+80 °C (no condensation permitted)
Climatic condition
Class 1K3 as per DIN EN 60721-3-1, 5% ... 95 %
Mechanical condition
Class 1M2 as per DIN EN 60721-3-1
Temperature range
-40...+80 °C (no condensation permitted)
Protection class according to DIN EN
60529
IP20 (when all terminals are fitted)
NOTICE
The limits of the technical data must be strictly adhered to.
46
4
CMS Components
4.3.3
Terminal Assignment
Fig. 4-13 AEC-VS 230 VAC or 120 VAC terminal
assignment
47
Fig. 4-14 AEC-VS 24 VDC terminal assignment
4
4.3.4
CMS Components
Functional Description
The AEC-VS is equipped with:
•
Pulse input for connecting inductive proximity sensors with NAMUR interface
•
Pulse input for connecting inductive proximity sensors with 3-wire interface
•
Analogue input for the connection of rotary encoders with current interface 0/4 - 20 mA or
position indicators from actuator drives with current interface 0/4 - 20 mA
•
Non-failsafe, digital output (typically configured for ’Fan ON’)
•
Analogue current output 0/4 - 20 mA
•
Analogue voltage output 2/0 - 10 V
•
Non-failsafe, digital input (typically configured with ’Fan fault’)
Channel configuration
Parameters are scaling the channel feedback.
•
AEC-VS configuration lower range (P 48, P 50)
•
AEC-VS configuration upper range (P 49, P 51)
The type of the used input must be set in ’AEC-VS configuration input’.
Setting the parameters require a reboot of the system.
4.3.5
LEDs
LED
Colour
Explanation
PWR
Gree
n
LED is active as soon as the device is supplied with voltage.
ERR
Burner firing-rate
In operation
– ON: There is a fault
– Flashing at 2 Hz:
Device initialising
– ON: There is a fault.
– OFF: No fault
iLSB
Yellow
– Flashing at 2 Hz:
iLSB initialising
– Permanent light:
iLSB successfully initialised
– OFF and ERR-LED OFF:
Passive mode*
– OFF and ERR-LED ON:
Fault during system layer
initialisation
– Permanent light: iLSB communication OK,
Module is in operation
– Short flashing (60 ms on/140 ms off):
Synchronisation
– Short flashing (140 ms on/60 ms off): IDLE
– Short flashing (50 ms on/50 ms off):
Middleware fault
S1
Yellow
– Flashing at 2 Hz:
EEPROM initialising
– Permanent light:
EEPROM successfully
initialised
– OFF: There are no indications/messages from the
middleware.
– ON: There are indications/messages from the
middleware
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CMS Components
S2
*
Yellow
Burner firing-rate
In operation
– Flashing at 2 Hz:
ICOM initialising
– Permanent light:
ICOM successfully
initialised
– Flashing at 2 Hz:
PEC identification activated.
Passive mode = PEC not taught-in
LED
Colour
Description
Nam
Yellow
Each pulse at the Namur input switches the LED. The LED flashes at half pulse frequency.
3-Wire
Yellow
Each pulse at the 3-wire input switches the LED. The LED flashes at half pulse frequency.
4.3.6
Connection Diagram
Fig. 4-15 AEC-VS connection diagram
* 4 … 20 mA or 0 … 10 V
4.3.7
Interfaces
Failsafe communication via iLSB.
49
4
4.3.8
CMS Components
Sensors Suitable for CMS
The following sensors are tested with the CMS:
•
Namur sensor type 663R8101
•
3-wire sensor type 663R8103
4.4
SDI - Safe Digital Input
4.4.1
For Your Safety
See chapter 2 Safety
4.4.2
Technical Data
Fig. 4-16 SDI photo
50
4
CMS Components
Fig. 4-17 SDI dimensional drawing
Part number
Type 668R0400-XX*
SDI Safe Digital Input component
*
XX = depends on configuration
Function
Supply voltage
24 VDC +/−20%, SELV (by plug connection from MCC)
Current draw
Min: 40 mA
Max.: 45 mA
Power consumption
1.5 W max.
Digital signal inputs
Nominal input
current:
2.3 mA (230 VAC), impedance 100 kΩ
2.1 mA (120 VAC), impedance 57 kΩ
2.1 mA (24 VDC), impedance 11 kΩ
Signal ON (Min.):
0.78 mA (230 VAC) 77 VAC
0.97 mA (120 VAC) 56 VAC
0.55 mA (24 ADC) 6.9 VDC
Signal OFF
(max.):
0.35 mA (230 VAC) 36 VAC
0.35 mA (120 VAC) 21 VAC
0.27 mA (24 VDC) 4 VDC
Since the inrush currents on the contacts are low, use gold-plated silver contacts.
Housing
Dimensions (H × W × D) [mm]
120 × 22.8 × 121
Weight [kg]
0,140
Flammability
UL94 V-0
Environmental conditions
Operation
Transportation
Climatic conditions
Class 3K5 according to DIN EN 60721-3-3, 5-95%
Mechanical conditions
Class 3M5 according to DIN EN 60721-3-3
Temperature range
−30 … +70°C (non-condensing)
Climatic conditions
Class 2K4 according to DIN EN 60721-3-2,  95%
Mechanical conditions
Class 2M2 according to DIN EN 60721-3-2
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CMS Components
Environmental conditions
Storage
Electrical safety
Temperature range
−40 … +80°C (non-condensing)
Climatic conditions
Class 1K3 according to DIN EN 60721-3-1, 5-95%
Mechanical conditions
Class 1M2 according to DIN EN 60721-3-1
Temperature range
−40 … +80°C (non-condensing)
IP rating according to DIN EN 60529
IP20 ( as long as all terminals are mounted)
NOTICE
The limits of the technical data must be strictly adhered to.
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4
CMS Components
4.4.3
Terminal Assignment
Fig. 4-18 Terminal assignment SDI 230 VAC or
120 VAC
53
Fig. 4-19 Terminal assignment SDI 24 VDC
4
CMS Components
4.4.4
Functional Description
Each SDI module provides up to failsafe digital inputs which can be used to expand the I/O of
a CMS system. The safe digital inputs are assigned using the CMS configuration software.
4.4.5
LEDs
LED
Colour
Explanation
PWR
Gree
n
LED is active as soon as the device is supplied with voltage.
ERR
*
Burner firing-rate
In operation
– ON: There is a fault
– Flashing at 2 Hz:
Device initialising
– ON: There is a fault.
– OFF: No fault
iLSB
Yellow
– Flashing at 2 Hz:
iLSB initialising
– Permanent light:
iLSB successfully initialised
– OFF and ERR-LED OFF:
Passive mode*
– OFF and ERR-LED ON:
Fault during system layer
initialisation
– Permanent light: iLSB communication OK,
Module is in operation
– Short flashing (60 ms on/140 ms off):
Synchronisation
– Short flashing (140 ms on/60 ms off): IDLE
– Short flashing (50 ms on/50 ms off):
Middleware fault
S1
Yellow
– Flashing at 2 Hz:
EEPROM initialising
– Permanent light:
EEPROM successfully
initialised
– OFF: There are no indications/messages from the
middleware.
– ON: There are indications/messages from the
middleware
S2
Yellow
– Flashing at 2 Hz:
ICOM initialising
– Permanent light:
ICOM successfully
initialised
– Flashing at 2 Hz:
PEC identification activated.
Passive mode = PEC not taught-in
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4
CMS Components
4.4.6
Connection Diagram
Fig. 4-20 SDI connection diagram
4.4.7
Interfaces
Failsafe communication via iLSB.
55
4
4.5
CMS Components
SDO - Safe Digital Output
Extension Module for Failsafe Digital Outputs
4.5.1
For Your Safety
See chapter 2 Safety
4.5.2
Technical Data
Fig. 4-21 SDO photo
Fig. 4-22 SDO dimensional drawing
56
4
CMS Components
Part number
Type 668R0500-XX*
SDO Safe Digital Output component
*
XX = depends on configuration
Function
Supply voltage
Module
Outputs
24 VDC (by connecting plugs from MCC)
230 V/120 V +10/-15 %, 47-63 Hz, 24 VDC ± 20 %
Backup fuse max. for outputs
8 A quick-acting
Current draw
Min: 40 mA
Max: 170 mA
Power consumption
5W
Digital outputs
Imax = 2 A per output
cos φ ≥ 0.2
Max. total current over all outputs: 8 A
Housing
Dimensions (H × W × D) [mm]
120 × 45.3 × 121
Weight [kg]
0,335
Flammability
UL94 V-0
Environmental conditions
Operation
Transportation
Storage
Electrical safety
Climatic conditions
Class 3K5 according to DIN EN 60721-3-3, 5-95%
Mechanical conditions
Class 3M5 according to DIN EN 60721-3-3
Temperature range
−30 … +70°C (non-condensing)
Climatic conditions
Class 2K4 according to DIN EN 60721-3-2,  95%
Mechanical conditions
Class 2M2 according to DIN EN 60721-3-2
Temperature range
−40 … +80°C (non-condensing)
Climatic conditions
Class 1K3 according to DIN EN 60721-3-1, 5-95%
Mechanical conditions
Class 1M2 according to DIN EN 60721-3-1
Temperature range
−40 … +80°C (non-condensing)
IP rating according to DIN EN 60529
IP20 (as long as all terminals are mounted)
NOTICE
The limits of the technical data must be strictly adhered to.
57
4
CMS Components
4.5.3
Terminal Assignment
Fig. 4-23 Terminal assignment SDO 230 VAC or
120 VAC
58
Fig. 4-24 Terminal assignment SDO 24 VDC
4
CMS Components
4.5.4
Functional Description
SDO is a module which is designed for failsafe digital outputs. It enhances the CMS system.
SDO is equipped with 8 failsafe digital outputs These are assigned to the CMS system by software functions.
4.5.5
LEDs
LED
Colour
Explanation
PWR
Gree
n
LED is active as soon as the device is supplied with voltage.
ERR
*
Burner firing-rate
In operation
– ON: There is a fault
– Flashing at 2 Hz:
Device initialising
– ON: There is a fault.
– OFF: No fault
iLSB
Yellow
– Flashing at 2 Hz:
iLSB initialising
– Permanent light:
iLSB successfully initialised
– OFF and ERR-LED OFF:
Passive mode*
– OFF and ERR-LED ON:
Fault during system layer
initialisation
– Permanent light: iLSB communication OK,
Module is in operation
– Short flashing (60 ms on/140 ms off):
Synchronisation
– Short flashing (140 ms on/60 ms off): IDLE
– Short flashing (50 ms on/50 ms off):
Middleware fault
S1
Yellow
– Flashing at 2 Hz:
EEPROM initialising
– Permanent light:
EEPROM successfully
initialised
– OFF: There are no indications/messages from the
middleware.
– ON: There are indications/messages from the
middleware
S2
Yellow
– Flashing at 2 Hz:
ICOM initialising
– Permanent light:
ICOM successfully
initialised
– Flashing at 2 Hz:
PEC identification activated.
Passive mode = PEC not taught-in
59
4
CMS Components
4.5.6
Connection Diagram
Fail-safe relay outputs
Fig. 4-25 SDO connecting diagram
4.5.7
Interfaces
Failsafe communication via iLSB.
60
4
CMS Components
4.6
SAI - Safe Analogue Input
4.6.1
For Your Safety
See chapter 2 Safety
4.6.2
Technical Data
Fig. 4-26 SAI photo
Fig. 4-27 SAI dimensional drawing
61
4
CMS Components
Part number
Type 668R0600-XX*
SAI Safe Analogue Input Component
*
XX = depends on configuration
Function
Supply voltage
24 VDC ±20% (by connecting plug from MCC)
Current draw
Min: 65 mA
Max: 350 mA
Power consumption
8.4 W
Housing
Dimensions (H × W × D) [mm]
120 x 22,8 x 121
Weight [kg]
0.131
Flammability
Complies with IACS, E10, test 21
Environmental conditions
Operation
Transport
Storage
Electrical safety
Climatic conditions
Class 3K5 according to DIN EN 60721-3-3, 5% … 95%
Mechanical conditions
Class 3M5 according to DIN EN 60721-3-3
Temperature range
−30 - +70°C (non-condensing)
Climatic conditions
Class 2K4 according to DIN EN 60721-3-2,  95%
Mechanical conditions
Class 2M2 according to DIN EN 60721-3-2
Temperature range
−40 - +80°C (non-condensing)
Climatic conditions
Class 1K3 according to DIN EN 60721-3-1, 5% … 95%
Mechanical conditions
Class 1M2 according to DIN EN 60721-3-1
Temperature range
−40 - +80°C (non-condensing)
IP rating according to DIN EN 60529
IP20 (if all terminal are mounted)
NOTICE
The limits of the technical data must be strictly adhered to.
62
4
CMS Components
4.6.3
Terminal Assignment
Fig. 4-28 SAI 230 VAC terminal assignment
4.6.4
Functional Description
Terminal configuration
Six inputs can be configured for each SAI by ’SAI terminal configuration’.
The SAI parameter array is initiated based on the sequence number of the SAI module address.
•
SAI 1: P 1270 1-6
•
SAI 2: P 1270 7-12
•
SAI 3: P 1270 13-18
For more information refer to the parameter list document no. DLT7202
Setting the parameters require a reboot of the system.
63
4
CMS Components
NOTICE
It must be possible to measure a resistance of 120  between unconnected terminals. If the
measured value is greater than 120  and goes to infinity, a resistance has burned out. The
device must be replaced. If the measured value is 120  the error is outside the device in the
event of an error.
Using an analogue input as a digital input
The analogue inputs of the CMS (MCC or SAI) can be used as digital signals. To do so, the
IO configuration must be set as follows:
How to set the IO configuration to analogue-digital usage
1. In CMS Remote Software select: Menu CMS >> Configuration >> IO-Matrix
2. Set the analogue input at MCC or SAI to a digital signal
NOTICE
Failsafe digital signals may only be configured to failsafe analogue inputs!
NOTICE
For MCC: Only digital inputs that are not fail-safe may be configured to the analogue input of
the MCC.
3. Configure the hysteresis:
P 1260 … 1268 = SAI,
P 1269 = MCC analogue input 1
P 1326 = MCC analogue input 2
4. Configure the hysteresis:
Example: SAI 1 terminal X15/16 (failsafe input), upper threshold 10000 μA, lower threshold 4000 μA P.1260.0 = 10000 << 16 | 4000 << 1 = 655368000
This means that from a value of 10,000 μA on a logic 1 is detected and from a value of
4000 μA a logic 0 is detected.
4.6.5
LEDs
LED
Colour
Explanation
PWR
Gree
n
LED is active as soon as the device is supplied with voltage.
ERR
Burner firing-rate
In operation
– ON: There is a fault
– Flashing at 2 Hz:
Device initialising
– ON: There is a fault.
– OFF: No fault
64
4
*
CMS Components
Burner firing-rate
In operation
iLSB
Yellow
– Flashing at 2 Hz:
iLSB initialising
– Permanent light:
iLSB successfully initialised
– OFF and ERR-LED OFF:
Passive mode*
– OFF and ERR-LED ON:
Fault during system layer
initialisation
– Permanent light: iLSB communication OK,
Module is in operation
– Short flashing (60 ms on/140 ms off):
Synchronisation
– Short flashing (140 ms on/60 ms off): IDLE
– Short flashing (50 ms on/50 ms off):
Middleware fault
S1
Yellow
– Flashing at 2 Hz:
EEPROM initialising
– Permanent light:
EEPROM successfully
initialised
– OFF: There are no indications/messages from the
middleware.
– ON: There are indications/messages from the
middleware
S2
Yellow
– Flashing at 2 Hz:
ICOM initialising
– Permanent light:
ICOM successfully
initialised
– Flashing at 2 Hz:
PEC identification activated.
Passive mode = PEC not taught-in
4.6.6
Connection Diagram
Fig. 4-29 SAI connection diagram
Assignment of terminal blocks X11–X16
Si In
failsafe input
PIN 1
Ref+
nSi In
non-failsafe input
PIN 2
Input+
PIN 3
Input−
PIN 4
GND
65
4
CMS Components
SAI terminal assignment
Pulses – NAMUR
Pulses – 3-wire
Pot
Pt100/Pt1000
0 … 10 V
0 … 20 mA
Connection examples
+24 VDC
from MCC (e.g. X33 pin 2/4)
Pin 1
Ref+
Pin 2
In+
Pin 3
In-
Pin 4
GND
SAI X11–X16
Fig. 4-30 0 … 10 V signal transmitter (here: pressure transmitter)
+24 VDC
Pin 1
Ref
Pin 2
In+
Pin 3
In-
Pin 4
GND
SAI X11–X16
Fig. 4-31 0/4 … 20 mA signal transmitter, 3-wire
(here: pressure transmitter)
66
4
CMS Components
+24 VDC
from MCC (e.g. X33 pin 2/4)
Pin 1
Ref+
Pin 2
In+
Pin 3
In-
Pin 4
GND
SAI X11–X16
Fig. 4-32 0/4 … 20 mA signal transmitter, 2-wire
(here: pressure transmitter)
Pin 1
Ref+
Pin 2
In+
Pin 3
In-
Pin 4
GND
SAI X11–X16
Fig. 4-33 0/4 … 20 mA signal transmitter, active signal
Pin 1
Ref+
Pin 2
In+
Pin 3
In-
Pin 4
GND
SAI X11 - X16
Fig. 4-34 0 ... 10 V signal transmitter, active signal
NOTICE
3-wire pulse generators must be operated with the provided voltage of 12 V in order to avoid
destruction of the inputs. The functionality of the encoders is not limited by a specification of
10 - 30 V.
67
4
CMS Components
Type of
Input
Configuration Software
Configuration Software
Sensors
Connection
Parameter
IO-Matrix
Non-failsafe
1 per input = 1 nsi
signal
see Fig. 4-29 SAI connection diagram
P 1270
Bit 0 ... 6: Function
Bit 7 = 0
Mapping as nsi AI
Failsafe,
linked
1 per 2 inputs =
1 si signal
see 4.6.6 Connection Diagram
P 1270
Bit 0 ... 6: Function
Bit 7 = 1
Mapping as si AI
Failsafe,
not linked
2 per 2 input = 1 si
signal
see Fig. 4-29 SAI connection diagram
P 1270
Bit 0 ... 6: Function
Bit 7 = 0
Mapping as si AI
Switch in parallel pairs IN+ and IN(Pin 2 and 3)
– Input 1 to 2
– Input 3 to 4
– Input 5 to 6
– Pt100/Pt1000:
Ref+ (PIN1) additional in parallel
Sensor connections are independent to each other
Allocation between Function and Bits see Parameter list DLT7202.
4.6.7
Interfaces
Failsafe communication via iLSB.
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4
CMS Components
4.7
UI400 - User Interface
4.7.1
For Your Safety
See chapter 2 Safety
4.7.2
Technical Data
Fig. 4-35 UI400 photo
Fig. 4-36 UI400 mounting dimensions
Cut-out for UI400 installation: 108 mm × 61 mm:
Part number
UI400 user interface, connection via LSB
Type 668R0300
Function
Supply voltage
Via LSB
Power consumption
1W
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4
CMS Components
Function
Current draw
Imin: 32 mA – with screen saver, backlight OFF
Imax: 16 mA – with max. 20 mA/10 V at setpoint outputs.
Housing
Dimensions (H × W × D) [mm]
64 × 112 × 26
Weight [kg]
0,149
Flammability
Complies with IACS, E10, test 21
Environmental conditions
Operation
Transport
Storage
Electrical safety
Climatic conditions
Class 3K5 according to DIN EN 60721-3-3, 5% …
95%
Mechanical conditions
Class 3M5 according to DIN EN 60721-3-3
Temperature range
−20 - +60°C (non-condensing)
Climatic conditions
Class 2K3 according to DIN EN 60721-3-2,  95%
Mechanical conditions
Class 2M2 according to DIN EN 60721-3-2
Temperature range
−40 - +80°C (non-condensing)
Climatic conditions
Class 1K3 according to DIN EN 60721-3-1, 5% …
95%
Mechanical conditions
Class 1M2 according to DIN EN 60721-1
Temperature range
−40 - +80°C (non-condensing)
IP rating according to DIN EN 60529
IP54
NOTICE
The limits of the technical data must be strictly adhered to.
4.7.3
Functional Description
The UI400 is an HMI for configuration and monitoring.
4.7.4
Pin Assignment
Fig. 4-37 UI400 terminal assignment
70
+
RD
+24 VDC
-
BK
GND
H
OG
CAN H
L
BR
CAN L
4
4.7.5
CMS Components
Interfaces
Communication via LSB with CMS.
4.8
Graphic User Interface - GUI607/GUI610/GUI615
4.8.1
For Your Safety
4.8.2
•
Only use with SELV supply voltage in accordance with DIN EN 60730.
•
If this is not available, the GUI must be supplied by the 24 V output of the CMS.
Technical Data
4.8.2.1 GUI607
Fig. 4-38 GUI607
Fig. 4-39 Ensure unobstructed air circulation! >20 mm
71
4
CMS Components
Fig. 4-40 GUI607 mounting dimensions in mm
Cut-out for GUI706 installation: 187 mm × 136.5 mm for a sheet thickness of 2 mm
Part number
GUI607 graphical user interface, 7" 24 VDC, panel installation
Type 668R1000
Function
Supply voltage
24 VDC −15/+20% SELV
max. AC voltage component 5% with inverse-polarity protection
Maximum backup fuse
10 A slow-blow
Power consumption
Module electronics current consumption
Type 0.3 A, max. 1.2 A at +24 VDC
Display diagonal/resolution
7" display, 800 × 400 (WVGA)
Touch screen type
Resistive
Colours
TFT: 16.7 M (24 bits/pixel)
CPU
800 MHz ARMÒ CPU with Cortexä-A9 single core
RAM/flash/non-volatile memory
256 MB RAM/256 MB flash/100 kB FRAM
Communication interfaces
2x Ethernet, 10/100 Base, RJ45
Housing
Dimensions (H × W × D) [mm]
222 × 152 × 57
Weight [kg]
0.6
Installation
Integrated locking tabs
Flammability
72
4
CMS Components
Environmental conditions
Operation
Transport
Storage
Electrical safety
Mech. safety
Temperature range
0 - +55 °C (non-condensing)
Relative humidity
Max. 85%, non-condensing
Temperature range
−20 - +70 °C (non-condensing)
Relative humidity
Max. 85%, non-condensing
Temperature range
−20 - +70 °C (non-condensing)
Relative humidity
Max. 85%, non-condensing
IP rating according to DIN EN 60529
IP20
IP54 front (IP65 only with tensioned twist lock)
Protection class
III
Dielectric strength
EN 61131-2
ESD resistance
EN 61131-2
Electrostatic discharge
EN 55011 class B, group 1
Vibration
Sinusoidal (EN 90068-2-6)
Test: Fc; 10 - 150 Hz, 1 G (operating mode)
Shock resistance
15 G (approx. 150 m/s2), duration 10 ms, semisinusoidal
(EN 6068-2-27)
Test: Ea
Certification:
CE
EN 61131-2
CB Scheme
IEC 61010-2-201
cULus
UL 61010-2-201
NOTICE
The limits of the technical data must be strictly adhered to.
73
4
CMS Components
4.8.2.2 GUI615
Fig. 4-41 GUI615
Fig. 4-42 Ensure unobstructed air circulation!
>20 mm
Fig. 4-43 Dimensional drawing GUI615
74
4
CMS Components
Part number
GUI615 graphical user interface, 7" 24 VDC, panel installation
Type 668R1004
Function
Supply voltage
24 VDC −15/+20% SELV
max. AC voltage component 5% with inverse-polarity protection
Maximum backup fuse
10 A slow-blow
Power consumption
Module electronic current consumption
Type 0.8 A, max. 1.2 A at +24 VDC
Display diagonal/resolution
15.6" display, 1366 × 768 (WXGA)
Touch screen type
Resistive
Colours
TFT: 16.7 M (24 bits/pixel)
CPU
800 MHz ARMÒ CPU with Cortexä-A9 single core
RAM/flash/non-volatile memory
512 MB RAM/2048 MB flash/100 kB FRAM
Communication interfaces
2x Ethernet, 10/100 Base, RJ45
Housing
Dimensions (H × W × D) [mm]
425 × 280 × 55
Weight [kg]
3 kg
Installation
Removable tensioned clamps
Environmental conditions
Operation
Transport
Storage
Electrical safety
Mech. safety
Temperature range
0 - +55 °C (non-condensing)
Relative humidity
Max. 85%, (non-condensing)
Temperature range
−20 … +70 °C (non-condensing)
Relative humidity
Max. 85%, (non-condensing)
Temperature range
−20 … +70 °C (non-condensing)
Relative humidity
Max. 85%, (non-condensing)
IP rating according to DIN EN 60529
IP20 / IP65 front
Protection class
III
Dielectric strength
EN 61131-2
ESD resistance
EN 61131-2
Electrostatic discharge
EN 55011 class B, group 1
Vibration
Sinusoidal (EN 90068-2-6)
Test: Fc; 10 - 150 Hz, 1 G (operating mode)
Shock resistance
15 G (approx. 150 m/s2), duration 10 ms, semisinusoidal (EN 6068-2-27); Test: Ea
Certification:
CE
EN 61131-2
CB Scheme
IEC 61010-2-201
cULus
UL 61010-2-201
NOTICE
The limits of the technical data must be strictly adhered to.
75
4
4.8.3
CMS Components
Functional Description
The GUI6xx models are HMIs for the configuration and monitoring of a burner.
The following models are available:
4.8.4
•
GUI 607 with 7" screen diagonal
•
GUI 610 with 10" screen diagonal
•
GUI 615 with 15" screen diagonal
Connection Diagram
Fig. 4-44 Connection assignments GUI607
No.
Description
No.
Description
1
Display 7 "
X1
Power supply
2
Mounting clamp (3 pcs.)
X3
USB 2.0
3
Turning bolt (6 pcs.) for IP 65
X4
Ethernet
S1
Function key (reset and run/
stop)
X8
Do not use
LED
LEDs: PWR, run/stop, error
μSD
Connection for microSD card (for further options)
76
4
CMS Components
Fig. 4-45 GUI615 connection diagram
4.8.5
No.
Description
No.
Description
1
Display 16,5 "
X6
EtherCAT
2
LEDs: PWR, Run/Stop, Error
X8
CAN-Bus
3
LEDs: Power, digital I/O
X9
RS-232/RS-485
4
Ground
X11
Do not use
X1
Power supply, digital inputs
and outputs
S1
Do not use
X2
Analogue inputs
S2
Termination resistor CAN (120 )
X3
USB 2.0
S3
Terminating resistor RS-485 (120 )
X4
Ethernet
X5
USB 2.0
Interfaces
2x Ethernet, 10/100 Base, RJ45 (1 active)
NOTICE
Consult the Ethernet specification.
77
4
CMS Components
4.9
Router
4.9.1
For Your Safety
4.9.2
•
When connecting the CMS to a local Ethernet LAN or WLAN, the applicable IT security
guidelines must be respected.
•
The network must be protected against any unauthorised access.
Functional Description
Recommendation for Ethernet-based communication:
Weidmüller IE-SW-BL05-5TX Fast Ethernet.
Other suitable routers can also be used as an alternative.
As an alternative, communication can also be established using the CMS remote software via
WLAN. Recommendation: ALF high-speed WLAN router, type 9352-ALF-GK
78
5
5
Functional Description with Process Diagrams
Functional Description with Process Diagrams
The following process diagrams are examples only. The actual process diagrams will depend
on the CMS configuration.
5.1
Basic Burner Sequencer Functionality
NOTICE
The special points required, such as pre-purge position and post-purge position must be
set.
5.1.1
Default Process Flow for Gas Modulating with Pilot Burner
Fig. 5-1 Process sequence chart for gas modulating with pilot burner
79
5
Functional Description with Process Diagrams
Signal bar
Significant times and their parameters
Standard
Signal must be present.
t4*
Parasitic light monitoring time
P803
5.0 s
Signal must not be present.
t5
Pre-ventilation time
P318
1 - 999 s
Signal can be present.
t6
Transformer pre-activation time
P309
3.0 s
t7
1st
safety time
P305
4.0 s
t8
Stabilization time
P310
3.0 s
t9
2nd
P308
3.0 s
t11
Control release delay time
P380
0.0 s
t12
Block and bleed of the gas train
P334
3.0 s
t13
Post-ventilation time
P319
0.0 s
t22
Program monitoring time
P304
600 s
t23
Irrelevance time
P323
2.0 s
safety time
Fig. 5-2 Gas train for standard sequence for gas modulating with pilot burner
V1
Gas side fuel valve
M
V2
Burner side fuel valve
Pmin Min. gas pressure monitor
V3.1 Gas side pilot valve
80
Gas damper servomotor
V4.1 Burner side pilot valve
5
5.1.2
Functional Description with Process Diagrams
Default Process Flow for Gas Modulating Without Pilot Burner
Fig. 5-3 Process sequence chart for gas modulating without pilot burner
Signal bar
Significant times and their parameters
Standard
Signal must be present.
t4*
Parasitic light monitoring time
P803
5.0 s
Signal must not be present.
t5
Pre-ventilation time
P318
1 - 999 s
Signal can be present.
t6
Transformer pre-activation time
P309
3.0 s
t7
1st
P305
4.0 s
t11
Control release delay time
P380
0.0 s
t12
Block and bleed of the gas train
P334
3.0 s
t13
Post-ventilation time
P319
0.0 s
t22
Program monitoring time
P304
600 s
t23
Irrelevance time
P323
2.0 s
81
safety time
5
Functional Description with Process Diagrams
Fig. 5-4 Gas train for standard process flow gas modulating without pilot burner
5.1.3
V1
Fuel valve on gas side
M
Actuator drive for gas damper
V2
Fuel valve on burner side
Pmin Min. gas pressure monitor
Default Process Flow for Oil Modulating With Pilot Burner
Fig. 5-5 Process sequence chart for oil modulating with pilot burner
Signal bar
Significant times and their parameters
Standard
Signal must be present.
t4*
Parasitic light monitoring time
P803
5.0 s
Signal must not be present.
t5
Pre-ventilation time
P318
1 - 999 s
Signal can be present.
t6
Transformer pre-activation time
P309
3.0 s
t7
1st
P305
4.0 s
82
safety time
5
Functional Description with Process Diagrams
Signal bar
Significant times and their parameters
Standard
t8
Stabilization time
P310
3.0 s
t9
2nd
P308
3.0 s
t11
Control release delay time
P380
0.0 s
t12
Block and bleed of the gas train
P334
3.0 s
t13
Post-ventilation time
P319
0.0 s
t22
Program monitoring time
P304
600 s
t23
Irrelevance time
P323
2.0 s
safety time
Fig. 5-6 Oil train for standard process flow oil modulating with pilot burner
V1
Fuel valve on oil side
V2
Fuel valve on burner side
V3
Pilot valve on gas side
V4
Pilot valve on burner side
83
M
Actuator drive for gas damper
5
5.1.4
Functional Description with Process Diagrams
Default Process Flow for Oil Modulating Without Pilot Burner
Fig. 5-7 Process sequence chart for oil modulating without pilot burner
Signal bar
Significant times and their parameters
Standard
Signal must be present.
t4*
Parasitic light monitoring time
P803
5.0 s
Signal must not be present.
t5
Pre-ventilation time
P318
1 - 999 s
Signal can be present.
t6
Transformer pre-activation time
P309
3.0 s
t7
1st
P305
4.0 s
t11
Control release delay time
P380
0.0 s
t13
Post-ventilation time
P319
0.0 s
t22
Program monitoring time
P304
600 s
t23
Irrelevance time
P323
2.0 s
safety time
Fig. 5-8 Oil train oil modulating without pilot burner
V1
Fuel valve on oil side
V2
Fuel valve on burner side
84
M
Actuator drive for gas damper
5
Functional Description with Process Diagrams
5.2
Additional Burner Sequencer Functionality
5.2.1
Start Without Pre-Purge
NOTICE
The external signal for pre-purge suppression must be fail-safe.
5.2.1.1 Requirements
NOTICE
This function may only be activated if local regulations and the system configuration permit a
burner start without pre-purge or if sufficient pre-purge is ensured by other measures.
NOTICE
The function must be mapped.
5.2.1.2 Required Inputs/Outputs
The following digital inputs are required for the "pre-purge suppression" function:
•
Pre-purge suppression without testing for air pressure drop
If this input is mapped and activated, no pre-ventilation is carried out.
•
Pre-purge suppression for gas according to EN676
If this input is mapped and activated, no pre-purge according to EN676 is carried out in
gas operation.
For a description of the digital inputs, see chapter 3.2 Digital Input/Output Functions
5.2.1.3 Required Parameters
This function does not require any special parameters.
5.2.1.4 Functional Description
Pre-purge suppression by an external signal
The pre-purge function can be skipped with the ’Pre-purge suppression’ signal. If the signal is
present before ’Burner start-up’, the actuators move directly to the ignition position.
The external light monitoring of the flame scanner is carried out prior to the start of the flame
detection (P 803).
85
5
Functional Description with Process Diagrams
5.2.2
Standby Mode
NOTICE
The pilot flame scanner must either be approved for continuous operation or the pilot flame is
monitored together with the main flame with a flame scanner approved for continuous operation.
NOTICE
For the standby function, please consult both the Installation Manual and Commissioning
Manual, and also take into account the specific requirements for the combustion system.
5.2.2.1 Requirements
Paid option
•
The burner must be equipped with a pilot valve and a pilot flame and must be ignitable by
this valve/flame.
•
The standby operation input must be configured (see chapter Inputs/Outputs, Measurement Values).
•
The fuel supply for the ignition must not be taken from between the main valves
5.2.2.2 Required Inputs/Outputs
Inputs:
•
Standby operation is active
•
Pilot air pressure monitor (optional)
Outputs:
•
Pilot valve
•
Pilot air fan (optional)
5.2.2.3 Required Parameters
P no.
42
808
Description
Attributes
Standby mode (0 = OFF, 1 = ON)
V1.0.0.0
Standby mode
0 = OFF
1 = ON
Write: 4
Read: 7
Default: 0
Min.: 0
Max.: 1
Pilot air operation (0-OFF; 1-Pilot fan output and pilot fan air pressure signals)
V1.1.0.0
0: Pilot air operation OFF
1: Pilot air operation ON
The pilot air operation requires the pilot fan output and the air pressure signals of the pilot
fan.
Write: 2/GUI/UI
Read: 0
Default: 0
Min: 0
Max:1
86
5
Functional Description with Process Diagrams
5.2.2.4 Functional Description
Fig. 5-9 Process sequence chart for standby operation with the example of gas
Signal bar
Significant times and their parameters
Standard
Signal must be present.
t2
Filling time of the gas path
P313
2.0 s
Signal must not be present.
t9
2nd safety time
P308
3.0 s
Signal can be present.
t11
Control release delay time
P380
0.0 s
t12
Block and bleed of the gas line
P334
3.0 s
t23
Irrelevance time
P323
2.0 s
87
5
Functional Description with Process Diagrams
Fig. 5-10 Gas train for standard sequence for gas modulating with pilot burner
Fig. 5-11 Oil train for standard process flow oil modulating with pilot burner
V1
Gas side fuel valve
M
V2
Burner side fuel valve
Pmin Min. gas pressure monitor
V3.1 Gas side pilot valve
5.2.3
Gas damper servomotor
V4.1 Burner side pilot valve
Purging the Fuel Train
Purging oil gun and gas train
This function is used to discharge residual fuel from an oil gun or gas train into the flame. If
the oil gun or gas train is purged then the 2nd safety time (pilot valve and fuel valve open) is
increased at the next burner start sequence as the oil gun or gas train will have to be primed
again before ignition.
5.2.3.1 Requirements
The special curve point ’Purge oil gun’ must be configured.
How to set the special curve points see chapter 6.3.2 Configuring Special Points.
5.2.3.2 Required Inputs/Outputs
For purging the oil gun, 2 additional logical input signals are required:
•
Purge valve
•
Atomiser steam valve
88
5
Functional Description with Process Diagrams
5.2.3.3 Required Parameters
P no.
809
Description
Attributes
Extension of 2
nd
safety time [s]
V1.0.0.0
nd
810
812
813
Extension of 2 safety time in s for e.g. oil gun or gas train purging
0: no purging
1…999: extension of 2nd safety time for oil
Write: 4/GUI/UI
Read: 0
Default: 0
Min.: 0
Max.: 999
Duration of purging/blow out [s]
V1.0.0.0
Duration of purge process (purging, blow out) in s
0: No purging
1…999: Duration of process
Write: 1/GUI/UI
Read: 0
Default: 0
Min.: 0
Max.: 999
Delay in opening purge valve. (0 – valve opens after closing the fuel valve; 1 – valve opens
after reaching ignition position.)
V1.0.0.0
Delay in opening purge valve
0: The valve opens after closing of the fuel valve.
1: The valve opens after reaching the ignition position.
Write: 4/GUI/UI
Read: 0
Default: 0
Min.: 0
Max.: 1
Activation of the purging process: (0 – no purging; 1 – automatic after switching off or manually via input; 2 – manual only via input)
V1.0.0.0
Setting whether and how purging is activated.
0: no purging
1: automatic purging after switch-off or purging is started manually by an input
2: purging is started manually by an input
Write: 4/GUI/UI
Read: 0
Default: 0
Min.: 0
Max.: 255
5.2.3.4 Purging After Operation
If 'Purge fuel train' is active then all the fuel valves are closed after the burner ON signal has
been removed, i.e. the burner is commanded off. The atomiser valve remains active and the
oil valve is set to its purge position. The spark igniter and pilot valve are then activated and
once the flame has been established the stabilisation timer is started and run. Pilot flame monitoring is active during this period. The pilot flame or main flame must be lit during purge operation. The purge process is only started once a flame has been established.
The function can be used only if CMS is configured to ’Start with pilot burner’.
After the stabilisation time t2 for the pilot flame is complete (P 310), the system waits until the
oil actuator has reached the purge position.
P 812 = 0 → the parameter set purge duration t3 (P 810) starts, while the actuators move to
the programmed special point ’Purge oil gun’.
P 812 = 1 → The programmed special point ’Purge oil gun’ is moved to before the time t3 expires. .
After the expiry of t3, the purge valve and atomiser valve are closed. The spark igniter and
pilot valve are also deactivated. The burner sequencer transitions to the mode OFF.
NOTICE
If the burner should reach low fire before purging, the control release must be removed before
the switch-off command and the time taken for the burner to reach base fire must be waited
out.
89
5
Functional Description with Process Diagrams
NOTICE
This function is active only from software version 2.0.
Process Diagram 'Purging after Operation'
Fig. 5-12 Process sequence chart for purging oil gun
7
Control
t6
Transformer pre-activation time P309
0.0 s - 40.0 s
8
Burner OFF
t13
Post-ventilation time P 319
0.0 s - 999 s
t19
Duration of purging P 810
0.0 s - 999.9 s
t5 is the waiting time until the actuators have reached the purging position. The purging valve
is then opened.
t5 + t3 produce the purging duration (total). During the entire process, the safety interlock
chain oil must be secured.
NOTICE
If the purging valve is activated by P 812 = 1 and after closing the oil valve, without having
waited for t2, t5 first and not having reached the required position, the flame will not be monitored during the time t2.
90
5
Functional Description with Process Diagrams
Fig. 5-13 Oil train for standard process flow oil modulating with pilot burner
Time of Purge after Operation
The purging takes place before an optionally configured post-purge and the valve leakage test
following operation (relevant when switching off from mixed operation). The post-purge and
valve leakage test are delayed correspondingly, and then run afterwards in parallel as before.
Restarting with Extended 2nd Safety Time when Igniting - Flag
CMS sets a failsafe flag which stores the outcome of whether the last oil gun purge was successful or not.
If a purge was successful then the oil gun/lance is deemed to be empty and the 2nd safety time
is correspondingly extended by the relevant parameter value for ignition with oil to allow time
for the oil gun/lance to be primed. The flag is retained even in the event of a power outage or
fault.
If the purging was not completed successfully, the next system start is a regular start and does
not involve any extension of the 2nd safety time.
NOTICE
Recommendation:
If the purging process does not complete without errors, the burner must be restarted and
must be purged again. This prevents oil residues drying onto the inside of the oil gun.
The higher-level control functions and instructions for operating personnel must be documented as appropriate.
NOTICE
A fault shut-down during purging can lead to a situation where the gun is only partially discharged. Since the flag for extending the safety time during the start is not set in this case, the
regular safety time is used for the start. This, in turn, can lead to a series of ignition failures.
5.2.3.5 Purging with Digital Input
Requirements for ’Purging by digital input’
•
Burner switches OFF.
•
The flame mus be OFF.
A pulse is set by the input signal ’Start purging’, which initiates the sequence ’Burner start’.
91
5
Functional Description with Process Diagrams
After the pre-ventilation time has elapsed, the compound moves to the ignition point and the
pilot burner is started. The spark igniter remains active throughout the stabilisation time and
the entire purging time. The fuel valves do not open.
The purging time starts after the stabilisation time. The purging valve opens immediately and
the channels move to the purging position.
Alternatively, a purging position can be configured in P xxx. In this case, the purging starts not
before this position has been reached.
After the delay time for opening the fuel valves (P xxx) has elapsed, the fuel valves move to
the upper range limit. If the value 0 is set, the fuel valves remain in the purging position.
The atomiser valve, as defined in the parameter, remains active throughout the entire burning
and purging period and is monitored with the input ’atomizer air pressure > min.’ if mapped.
After activation of the ignition valve, an irrelevance time of 3 s for the atomiser air pressure
expires. The atomiser air pressure is only monitored when using fuel oil.
5.2.3.6 Purging Oil Gun during Standby Operation and Fuel Changeover by Pilot Burner
The oil gun must be purged during a changeover via pilot burner and in standby mode. In
these modes, both the spark igniter and the pilot valves are always opened before the fuel
valves close.
After the stabilisation time has elapsed, the fuel valve closes and the oil gun purging process
then starts. The atomiser valve remains active until the end of the purging.
5.2.3.7 Operating Modes for the 'Purging Fuel Train Function
Purging takes place:
5.2.4
•
After operation
•
During changeover via OFF from oil to gas: Purging after operation.
•
During changeover via pilot burner from oil to gas: Purging into the pilot flame.
•
In the standby mode for oil operation: Purging into the pilot flame.
•
In OFF mode: Activation takes place by a special signal (V1.2.0.0 and higher).
Pilot Burner - Continuous Operation
If the pilot burner is configured for continuous operation, the pilot valve remains open even
after the end of the 2nd safety time.
NOTICE
The pilot flame must be monitored separately.
5.2.4.1 Requirements
NOTICE
The function has to be mapped.
5.2.4.2 Required Inputs/Outputs
•
Input ’Pilot burner operation’
92
5
Functional Description with Process Diagrams
5.2.4.3 Required Parameters
P no.
302
Description
Attributes
Control and monitoring of the pilot burner
(0-Start without; 1-Start with; 2-even active in operation; 3-Start with, only pilot flame may be
present during ignition; 4-active in operation, with continuous operation monitoring, only pilot
flame may be present during ignition; 9-Start with, can be switched on during operation)
V1.0.0.0
0 = Start without pilot burner
1 = Start with pilot burner
2 = The pilot burner is active in operation, too.
3 = Start with pilot burner. Only pilot flame may be present during ignition.
4 = Pilot burner is active in operation, with continuous operation monitoring.
Only pilot flame may be present during ignition.
9 = Start with pilot burner.
The pilot burner can be switched on during operation.
Write: 2/GUI/UI
Read: 0
Default: 0
Min: 0
Max: 9
5.2.4.4 Process Sequence Chart: Pilot Burner Continuous Operation
Fig. 5-14 Example: Process sequence chart for gas modulating with pilot burner continuous operation
Signal bar
Significant times and their parameters
Standard
Signal must be present.
t4*
Parasitic light monitoring time
P803
5.0 s
Signal must not be present.
t5
Pre-ventilation time
P318
1 - 999 s
Signal can be present.
t6
Transformer pre-activation time
P309
3.0 s
93
5
Functional Description with Process Diagrams
Signal bar
5.2.5
Significant times and their parameters
st
Standard
t7
1 safety time
P305
4.0 s
t8
Stabilization time
P310
3.0 s
t9
2nd
P308
3.0 s
t11
Control release delay time
P380
0.0 s
t12
Block and bleed of the gas train
P334
3.0 s
t13
Post-ventilation time
P319
0.0 s
t22
Program monitoring time
P304
600 s
t23
Irrelevance time
P323
2.0 s
safety time
CPI/POC - Closed Position Indication/Proof of Closure
5.2.5.1 Requirements
The gas valves to be monitored must be equipped with limit switches (CPI/POC).
5.2.5.2 Required Inputs/Outputs
CPI/POC input for 1st main valve for each fuel
CPI/POC input for 2nd main valve for each fuel
For a description of the digital inputs, see chapter 3.2 Digital Input/Output Functions
5.2.5.3 Required Parameters
P no.
329
Description
Attributes
Special functions of burner sequencer
V1.0.0.0
0 = gas valve 1 opens together with pilot valve in the 1st safety time during ignition
1 = gas valve 1 opens together with gas valve 2 in the 2nd safety time during ignition
Write: 2/GUI/UI
Read: 0
Default: 0
Min.: 0
Max.: 7
5.2.5.4 Functional Description
The CPI/POC input monitors the position of the main valve to the CLOSED position by a limit
switch in the main valve.
As soon as the valve opens, the limit switch contact is also opened. If this contact does not
switch correctly, a fault shut-down is initiated.
94
5
Functional Description with Process Diagrams
5.2.6
Valve Leakage Test
NOTICE
The gas pressure test switch and design and volume of the test section pipework must be set
and designed such that the valve test system reliably detects even the smallest gas leakage
by the valve testing system at maximum combustion thermal output.
EN1648 requires a minimum gas leakage of 0.1% volume in relation to the gas flow rate at
maximum combustion thermal output, but at least 50 dm3/hr.
5.2.6.1 Requirements
NOTICE
The function must be mapped.
The pressure switch between the 2 main valves must be mapped either for valve leakage test
or gas pressure min. and valve leakage test.
5.2.6.2 Required Parameters
P no.
311
313
334
802
Description
Attributes
Valve leakage test before burner start-up [0.1 s]
V1.0.0.0
Configured duration of the valve leakage test in 0.1 s
Write: 1/GUI/UI
Read: 0
Default: 200
Min.: 50
Max.: 9999
Fill time of the valve leakage test [0.1 s]
V1.0.0.0
Fill time of the valve leakage test in 0.1 s
Write: 4/GUI/UI
Read: 0
Default: 20
Min.: 20
Max.: 50
Block and bleed time of valve leakage test line [0.1 s]
V1.0.0.0
Time in 0.1 s for which the gas valve 2 is opened for block and bleed of the valve leakage
test line.
Write: 0/GUI/UI
Read: 0
Default: 10
Min.: 0
Max.: 25
Type of valve leakage test (0–none; 1–together with pre-purge; 2–after pre-purge is completed; 4–after burner operation; 5–before operation together with the pre-purge; 6–before
operation after pre-purge is completed)
V1.0.0.0
Type of valve leakage test:
0: no valve leakage test
1: valve leakage test starts together with the pre-purge
2: valve leakage test starts after pre-purge is completed
4: valve leakage test after burner operation
5: valve leakage test before operation starts together with pre-purge and after burner
operation
6: valve leakage test before operation starts after pre-purge is completed and after burner
operation
Write: 1/GUI/UI
Read: 0
Default: 0,1,0,0
Min.: 0
Max.: 7
95
5
Functional Description with Process Diagrams
5.2.6.3 Functional Description
The gas valve leakage test checks the integrity of main gas valves 1 & 2. The supply gas pressure is used to carry out this automatic test procedure. After a controlled burner shutdown,
any gas in test line (the space within the pipework between the two main gas valves) will have
been burnt off and so the pressure in the test section should be atmospheric i.e. gas pressure
> min = 0.
The CMS checks this and if true then Main gas valve 1 is opened for a short time to allow gas
to flow into the test line.
The CMS checks that the gas pressure > min value changes to = 1. This pressure condition
must remain for 30 seconds after which the gas valve leakage test is deemed successful and
complete.
If the valve leakage test line is not empty at the start (e.g. as a result of a previous fault shutdown), main gas valve 2 opens first. The valve leakage test line is vented (into the combustion
chamber or over the roof, depending on the system; for suggested circuit, see Appendix). It is
checked, whether the line remains pressureless for 30 seconds. Otherwise the procedure is,
as described previously.
The valve leakage test is performed before ignition.
The pressure monitor for the valve leakage test line must be connected to ’Gas pressure >min’
input (terminal 47). This also monitors the minimum gas pressure during normal operation. If
there is a requirement for another minimum pressure device to be monitored during normal
operation then this should be incorporated into gas safety interlock for this purpose.
However, the test line must be designed to ensure that the test time of 30 seconds per valve
is sufficient for reliable detection of a 0.1% leak of the fuel gas consumed at maximum combustion heat output, but at least 50 dm3/h.
NOTICE
Respect the national safety regulations and standards.
96
5
Functional Description with Process Diagrams
5.2.6.4 Valve Leakage Test Flow Chart
Fig. 5-15 Process flow for valve leakage test
97
5
Functional Description with Process Diagrams
5.2.6.5 Process Sequence Chart
Principle sequence of a valve leakage test
Fig. 5-16 Principle sequence of a valve leakage test
Signal bar
Significant times and their parameters
Standard
Signal must be present.
t2
Filling time of the gas train*
P313
2.0 s
Signal must not be present.
t12
Block and bleed time of the gas train*
P334
3.0 s
Signal can be present.
t17
Valve leakage test time
P311
2.0 s
* Calibrate name with parameter
5.2.6.6 Calculation Example
If the pressure monitor is also deployed to monitor the minimum gas pressure (logic signal ’Fuel train pressure > min’), the monitor must then be configured to the burner's minimum gas
pressure. If the pressure monitor is only deployed for the valve leakage test, the monitor must
be configured to half the gas inlet pressure pine.
The valve leakage test time t3 is configured on the MCC burner control unit. t3 must be configured so that the maximum permitted valve leakage rate QLeak is reliably detected. In EN
1643 and ISO 23551-4, the maximum leakage rate is given as 0.1% nominal volumetric flow
of the gas or a minimum of 50 l/h.
Example 1
Burner output = 1000 kW
Fuel = H natural gas, calorific value = 10 kW/m3
Nominal gas volumetric flow = 100 m3/h
Max. leakage rate = 0.1 m3/h or 100 l/h
Example 2
Burner output = 1000 kW
Fuel = propane, calorific value = 25.9 kW/m3
Nominal propane volumetric flow = 38.6 m3/h
Max. leakage rate = 50 l/h (not 38.6 l/h)
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Functional Description with Process Diagrams
Calculation
Fig. 5-17 Schematic
The test volume Vtest must be calculated from the pipe diameter and the valve volumes. The
valve volumes are specified by the valve manufacturer. If a double valve is utilised as valve 1
and valve 2, the test volume will be specified by the valve manufacturer.
The leakage volume VLeak is calculated with the help of Boyle's law.
p1  V1 = p2  V2
p = absolute pressure
V = gas volume
The following applies for the valve 1 test:
If t3 is negative, at least 1 s must be configured.
If the t3 calculation for valve 2 yields a value larger than t3 for valve 1, the value must be configured that was calculated for valve 2.
Qleak
Leakage rate in l/h
psw
Absolute pressure at pressure monitor switching point (configured excess pressure + atmospheric pressure)
psw e
Excess pressure configured at pressure monitor switching point
pout e
Excess pressure at gas valve V2 output at the time of block and bleed
pAtm
Atmospheric pressure (average of 101.3 kPa at sea level)
Vtest
Test volume between the valves
t3
Configured test time CMS
99
5
Functional Description with Process Diagrams
NOTICE
pswitch must always be larger than pout .
If not, a leak will be detected at V1 even though V1 is leak-tight.
The following applies for the valve 2 test:
If t3 is negative, at least 1s s must be configured.
If the t3 calculation for valve 1 yields a value larger than t3 for valve 2, the value must be configured that was calculated for valve 1.
Qleak
Leakage rate in l/h
psw
Absolute pressure at pressure monitor switching point (configured excess pressure + atmospheric pressure)
psw e
Excess pressure configured at pressure monitor switching point
pin
Absolute inlet pressure at gas valve V1
pin e
Excess inlet pressure at gas valve V1
pAtm
Atmospheric pressure (average of 101.3 kPa at sea level)
Vtest
Test volume between the valves
t3
Configured test time CMS
5.2.6.7 Suggested Circuit For Venting
Fig. 5-18 Block and bleed by the roof (recommendation)
100
D
Block and bleed by the roof
V1
Gas-side valve
V2
Burner-side valve
P
Gas min.
X
Terminal
Y
Terminal
5
Functional Description with Process Diagrams
5.3
Electronic Ratio Control System
5.3.1
Requirements
The control elements of the burner (dampers, etc.) must be equipped with actuators or frequency inverters which are approved and equipped with approved feedback systems.
5.3.2
Required Inputs/Outputs
Outputs
5.3.3
•
Each actuator requires 1 AEC-TPS output.
Up to 2 actuators per AEC-TPS are possible.
•
Each frequency inverter requires 1 AEC-VS output.
Only 1 frequency inverter per AEC-VS is possible.
Required Parameters
Parameter groups:
5.3.4
•
Burner Sequencer.
•
Channel configuration
•
Actuators
•
Electronic ratio control
•
Monitoring bands
Commissioning
Recommendation:
For commissioning of the CMS system, program the special points for OFF and for pre-ventilation in the current curve set and all curve sets used in succession.
Particularly when setting while the burner is in operation, the actuator positions for pre-ventilation and OFF (CLOSE) must be defined and accessible, see chapter 8.9 Settings .
5.3.5
Physical actuator types
5.3.5.1 Continuous Actuators
Configuration
Adjust a continuous actuator with one of these two methods:
1
Externally switched and permanently supplied
2
Use the non-failsafe output of the AEC-VS of the BS only if it is activated in the curve set.
In the second configuration method, either the ’Special point in OFF’ or the lower range limit
must be programmed manually for the channel when it is switched OFF. The ’Special point in
OFF’ must be programmed in a curve set in which the channel is active.
The band monitoring of the CMS electronic ratio control also monitors channels that are not
active in the curve set for keeping their OFF position (CLOSE). This is set to the lower range
limit.
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5
Functional Description with Process Diagrams
In the described configuration a switched OFF channel drops below its lower range limit without the additional measures listed above.
The range limits are automatically defined and extended by programming the curve range of
the active channels in the curve set. In this process, the actuator is switched ON. The feedback of the switched ON and supplied actuator is higher than the actuator in switched OFF
state.
Scaling
When scaling the feedback by parameter ’AEC-VS, configuration of the lower / upper range’
the following must be observed:
•
The actual rpm range must be covered by the values.
•
The feedback set points must be below or at most on the set point curve.
•
The values must increase over the entire firing rate range.
Rule of distance
When adjusting continuous channels, make sure that the minimum feedback set point does
not fall below the minimum distance of 0 and the maximum feedback set point does not fall
below the minimum distance of 999. This minimum distance is calculated from the width of the
B-band of the corresponding direction.
5.3.5.2 Actuators with TPS Control
Scaling
When scaling the feedback by parameter 'AEC-TPS configuration lower / upper range', make
sure that the values increase over the entire firing rate range.
Installation of the Potentiometers
When mounting the potentiometers ensure that the angle range of the potentiometer used
does not exceed the limits of 0.7 % or 96 % of the mechanical potentiometer angle range.
5.3.6
Logical Actuator Channels
Channel functions
Logical channels that are to be controlled by the CMS electronic ratio control must be configured with a channel function. Parameter value >0.
Flue gas channels
In opposite to existing products, flue gas ducts no longer show any special behaviour at the
ignition point.
If the flue gas duct shall open at the ignition point or remain in the OPEN position, the ignition
point must be programmed to this.
The pre-purge position is not driven bypassing the ignition point.
Liquid gas
If the fuel channels for LPG are to remain CLOSED until ignition, the pre-purge point for these
channels must be programmed accordingly (lower range limit).
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Functional Description with Process Diagrams
5.4
Burner Firing Rate Controller
5.4.1
Requirements
NOTICE
Purchase option: This function must be purchased and mapped.
5.4.2
Required Inputs/Outputs
The actual value is assigned to the analogue input in the IO-Matrix dialogue of the CMS Remote Software.
The setpoint values can be switched by means of the digital input signal ’PLC firing rate controller input setpoint changeover’.
5.4.3
•
Input HIGH: setpoint 1
•
Input LOW: setpoint 2
Required Parameters
5.4.3.1 Configuration
Activate or deactivate the firing rate in P0040.
Set the PID settings in P0057, P0058 and P0059.
P no.
40
57
58
59
Description
Attributes
Operating mode of the firing-rate controller (0-OFF; 1-constant control; 2-controlled by
atmospheric conditions)
V1.0.0.0
Operating mode of the firing-rate controller
0 = OFF
1 = constant control
2 = controlled by atmospheric conditions
Write: 1/GUI/UI
Read: 0
Default: 0
Min: 0
Max: 2
P Term
V1.0.0.0
Proportional term of the controller.
Write: 0/GUI/UI
Read: 0
Default: 3
Min: 0
Max: 65535
I Term
V1.0.0.0
Integral term of the controller
Write: 0/GUI/UI
Read: 0
Default: 60
Min: 0
Max:999
D Term
V1.0.0.0
Derivative term of the controller
Write: 0/GUI/UI
Read: 0
Default: 10
Min: 0
Max: 65535
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5
Functional Description with Process Diagrams
5.4.3.2 I Term
The firing rate controller can use an actual current value (mA), the boiler temperature (°C, °F)
or the steam pressure (bar, psi) as the actual value for control. P 61 defines the unit of the
actual value.
For steam pressure, P 62 and P 63 are also required.
P no.
61
Description
Attributes
Selection of the actual value input and the unit for indication (0-Digit; 1-°C; 2-bar; 3-mA; 4°F; 5-psi)
V1.0.0.0
Selection of the unit in which the input for actual value is to be indicated
Write: 0/GUI/UI
Read: 0
Default: 2
Min: 0
Max:5
0 = Digit
1 = °C
2 = bar
3 = mA
4 = °F
5 = psi
62
63
Pressure input: Scaling minimum
V1.0.0.0
Pressure at 4 mA input current in 0,1 units (bar, psi).
Input of the lower limit of the display range, which corresponds to 4 mA at the input, if the
input is configured as pressure input.
This parameter can only be active if P 61 = 2
Example: Value = 100, is equal to a minimum pressure of 10,0 bar/psi
Write: 1/GUI/UI
Read: 0
Default: 0
Min: 0
Max:999
Scaling maximum
V1.0.0.0
Pressure at 20 mA input current in 0,1 units (bar, psi).
Input of the upper limit of the display range, which corresponds to 20 mA at the input, if the
input is configured as pressure input. This parameter can only be active if P 61 = 2
Example: Value= 500, is equal to a maximum pressure of 50,0 bar/psi
Write: 1/GUI/UI
Read: 0
Default: 160
Min: 0
Max: 999
5.4.3.3 Constant Controller
If the firing rate controller is used as a constant control, its setpoint is obtained from the parameters
P no.
49
51
•
P 49 for setpoint 1
•
P 51 for setpoint 2
Description
Attributes
Controller 1 maximum value (only for control by atmospheric conditions)
V1.0.0.0
Controller setpoint 1 max. for control by atmospheric conditions
Enter the setpoint maximum for the controller in °C or bar. The setting is active if the input
"Setpoint changeover" = 0.
Write 0/GUI/UI
Read: 0
Default: 84
Min: -32768
Max: 32767
Controller 2 maximum value (only for control by atmospheric conditions)
V1.0.0.0
Controller setpoint 2 maximum for control by atmospheric conditions
Enter the setpoint maximum for the controller in °C or bar. The setting is active if the input
"Setpoint changeover" = 1.
Write: 0/GUI/UI
Read: 0
Default: 84
Min: -32768
Max: 32767
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5
Functional Description with Process Diagrams
5.4.3.4 Controlled by Atmospheric Conditions
P no.
48
49
50
51
Description
Attributes
Controller setpoint 1 (for constant control/min. value for control by atmospheric condition)
Controller setpoint 1 minimum. Setting the minimum set point for the controller controlled by
atmospheric conditions in °C or bar.
The setting is active if the input ’Setpoint changeover’ = 0.
If the firing rate controller is configured as a constant controller, setpoint 1 is set here
Write: 0/GUI/UI
Read: 0
Default:84
Min: -32768
Max: 32767
Controller 1 maximum value (only for control by atmospheric conditions)
V1.0.0.0
Controller setpoint 1 max. for control by atmospheric conditions
Enter the setpoint maximum for the controller in °C or bar. The setting is active if the input
’Setpoint changeover’ = 0.
Write 0/GUI/UI
Read: 0
Default: 84
Min: -32768
Max: 32767
Controller 2 setpoint (constant control/min. value for control by atmospheric conditions)
V1.0.0.0
Enter the setpoint minimum for the controller controlled by atmospheric conditions in °C or
bar. The setting is active when the input ’Setpoint changeover’ = 1.
If the firing rate controller is configured as a constant controller, setpoint 2 is set here.
Write: 0/GUI/UI
Read: 0
Default: 84
Min: -32768
Max: 32767
Controller 2 maximum value (only for control by atmospheric conditions)
V1.0.0.0
Controller setpoint 2 maximum for control by atmospheric conditions
Enter the setpoint maximum for the controller in °C or bar. The setting is active if the input
’Setpoint changeover’ = 1.
Write: 0/GUI/UI
Read: 0
Default: 84
Min: -32768
Max: 32767
52
Temperature range minimum
53
Temperature range maximum
V1.0.0.0
Upward limitation of the set point for control by atmospheric conditions 0,1 °C or Digit.
This is the lower limit of the outdoor temperature.
0 ... 249 = 0,0 ... 24,9 °C
250 ... 500 = -25,0 ... 0,0 °C
Write: 0/GUI/UI
Read: 0
Default: 25
Min: -32768
Max: 32767
Upward limitation of the set point for setpoint shift in 0,1 mA or Digit. This is the lower limit of
the current input (min. = 0 max. = 500).
0 = 0,0 mA
40 = 4,0 mA
200 = 20,0 mA
5.4.3.5 Limiting the Firing Rate Controller
P no.
43
Description
Attributes
Start-up sequence: max. actual value
V1.0.0.0
Parameter for start-up sequence:
max. start-up temperature/pressure related to actual value input.
Set the temperature to which the start-up sequence shall be active until reaching.
Write: 0/GUI/UI
Read: 0
Default: 0
Min: 0
Max:999
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5
Functional Description with Process Diagrams
P no.
Description
44
45
46
Attributes
Start-up sequence: firing-rate [Digit]
V1.0.0.0
Start-up output in digit depending on internal firing-rate.
Enter the burner firing-rate with which the burner shall start in the start-up sequence.
Write: 0/GUI/UI
Read: 0
Default: 0
Min: 0
Max:999
Start-up sequence: start-up time [s]
V1.0.0.0
Start-up time in s
Enter the maximum duration, during which the start-up sequence should effect.
Write: 0/GUI/UI
Read: 0
Default: 1
Min: 0
Max:32767
External firing-rate limit [Digit]
V1.0.0.0
External firing-rate limit in digit depending on the internal firing-rate.
Only for activated burner firing-rate controller.
Write: 0/GUI/UI
Read: 0
Default: 999
Min: 0
Max:999
5.4.3.6 Burner Shut-OFF
P no.
47
54
Description
Attributes
Soft stop time  burner run-out time [s]
V1.0.0.0
Currently without function.
Write: 0/GUI/UI
Read: 0
Default: 0
Min: 0
Max:100
switch-on threshold
V1.0.0.0
Switch-off hysteresis for the lower control range
If the actual value falls below the setpoint minus the value set in this parameter, the burner is
switched on again.
Write: 0/GUI/UI
Read: 0
Default: 1
Min: -32768
Max: 32767
Enter the switch-on point as the difference to the setpoint.
Switch on value = setpoint value - parameter content.
Example: The burner shall start at 110.
Setpoint value = 120, parameter value = 10, switch-on point = 120 - 10 = 110.
If the burner should switch on again above the setpoint, negative values can also be
entered. Thereby corresponds -1 = 65535 and -999 = 64537.
Parameter content = 65536 - difference.
Example: The burner shall start at 125.
Setpoint value = 120, parameter value = 65536 - 5 = 65531, switch-on point = 120 - (-5) =
125.
55
Switch-off threshold for the upper control range
V1.0.0.0
Switch-off hysteresis of the upper control range in °C or bar (x.xx)
Input of the upper control range. If the actual value exceeds the setpoint by this value, the
burner runs at base fire.
The value entered corresponds to the difference between the current setpoint and the upper
limit of the control range. Depending on the setting in P 61, the content is interpreted as °C
(directly without decimal point) as bar (resolution 0.1 bar - range 0.1 to 99.9 bar) or in digits.
Write: 0/GUI/UI
Read: 0
Default: 5
Min: 0
Max:999
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5
Functional Description with Process Diagrams
P no.
Description
56
5.4.4
Attributes
Burner OFF threshold
V1.0.0.0
Burner OFF (Difference to the setpoint) in °C or bar (xx.x).
Adjustment of the switch-off limit of the firing rate controller.
If the actual value exceeds the setpoint by the value entered in this parameter, the burner is
switched OFF.
The value entered is the difference between the current setpoint and the value at which the
burner is switched OFF. This value must be higher than the set upper limit of the control
range (P 55). Depending on the setting in P 61, the content is interpreted as °C (directly
without decimal point), as bar (resolution 0.1 bar, range 0.1 to 99.9 bar), or in digits.
Write: 0/GUI/UI
Read: 0
Default: 15
Min: 0
Max:999
Functional Description
Constant Control
The constant controller calculates a preset firing rate based on the actual value and the setpoint.
The unit of the setpoint corresponds to the unit of the actual value.
Control by Atmospheric Conditions
The firing rate controller controlled by atmospheric conditions determines its setpoint based
on the outdoor temperature. This must be assigned to an analogue temperature input.
See SAI configuration in chapter 4.6 SAI - Safe Analogue Input
The setpoint shift (setpoint pair and edge temperature) generates the setpoint. The firing rate
controller controlled by atmospheric conditions determines the firing rate default based on the
actual value and the generated setpoint.
Limiting the Firing Rate
If the parameters are set correctly, the presetting of the firing rate controller is limited by the
start-up circuit.
Burner Shut-off with Switching Thresholds:
Shut-off threshold:
If the firing rate controller detects that the boiler temperature or steam pressure exceeds a
configured threshold (switch-off threshold), it removes the signal ’burner ON’ in the CMS and
sets the logical signal ’burner OFF’.
Switch-on threshold:.
The signal ’burner ON’ is deactivated if the temperature falls below the switch-on threshold.
Base fire threshold:
If the base fire threshold is exceeded, the burner runs to base fire. In this case, it is switched
off after a certain time (soft stop time) if the actual value does not drop below the base fire
threshold.
5.5
SPS Parameters
The parameters between 1900 and 1999 are allocated to PLC. These parameters are freely
programmable by PLC programs. These are 16-bit parameters with full range of values. The
parameters can be edited in AL0.
At currently 50 of these PLC parameters are available. If required, it can be extended to up to
100 parameters.
107
6
Commissioning
6
Commissioning
6.1
Parameter and Password Input
How to set the password see chapter:
7.1.5.1 Password
7.2.2 Password
7.3.3.3 Access Rights Menu
For the parameter listing see chapter Parameter
6.2
Commissioning Tests
An appropriate checklist has been developed for a final check of the commissioning and for
its documentation. This list can be found in the appendix in chapter 12.2 Acceptance and Inspection. This list is only a subset of the system tests to be performed. In addition, defined
system tests of the ECU manufacturer are applicable.
NOTICE
The internal information on the entire installation (commissioning) must also be considered.
6.3
Programming of Curves
Accessing the CMS menu ’RC curves’ and submenus (AL1)
Fig. 6-1 Accessing the CMS menu ’RC curves’ and submenus
The curve screen shows the setpoint curves for the channels (ratio controller) per curve set.
The user can switch between showing a curve-based format (setpoint graphic) and a display
in tabular format (curve table).
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6
6.3.1
Commissioning
Programming Curves
Programming RC curves (AL2)
The curve screen shows the setpoint curves for the channels (ratio controller) per curve set.
Two different views are available:
•
setpoint graphic
•
curve table
To change a curve in the CMS, the CMS must first be switched into the START CONFIGURATION mode.
NOTICE
This function is relevant for safety.
The function must be confirmed a second time within 8 seconds.
In CONFIGURATION mode, two device functions are available in the curve view window:
•
Save point
•
Delete curve set
NOTICE
Individual curve points can only be modified and cannot be deleted.
In CONFIGURATION mode, the spanner symbol is shown and the screen is also
displayed with a red border.
The firing rate or the setpoints for the channels can be adjusted using the arrow keys
or the appropriate buttons.
Fig. 6-2 Programming RC curves
109
6
Commissioning
RC curves: programming the ignition point (AL1)
1. Click the ’Start configuration’ button.
2. Enter a password if required to do so.
3. Dialogue box: ’Start configuration with fan?’
If a fan is present, the fan must be activated for programming the curve.
Feedback would otherwise be absent.
4. Click button
.
This ensures that all points are deleted.
5. Use the arrow keys to program the ignition point as 2nd base firing rate point
6. Click button
.
.
All channels must reach their setpoint.
The setpoint must match the actual value.
All channels are always saved together.
7. Click the ’Exit configuration’ button and then start the burner.
8. If ignition is successful, go to RC curves again and ’Start configuration’, and adjust the ignition point again or program the next base firing rate point.
9. If ignition failed (= burner OFF), adjust the ignition point:
First ’Start configuration’, then ’Exit configuration’ again and then start the burner.
110
6
6.3.2
Commissioning
Configuring Special Points
Configuring special points with the CMS Remote Software (AL1)
Special points determine how wide the various valves/dampers should open or close at certain
points in time.
1
2
3
4
5
6
Fig. 6-3 Configuring special points with the CMS remote software
1
Selecting the active channels
2
Graphical representation and configuration of special points
3
Tabular display of settings
4
Button to start configuration
5
Selecting the special points
6
Graphic for displaying and configuring the special points
Setting a special point
1.
button (4) – click to activate configuration of the special points.
2. Select the special point (5)
3. Select the channel (1)
4. Configure the point
5. Save the point
6. Click ’Exit configuration’
111
6
6.3.3
Commissioning
Configuring the Range Limits
Configuring the range limits with the CMS remote software (AL1)
Fig. 6-4 Starting the range limit configuration process
Step 2
Step 1
Fig. 6-5 Reading in the range limits 2 – CMS remote software
Step 3
112
6
Commissioning
1. Start-up to the upper and lower range limits (RL.U and RL.L).
RL.U: To proceed, use the up arrow key or enter the value for the
upper limit into the text box.
RL.L: To proceed, use the down arrow key or enter the value for
the lower limit into the text box.
Wait until the actual value in the grey box next to the configured limit value is reached and
then save the value.
2. Click ’Exit configuration’.
3. Close the window.
6.3.4
Shut-off Limits
6.3.4.1 Run to Shut-off Limits
The CMS tolerances, as they must be in every control system, have an effect on the positioning accuracy. These tolerances can be influenced by parameter settings.
When adjusting the combustion system, it must be ensured that the flame burns safely and
stably, even when these tolerances are taken into account.
To prove this, it is necessary to check the settings of the electronic ratio control not only for
the adjusted set points, but also at the so-called shut-off limits.
These are the actuator values the burner control unit can reach due to the permissible tolerances without switching off at this point.
This check must be made for the entire firing rate range and for all operating modes. This
check can only be omitted if one of the following statements is true:
•
The system is equipped with a failsafe CO or O2 monitoring system which can trigger a
burner shutdown in the event of incomplete combustion.
•
The system is equipped with a failsafe CO/O2 control which compensates for the tolerances of the combustion system.
•
It is ensured that the relevant operating mode contains enough excess air throughout the
entire range and that the tolerances of the burner control unit are therefore irrelevant.
•
The CMS parameters are set in such a way that the tolerances in the direction of air deficiency are 0 digits, i.e. there is only a tolerance to the excess air side.
NOTICE
If the verification of the shutdown limits on the basis of one of these measures can be omitted,
the effectiveness of this measure must be checked instead. For example, in the case of CO/
O2 monitoring or CO/O2 control, the stability of the combustion system must be checked at
the set shutdown limit value.
NOTICE
The approaching of the shutdown limits must be documented on basis of proof to authorities,
test centres, quality management systems, liability issues, etc.
6.3.4.2 Checking the Shut-OFF Limits of the CMS with the CMS Remote Software
113
6
Commissioning
1. Note the ’general tolerance limit’ for each channel used from parameter 520.1 - 520.10
(AL0).
2. Start burner
3. Open ’Curves/Electronic ratio Ctrl.’ (AL1)
4. Adjust the required firing rate pint with the arrow buttons.
(right/left)
5. Wait until the system has reached the point.
6. Select the required point.
7. Use the arrow buttons
ue from P 520 in the
(up/down) to move the channel by the corresponding valdirection of air deficiency.
8. Check the combustion.
9. Move back the channel to its original value
10. Repeat this test with all channels used at different firing rate points. Usually these are low
fire, medium fire and high fire.
NOTICE
Repeat these procedures for all relevant operating modes (curve sets).
NOTICE
If it is not ensured that the flame burns stably at the adjusted limits in the direction of excess
air and no 'CO in excess air' is generated, the check described above must be carried out in
the direction of excess air instead of in the direction of air deficiency.
6.3.4.3 Checking the O2 Effect
Check and ensure that the burner is burning stably at the shut-off limit of the O2 monitoring
taking into account all environmental influences and every firing rate range.
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Commissioning
Factory setting of the shutdown limit for O2 monitoring with active CO control = 0.4 vol.%.
Checking the O2 effect
1. Run to the shut-off limits
2. Check the correction influence
NOTICE
If the factory-set switch-off limit of 0.4 vol.% O2 is too low for the application, it can be raised
using the CMS Remote Software (AL4). If necessary, contact LAMTEC Support:
support@lamtec.de
+49 (0) 6227 6052-33
’How to’ see chapter 6.3.4.1 Run to Shut-off Limits
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7.1
Operation, Controls and Display with UI400
1
Display
2
BACK key
3
Cursor keys
4
ENTER key
Fig. 7-1 User interface
Display
The display shows in pictogram:
•
the menu structure
•
operating status
•
parameters
•
error messages
Back key
Back to previous window.
Cursor keys
To navigate in the menu using cursor keys
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.
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.
Use a flushing, red ENTER key to release a fault interlocker.
If the ENTER key is permanently lit red, a fault with an automatic restart is displayed.
7.1.1
Menu Functions
The menu is divided into three paths:
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INFO
MANUAL
SETTINGS
INFO
Select INFO path for information about the following:
•
Burner
•
Faults/Fault history
•
Software version
•
Display of check sums
•
Serial number
•
Actuator positions (current damper position for each channel)
•
Digital inputs/outputs
MANUAL
Select MANUAL to:
•
Start and stop burner by hand
•
Adjust internal burner firing rate
SETTINGS
Select the SETTINGS path for getting information/make changes to:
•
Password
•
Burner settings (display and settings)
•
Actuator elements settings (display)
•
Electronic ratio control system
•
Deletion of curve sets
•
Display settings
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7.1.2
Operating Control and Displays
Main Menu
1
INFORMATION menu path [selected]
2
Display of canal
3
Bar graph of internal firing rate in %
(0 - 100)
4
Fuel train
5
MANUAL menu path
6
SETTINGS menu path
7
Release level
8
Window number
Fig. 7-2 Main menu
For a complete description of the display symbols, see chapter 12.6 Display Symbols
NOTICE
The parameters of release level 1 must be protected by a password against unauthorised
changes. This password must differ to the factory settings.
7.1.3
Information Menu Path
Burner information
Error history
Software ver-
Checksums
sion
Configuration of continuous outputs
(display only)
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IP address
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Operating Control and Displays
7.1.3.1 Burner Details
Displaying Operating Hours, Burner Starts and Firing Rate Controller Settings
Display of operating hours
ON
Number of operating hours in total
(device connected with mains)
Number of operating hours in oil operation
Number of operating hours in gas operation
Display of burner starts
Number of burner starts in oil operation
Number of burner starts in gas operation
Display Firing rate
controller settings
119
I:
Actual value
S:
Setpoint
ON:
On
OFF:
Off
T:
Temperature
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Operating Control and Displays
7.1.3.2 Recalling Fault History
Displaying Burner Faults
01 Fault code (Last 10 faults are stored,
02 no. 01 is the latest fault)
No. of operating hours when
fault has occurred
D1 Diagnostic code 1
Duration of the fault
D2 Diagnostic code 2
NOTICE
Information concerning fault and diagnostic codes can be found in the list of fault codes.
For fault analysis a fault code and diagnostic code D1 or D2 is required.
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Fault unlock
How to unlock BT300
 A fault is pending and the ENTER key is flashing.
1. Press ENTER key.
CMS is not locked anymore.
Changing from fault unlock to main menu:
 A fault is pending and the ENTER key is flashing
1. Press BACK key.
ENTER key isn’t flashing any more.
The display returns to main menu.
An error number is flashing in the display on top, left hand.
UI400 can be used as usual.
Back to fault unlock
 An error number is flashing in the display on top, left hand.
1. Use BACK key to switch back to main menu.
2. Press arrow-key left.
ENTER key is flashing again.
CMS can be unlocked.
NOTICE
A permanent red light on the ENER key indicates gas shortage. A countdown is running to the
next start. This countdown can be interrupted by the ENTER key.
7.1.3.3 Software Version
Display software version
UI = Software version UI400
Software versions of the single modules are displayed.
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7.1.3.4 Display of Check Sums
0 ... 4 = Check sum, access levels 0 ... 4
The checksums are generated from the device parameters. The CMS calculates one checksum for the parameters of each access level (0, 1, 2 or 4). The UI400 indicates the checksums
in hexadecimal code.
The checksum shows whether the value of one or more parameters have been changed.
7.1.3.5 Positions of Actuators
Indication of the channel’s actual (left to right):
Channel 1 (air)
Channel 2
Channel 3
Optional channel (OFF; control of the frequency inverter)
NOTICE
The assignment of channels is depending on configuration settings!
7.1.3.6 Display IP Address
Display of IP address and subnet mask
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7.1.4
Operating Control and Displays
Manual Menu Path
MANUELL
Select MANUAL path to carry out actions as follows:
•
Switching burner ON and OFF
•
Presetting of burner firing rate
Start burner manually
Adjust burner firing rate
NOTICE
At least release level1 is required to start the burner.
The ’Burner ON’ control loop does not need to be switched on to start the burner from this
menu. The user interface assumes control in this menu.
If there is no ’Burner ON’ signal from other sources (terminal X10.2) software switches off the
burner when you exit the menu.
CAUTION!
If you carry out a manual start-up via display CMS no longer responds to ’Burner ON’ signal
input at connector X10.2. Therefore that limiters, monitors and other similar safety functions
must not be operated with this input!
NOTICE
Leaving of window will terminate manual burner operation!
NOTICE
Changes of burner firing rate are possible only while burner is running.
 If you want to adjust burner firing rate remember to start-up the burner first.
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7.1.5
Operating Control and Displays
Settings Menu Path
Password
Display settings
for program
sequence
Read configura
tion for continuous output
Configure curve
Delete curve
Configure
controller
Configure
password
Configure
display
NOTICE
The level 1 parameters must be protected against unauthorised modification by setting a
password different to ’000000’.
7.1.5.1 Password
Reset access level
Password input
NOTICE
The parameters of release level 1 must be protected by a password against unauthorised
changes. This password must differ to the default settings.
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7.1.5.2 Program Sequence
Duration pre-purge period
Duration post purge period
valve leakage test
Pilot burner
Set duration of pre-purge period
Parameter number UI
Parameter modifications are transferred
CMS = Parameter number CMS
Parameter modifications are discarded
NOTICE
Both values are identical – Confirm with
The values are different – Cancel with
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NOTICE
Pre-purge starts as soon as damper reaches pre-purge position and - if you use a VSM - the
last but one point of electronic ratio curve is passed.
NOTICE
The second to last channel’s position must be lower than the position of the last curve point.
Set duration of the post-purge
NOTICE
Both values are identical – Confirm with
The values are different – Cancel with
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Operating Control and Displays
Valve Leakage Test
Valve leakage test ON/OFF
OFF
P802
P802 = 0 = Valve leakage test OFF
P802 = 1 = If valve leakage test before ignition is configured, the test runs
during ignition.
P802 = 2 = If valve leakage test before ignition is configured, the test runs
after pre-purge.
P802 = 4 = Valve leakage test after burner operation
Valve leakage test before ignition
P312
Valve leakage test after burner OFF
P315
Duration of Valve leakage test
P311
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Operating Control and Displays
Activate pilot burner
Pilot burner ON
Pilot burner OFF
7.1.5.3 Configuring the Servomotors
Displaying the Servomotors’ Configuration
Channel 1 = OIL = oil
Channel 2 = AIR = air
Channel 3 = OFF = OFF
Channel 4 = OFF = OFF (optional channel)
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Operating Control and Displays
7.1.5.4 Setting Curves
How to set the servomotor’s curve sets
...
Firing rate point - from ignition position up to 999
S Setpoint value channels 1 ... 3
I Actual value channels 1 ... 3
(in this case: channel 1 = oil, channel 2 = air channel
3 = OFF)
X Curve data for this firing rate point are stored yet
NOTICE
The servomotors are running to the new position immediately after the modification.
To adjust channel 4 the fan motor must be running. The feedback setpoint curve of channel 4
must rise continuously.
Pressing key BACK for longer than 2 s in menu ’Curve settings of the servomotor’
causes a fault shut down.
Pressing key BACK after finishing the curve settings leads back to menu ’ Settings’.
Pressing key BACK during changing the firing rate discards the modification.
NOTICE
The following firing rate points are available:
Ignition point
, 200, 250, 300, 400, 500, 600, 700, 800, 900, 999
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Operating Control and Displays
7.1.5.5 Deleting Curves
Delete firing-rate curve
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Operating Control and Displays
7.1.5.6 Adjusting Controller
PID controller settings
CO/O2 controller settings
•
Mode
•
ON/OFF
•
Speed
•
Correction mask
•
Physical units
•
Correction spreading
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Operating Control and Displays
7.1.5.7 Changing Password
Change password on UI400
7.1.5.8 UI400 Settings
Set display of UI400
Set brightness.
Set contrast
Set waiting time for screensaver
Change-over degrees/Fahrenheit
NOTICE
The screensaver cannot be set to 0!
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7.2
Operating Control and Displays
Operation, Controls and Display with GUI607/610/615
The GUI (graphical user interface) is a touch-sensitive panel. The panel visualises the system
with the parameter and curve data from the devices on the LSB (LAMTEC SYSTEM BUS).
The GUI is used to access, edit and store values.
Fig. 7-3 GUI607 graphical user interface
By touching the panel, the menus and submenus can be navigated, and the system can be
configured and operated.
The GUI is available in 7", 10" and 15" options.
NOTICE
The GUI display may vary depending on the device, configuration and software version.
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7.2.1
Process Diagram and Menu Navigation
Start screen
From the process diagram or start screen, all of the other menus and submenus can be accessed by touching the surface of the screen.
Fig. 7-4 GUI6xx – start screen/process diagram
1
Burner ON icon
8
Flue gas temperature in °C
2
Burner status display
9
Remote off
3
Recirculation in %
10
Manual burner firing rate screen
4
Password entry screen
11
Firing rate in %
5
O2 value in flue gas, in %
12
Combustion air delivery
6
CO value in flue gas, in %
13
Gas fuel train with gas pilot burner
7
Efficiency in %
14
Oil fuel train
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Operating Control and Displays
Navigating in menus and submenus
Fig. 7-5 GUI6xx – navigating in menus and submenus, part 1
1
First submenu
6
Cancel
2
Access alarm history
7
Confirm input
3
Touching anywhere in the shaded area
opens the first submenu 1
8
Manual burner firing rate
screen
9
Back button
4
Password entry
5
Error message after pressing remote off
General menu structure
1 Status bar
2 Command bar
3 Menu area/input window
Fig. 7-6 General menu structure
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Operating Control and Displays
Typical layout of icons and text on the status bar:
Status
Additional
status
Message
W001
Message
text
Operating
mode
Load bar
Curve set
GAS
Menu structure:
If a submenu is entered, the menu icon is inverted and shifts up to the top left-hand corner. If
the next level down is entered, the icon of the previous menu level is retained and the new
menu icon is displayed next to it.
Fig. 7-7 Structure of menus and submenus
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7.2.2
Operating Control and Displays
Password
Entering the 4-character password with the aid of the arrow keys (AL0).
A combination of letters and digits is possible.
4 access levels are available.
NOTICE
The password entry window can be accessed from all menus and submenus.
Fig. 7-8 GUI6xx – password entry for access levels
1
Password entry via arrow keys
2
Cancel
3
Confirm password
NOTICE
The parameters of release level 1 must be protected by a password against unauthorised
changes. This password must differ to the default settings.
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7.2.3
Operating Control and Displays
Burner Settings Menu
Accessing the burner statistics (AL1)
Fig. 7-9 GUI6xx – accessing the burner settings menu
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Operating Control and Displays
Accessing information about digital inputs and outputs (AL1)
Fig. 7-10 GUI6xx – information about digital inputs and outputs
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Operating Control and Displays
Accessing electronic ratio control information (AL1)
Fig. 7-11 Electronic ratio control information
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Accessing channel information (AL1)
Fig. 7-12 GUI6xx – channel information
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Operating Control and Displays
Accessing purging settings
NOTICE
Note: a minimum of access level 2 is required for the settings in the following menus!
Fig. 7-13 GUI6xx – purging menu
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Operating Control and Displays
Accessing the leakage test time settings (AL1)
Fig. 7-14 GUI6xx – setting the valve leakage test time
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Operating Control and Displays
Accessing the pilot burner settings (AL1)
Fig. 7-15 GUI6xx – accessing the pilot burner settings
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Operating Control and Displays
Editing curves and individual curves (AL1)
Fig. 7-16 Editing curves and individual curves
Increase value
Save curve point
Decrease value
Delete curve point
Increase firing rate
Activate automatic mode
Decrease firing rate
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Operating Control and Displays
Set upper and lower stop for the actuators (AL1)
Fig. 7-17 Set upper and lower stop for the actuators
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Operating Control and Displays
Channel configuration (AL1)
Fig. 7-18 Channel configuration
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7.2.4
Operating Control and Displays
Burner Firing-Rate Controller Menu
Accessing burner firing-rate controller information (AL1)
Fig. 7-19 Burner firing-rate controller information
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Accessing the burner firing-rate controller settings (AL1)
Fig. 7-20 Burner firing-rate controller settings
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Accessing the burner firing-rate controller input configuration (AL3)
Fig. 7-21 Burner firing-rate controller input configuration
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Accessing the burner firing-rate controller units (AL3)
Fig. 7-22 Burner firing-rate controller units
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7.2.5
Operating Control and Displays
CO/O2 Burner Optimisation Menu
Accessing the information for the burner's CO/O2optimisation (AL1)
Fig. 7-23 Burner optimisation information
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Operating Control and Displays
Accessing the CO/O2 settings (AL2)
Fig. 7-24 CO/O2 settings menu
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7.2.6
Operating Control and Displays
Flame Monitoring System Menu
Accessing the flame monitoring system information (AL1)
This menu cannot be used to make any changes.
Fig. 7-25 Flame monitoring system information
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7.2.7
Operating Control and Displays
System Functions Menu
Accessing the system information (AL1)
Fig. 7-26 System information menu
Accessing the system CRCs (AL1)
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Fig. 7-27 System CRCs menu
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Accessing the fault history (AL1)
Fig. 7-28 Fault history menu
Accessing dataset handling (AL3)
Saving and restoring a dataset:
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Fig. 7-29 Dataset handling menu
A dataset can be transferred from the CMS and saved with ’Store’.
A dataset can be transferred/restored to the CMS with ’Restore’.
Accessing module configuration (AL1)
The menu shows an overview of the modules deployed in the system.
Module registration and deregistration is possible with ’Register’/’Deregister’. For registration,
a screen with the Module IDs available for the module is opened.
’Flash LED’ causes an LED on the selected module to flash, and the button also flashes, so
as to make it clear which module should be flashing.
The information button leads to a separate window in which the individual inputs/outputs are
visible for the respective module.
The user is also given the option of searching for unknown/new modules.
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Operating Control and Displays
Fig. 7-30 Module configuration menu
Accessing the change password menu (AL1)
Change password
1. Enter old password.
2. Enter new password.
3. Confirm new password.
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Operating Control and Displays
Fig. 7-31 Change password menu
Accessing the CMS IP setting menu (AL2)
Change IP address
1. Tap the address field
2. Enter the IP address in the dialogue box.
3. Tap the dialogue box to confirm and save the address entered.
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Operating Control and Displays
Fig. 7-32 IP setting menu
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7.2.8
Operating Control and Displays
User Settings
Accessing the display settings
Fig. 7-33 Display settings menu
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Accessing the language settings (AL1)
Fig. 7-34 Language settings menu
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Operating Control and Displays
7.3
Operation, Controls and Display with CMS Remote Software
7.3.1
Remote Software
The CMS Remote Software visualises parameter and curve data from the devices on the
LAMTEC SYSTEM BUS (LSB). The software is used to edit and store values.
Once a connection is established, the current data from the device can be accessed. Special
screens can then be used to change individual parameters, delete curves or program curve
set points.
The current state of the CMS, which is determined by the parameter settings and curve data,
can be stored as a dataset on the PC (as a backup). These dataset backups can also be loaded back into the CMS at a later point in time in order to restore a specific CMS state.
The previous pages have described the most important activities that can be completed using
the CMS Remote Software. The following chapters describe the menu paths in the CMS Remote Software with their corresponding windows. Windows already described in the previous
chapters are only given a reference back to the corresponding chapter.
7.3.1.1 Installation Prerequisites
System requirements:
•
PC with Windows XP operating system or later
•
Administrator rights for installation (setup)
•
Screen resolution of at least 1024 × 768 pixels
7.3.1.2 Installing the Software
Description of the Symbols
Click mouse button (left click)
Read
Fill out
Important
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Operating Control and Displays
Fig. 7-35 Installation
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Operating Control and Displays
Fig. 7-36 Installation
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Operating Control and Displays
Fig. 7-37 Installation
7.3.2
Offline/Online
The software generally distinguishes between two operating modes:
•
Offline
•
Online
7.3.2.1 Offline Mode
In offline mode, there is no continuous connection to CMS (no parameter setting possible).
Offline mode is used simply as a display option for the data. Previously stored datasets from
end devices can therefore be displayed.
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Fig. 7-38 Offline mode
7.3.2.2 Online Mode
In ONLINE mode the end device is synchronised. The data of the end device are read out
completely. The permanent connection to the end device is monitored from both sides with a
time-out. While establishing connection to the device all functions are locked.
7.3.2.3 Connecting the CMS to the PC
Access code/access levels
See chapter 7.3.3.3 Access Rights Menu
Access code/access levels
See chapter 7.3.3.3 Access Rights Menu
Establishing a connection between PC and CMS
1. Establishing a connection between PC and MCC
Fig. 7-39 Connecting PC to MCC via Ethernet
NOTICE
The IP addresses must not be the same.
The IP addresses must be in the same subnet.
2. Open the CMS remote software
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Operating Control and Displays
Fig. 7-40 Establish a remote connection to the CMS
3. Configuring the IP address
The IP addresses must be identical.
Fig. 7-41 Connection data – enter target IP
4. Establishing a connection
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Operating Control and Displays
The connection between PC and CMS
is established.
Fig. 7-42 Connection data – establishing a connection
5. Close the window
Display of the
connected CMS
Fig. 7-43 Device overview – CMS remote software
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Operating Control and Displays
First connection with the device
Fig. 7-44 Register the first connection with the device and enter access level
Password entry required!
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7.3.3
Operating Control and Displays
CMS Remote Software User Interface
Fig. 7-45 CMS remote software start screen
1
Select functions
4
Device type
2
Menu bar
5
Software status – here "ONLINE"
3
Device overview
Fig. 7-46 CMS Remote Software icons on lower menu bar
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Operating Control and Displays
7.3.3.1 Dataset Menu
Fig. 7-47 Dataset menu in online mode
The ’Dataset’ menu path can be used to:
•
Open and save a dataset
•
Save or load a protected dataset
•
Compare datasets
•
Exit from the application
Opening a dataset
1. ’Open dataset’.
A window opens for selecting the dataset.
2. Browse to the dataset required and click the ’Open’ button.
The dataset is loaded.
Saving a dataset
1. In the menu, click ’Save dataset’.
The ’Save dataset’ window opens.
2. Browse to the directory where you want to save the dataset.
3. Click the ’Save’ button.
A window opens for entering information about the dataset.
4. Enter information about the dataset in the fields.
•
’Cancel’ button  cancels the process and closes the window.
•
’OK/Save’ button  saves the data entered.
NOTICE
When a dataset is saved, data is saved only if the user is authorised to access this data (=
access level). This dataset may therefore change depending on the specific access level.
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Saving a protected dataset
1. Same procedure as for saving a normal dataset.
NOTICE
When saving a protected dataset, all data is saved, regardless of the user's personal level of
authorisation (= access level). A protected dataset cannot be opened or edited.
A protected dataset can be read into the device regardless of the user's level of authorisation
(= access level).
Fig. 7-48 Saving a protected dataset
Loading a protected dataset into the device
1. In the menu, click ’Load protected dataset into device’.
2. Proceed as described in the section ’Loading a dataset into the device’.
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Operating Control and Displays
Fig. 7-49 Loading a protected dataset into the device
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Operating Control and Displays
Comparing datasets
1. In the menu, click ’Compare dataset’.
2. Proceed as shown below.
Fig. 7-50 Comparing CMS datasets
1 Current dataset
2 Open the dataset to be compared
3 The differences are shown
here
NOTICE
The dataset comparison feature is used for checking or troubleshooting.
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Operating Control and Displays
7.3.3.2 Connection Menu
Fig. 7-51 CMS connection menu
The "Connection" menu path can be used to:
•
Make a device selection
•
Assign CMS-Remote
•
Establish a connection (set online)
•
Drop a connection
Device selection
Fig. 7-52 CMS device selection menu
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Operating Control and Displays
Set online: see chapter 7.3.2.1 Offline Mode
Drop connection: Drops the connection to the CMS, see chapter 7.3.2.1 Offline Mode
CMS remote registration (AL1)
Fig. 7-53 CMS remote registration menu
This procedure must be completed once for each MCC.
7.3.3.3 Access Rights Menu
The ’Access rights’ menu path can be used to:
•
Set the password for the access level
•
Change the password for access level 1
•
Change the customer code for each device (once only)
Entering the password
Fig. 7-54 Entering the CMS password
Entering the level 1 password
1. Select the ’Access rights’ menu.
2. Click ’Enter password’.
3. In the ’Password’ field, enter the password for access level 1.
4. Click the ’Set password’ button.
You now have access to all functions at level 1.
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Operating Control and Displays
NOTICE
The ’Check password’ button can be used to check the validity of the password.
Changing the level 1 password
Instead of the factory setting, an individual password can be defined for customer level 1.
NOTICE
The parameters of release level 1 must be protected by a password against unauthorised
changes. This password must differ to the default settings.
Fig. 7-55 Changing the CMS level 1 password
Changing the level 1 password
1. Select the ’Change level 1 password’ menu option.
A window opens for entering the new password.
2. Enter the password in the top field.
3. Enter the password again in the field below and click the ’Write to device’ button.
The password for access level 1 has now been changed and the window closes.
NOTICE
Make a note of the new password for future access to operating level 1.
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Operating Control and Displays
Changing the customer code
Fig. 7-56 Changing the customer code and level 2 password
The customer code must be entered when commissioning a new device.
1. Access rights menu.
2. Select ’Change customer code’.
3. Enter new customer code.
4. Enter new service password.
5. Read the notice.
6. Click ’OK/Close’.
NOTICE
The customer code step must be completed once. This sets the customer-specific passwords.
The customer code cannot be changed or deleted.
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Operating Control and Displays
7.3.3.4 CMS Menu
The "CMS" menu path provides access to:
•
Parameters
•
Configuration
•
Safety
•
VR curves
•
CO/O2 data
•
Histories
•
Input/output measurement values
•
Manual burner firing rate specification
•
Cold check
•
System time and date
•
Module replacement
•
Device information
and the corresponding sub-menus available
Fig. 7-57 Menu CMS with sub-menus
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Operating Control and Displays
Parameter
Accessing the ’All parameters’ submenu
Fig. 7-58 CMS all parameters window
1 Enter the password (padlock symbol)
2 A search using groups is possible
Setting and changing values
1. Double-click to select the parameter value.
Alternative: use arrow keys to select up/down and then confirm with the ENTER key
2. Change the value by clicking the ▲ or ▼ buttons or by using the up/down arrow keys on
the keyboard.
3. Confirm value with the ENTER key or select a different parameter.
NOTICE
Only parameters at the current access level can be changed!
All parameters not at the current access level are greyed-out and cannot be changed.
A reset must be performed after changing some parameters. This is indicated with a system
message.
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Operating Control and Displays
Submenu ‘Firing rate controller parameters’
Fig. 7-59 CMS firing rate parameter
1 Enter the password (padlock symbol)
Setting and changing values
1. Enter the values numerically
Alternatively: Set the values with the up/down arrow keys
2. Confirm the values with the ENTER-key or chose another parameter.
NOTICE
Only parameters of the current access level can be changed.
All parameters which are not in the current access level have a grey background and cannot
be changed. Depending on how a parameter is changed, a RESET is mandatory. This is indicated by a message.
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Accessing the ’ O2 trim’ submenu
Fig. 7-60 CMS parameters for O2 trim window
Setting and changing values
1. Enter values numerically.
2. Confirm value with the ENTER key or select a different parameter.
NOTICE
Only parameters at the current access level can be changed!
All parameters not at the current access level are greyed-out and cannot be changed.
A reset must be performed after changing some parameters.
This is indicated with a system message.
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Operating Control and Displays
Accessing the ’CO Controller’ submenu
Fig. 7-61 CMS Parameter - CO controller window
Setting and changing values
1. Enter values numerically.
Alternatively: Set values with arrow keys up/down
2. Confirm value with the ENTER key or select a different parameter.
NOTICE
Only parameters at the current access level can be changed!
All parameters not at the current access level are greyed-out and cannot be changed.
A reset must be performed after changing some parameters.
This is indicated with a system message.
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Operating Control and Displays
Accessing the ’Channel Configuration’ submenu
Fig. 7-62 CMS parameters for channel configuration
1 Enter the password (padlock symbol)
2 Selection by pull down menus.
NOTICE
Only parameters at the current access level can be changed!
All parameters not at the current access level are greyed-out and cannot be changed.
A reset must be performed after changing some parameters.
This is indicated with a system message.
Accessing the ’Fuels Assignment’ submenu
Fig. 7-63 CMS parameters for fuels assignment
1 The password can be entered here (padlock
symbol)
2 Here the selection is possible
through drop down menus.
NOTICE
Only parameters at the current access level can be changed!
All parameters not at the current access level are greyed-out and cannot be changed.
A reset must be performed after changing some parameters.
This is indicated with a system message.
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Operating Control and Displays
Accessing the ’Correction’ submenu
Fig. 7-64 CMS parameters for the correction
1 The password can be entered here (padlock symbol)
Setting and changing values
1. Double-click to select the parameter value.
2. Confirm value with the ENTER key or select a different parameter.
NOTICE
Only parameters at the current access level can be changed!
All parameters not at the current access level are greyed-out and cannot be changed.
A reset must be performed after changing some parameters. This is indicated with a system
message.
Accessing the ’Burner Maintenance’ submenu
Fig. 7-65 CMS parameter for burner maintenance
1 The password can be entered here (padlock symbol)
Setting and changing values
1. Double-click to select the parameter value.
2. Confirm value with the ENTER key or select a different parameter.
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Operating Control and Displays
NOTICE
Only parameters at the current access level can be changed!
All parameters not at the current access level are greyed-out and cannot be changed.
A reset must be performed after changing some parameters. This is indicated with a system
message.
Accessing the ’AEC Parameter’ submenu
Fig. 7-66 CMS AEC parameters
1 The password can be entered here (padlock symbol)
Setting and changing values
1. Double-click to select the parameter value.
2. Confirm value with the ENTER key or select a different parameter.
NOTICE
Only parameters at the current access level can be changed!
All parameters not at the current access level are greyed-out and cannot be changed.
A reset must be performed after changing some parameters. This is indicated with a system
message.
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Operating Control and Displays
Accessing the ’Restarting’ submenu
Fig. 7-67 CMS Parameter for restarting the system
1 The password can be entered here (padlock symbol)
Setting and changing values
1. Double-click to select the parameter value.
2. Confirm value with the ENTER key or select a different parameter.
NOTICE
Only parameters at the current access level can be changed!
All parameters not at the current access level are greyed-out and cannot be changed.
A reset must be performed after changing some parameters. This is indicated with a system
message.
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Operating Control and Displays
Configuration
The first step in deploying a CMS is to register the individual modules with the system
. This provides the system with details of the modules' serial numbers, functions and number
. This data is then saved and filed as a dataset.
Normally, the modules included in the delivery are already registered with the system and
shown highlighted in green in the module management window. New modules, or modules
that replace existing modules or expand the system must be registered first. If multiple modules with the same function are included in the system, each module is issued with a unique
number by module management so they cannot be mixed up.
Fig. 7-68 Module registration procedure
1
Bright green: Module is present and registered.
Dark green: Module is present and not registered.
Red: Module no longer present (should be removed in order to avoid faults)
2
Register and deregister buttons
Module registration
1. Click the
button.
The system searches for existing modules and identifies and new modules not yet registered.
2. Click the
button.
The system is ready to register new and unfamiliar modules. The drop-down menus for
the registration process are active.
The I/O matrix is used to assign physical or logic signals to the input and output functions of
the CMS. Some of these signals are mandatory and some are optional. Apart from signal as-
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Operating Control and Displays
signment via the HMIs, the signals can also be assigned using a link matrix and a link table in
the remote control software.
Fig. 7-69 Accessing the parameter submenu ’I/O matrix’ and submenus
NOTICE
Important: the mapped signals must be connected to the right terminals!
The CMS offers the option of setting partial datasets that modify just one part of the parameters. These can be used to transfer only the IO matrix.
If the parameters are created as arrays, the partial dataset must always contain the entire array. This means for the IO matrix that it is not possible to create a sub-dataset where only one
signal was modified.
In this case, the current IO matrix must be exported and sent to LAMTEC for modification.
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7
Operating Control and Displays
Accessing the parameter submenu ’Chains’ and submenus (AL1)
Fig. 7-70 Accessing the parameter submenu ’Chains’ and submenus
A total of 10 signal chains are available for linking together various input signals. These chains
can consist of up to 16 links. These links must be assigned to a physical input via the I/O matrix
in the CMS remote software package.
Input functions already assigned (e.g. minimum gas pressure and maximum gas pressure)
can also be assigned to a signal chain.
Accessing the "Terminal assignment" submenu
Fig. 7-71 CMS Terminal assignment window
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7
Operating Control and Displays
Safety
Accessing the ’Level CRCs’ submenu (AL1)
Fig. 7-72 Accessing the CMS parameter submenu ’Level CRCs’
Displays the CRC checksums for the individual user levels as calculated and
stored in the device.
RC Curves
Accessing the CMS menu ’RC curves’ and submenus (AL1)
Fig. 7-73 Accessing the CMS menu ’RC curves’ and submenus
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Operating Control and Displays
The curve screen shows the setpoint curves for the channels (ratio controller) per curve set.
The user can switch between showing a curve-based format (setpoint graphic) and a display
in tabular format (curve table).
CO/O2 Data
Accessing CO/O2 data (AL1)
Fig. 7-74 CO/O2 data menu with submenus
The curves are programmed in this menu in the same way as in the RC curves menu – see
chapter 6.3.1 Programming Curves
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Operating Control and Displays
History
Accessing the ’Histories’ submenu
Fig. 7-75 CMS submenu Histories
The fault history shows the last 10 faults.
The following information is output for the individual faults:
Fig. 7-76 Show fault history
195
•
Fault number
•
Fault text
•
Affected module
•
Curve set
•
Date and time
•
Operating conditions
•
Firing rates
•
Setpoints
•
Actual values
7
Operating Control and Displays
In addition, the ’Historical I/O data’ tab shows the state of the existing inputs and outputs as a
time sequence.
Fig. 7-77 Showing the state of the inputs and outputs
Inputs/Outputs, Measurement Values
Accessing inputs, outputs and measurement values
The menu provides an overview of:
•
The current status of the digital inputs and outputs
•
PLC signals
•
Analogue measurement values:
– Display of flame intensity
– Internal load display
– Values from the burner firing-rate controller
•
Hints
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Operating Control and Displays
1 Digital inputs
2 Digital outputs
3 PLC Signals
4 Analogue measurement values
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7
Operating Control and Displays
4 Messages
Manual Burner Firing Rate Presetting
Accessing the ’manual burner firing rate’ submenu
Fig. 7-78 CMS manual burner firing rate window
Setting and changing values
1. Select parameter value internal/external value 1/2.
Set value with arrow keys up/down and confirm with the ENTER key
2. Alternative: Change the value by using the up/down arrow keys on the keyboard.
3. Confirm value with the ENTER key or select a different parameter.
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7
Operating Control and Displays
Cold Check
Accessing the cold check (AL1)
Fig. 7-79 Cold check menu with submenus
Performing a cold check
1. In the menu, click ’Cold check’.
The screen for performing a check of the outputs opens.
2. Start the cold check with the ’Start cold check’ button.
3. A dialogue box asks if the cold check mode should be activated: click ’OK’.
NOTICE
If this dialogue box is not confirmed with ’OK’ within a predefined time, the
procedure terminates automatically. The procedure can be repeated immediately.
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7
Operating Control and Displays
Date/Time
Date and time (AL1)
In the date/time menu, the system time can be applied as follows.
Fig. 7-80 Setting the date and time
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7
Operating Control and Displays
Replacing a Module
Fig. 7-81 Module replacement menu
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7
Operating Control and Displays
Device Information
Accessing device information (AL1)
Fig. 7-82 CMS device information menu
View of current device information, such as serial number or software versions
7.3.3.5 Options Menu
Tools
Firmware update (AL1)
Fig. 7-83 CMS firmware update menu
Performing a firmware update
1. Switch the CMS to the firmware update mode.
2. Select the target device.
3. Warning: check the PEC ID!
4. Select the hex image for MP and WP
(do not mix up the MP with the WP!)
5. Click the "Start firmware update" button.
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7
Operating Control and Displays
PLC update (AL1)
Fig. 7-84 PLC update
’Chart/Trace’ (AL1)
Fig. 7-85 CMS chart/trace
1 Start chart recording/pause/continue
203
2 Saving a record
7
Operating Control and Displays
All existing signals are always recorded together.
The signals of interest must only be selected for visualisation.
TCP-CAN Interface
Establishing a TCP-CAN connection
1. In the menu, click "TCP-CAN interface".
Fig. 7-86 TCP-CAN interface menu
2. Double-click the IP address in the bottom panel. This is then copied to the top input field for
the target IP address.
3. Click the "Connect" button.
4. Once the connection is established, the connection status is shown with a green highlight.
5. Click "OK" to exit the connection setup screen.
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Operating Control and Displays
Select Language
Fig. 7-87 Language selection menu
Selecting a language
1. In the menu, click "Language selection".
2. Select the language for the CMS remote software and confirm with "OK".
Access Code
Fig. 7-88 CMS access code menu
1. Enter the access code.
2. Click "Test code" to check the validity of the access code.
Then save the code.
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Operating Control and Displays
7.3.3.6 Help Menu
Help and version info (AL1)
The "Help" menu path can be used to:
•
Access the help screens for the CMS remote software
•
Access information about the CMS remote software version
Fig. 7-89 Help/version info menu
Accessing help
1. In the menu, click "Operator Manual/Help F1".
The CMS remote software documentation opens.
Version information
1. In the menu, click "Version info".
Information is displayed about the CMS remote software version.
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CO/O2 Control
8
CO/O2 Control
8.1
For Your Safety
The following factors must be taken into consideration for the assignment of the set-point values of the actuators for controlling the quantity of fuel and air and for setting the parameters
for correctional intervention:
•
Combustion chamber pressure
•
Fuel pressure
•
Temperature and pressure of the combustion air
•
Calorific value of the fuel
In the process, a safe, stable firing operation must be guaranteed across the entire output
range and in all firing operating modes.
This must be documented by measuring the characteristic values for an operation of the furnace at the shut-off limits of the ratio control, as well as the set limits of the correction circuits
(e.g. an O2 trim). To help you assess the situation, you should also refer to the informative
commissioning report.
It is essential that the procedure in chapter 6.3.4.1 Run to Shut-off Limits is observed.
For an equipment of the furnace with a failsafe CO controller, the check in the air deficiency
direction can be omitted. Instead, the shut-off limit of the CO controller (0.4 Vol.% O2) must
be checked; see chapter 6.3.4.1 Run to Shut-off Limits.
The correction limit in the excess air direction must also be limited to a non-critical range in
the event of CO controller operation.
If two or more systems of the CMS type are combined with a CO control device (e.g. two or
more burners for a combustion chamber), the safe operation of the combustion must be ensured with an additional flue gas monitoring system.
8.2
Safety Concept
The CO controller attempts to keep the combustion process within in the range of complete
combustion, i.e. just above the CO edge. To do this, the controller outputs a correction signal
which is evaluated by the electronic ratio control in order to move the positions of the actuating
devices in the direction of less or more air.
The set maximum correction range limits the possible influence of the controller. It is not possible to leave this range.
The position of the electronic ratio curve and correction range must be set in such a way that
the electronic ratio control can exceed the CO edge towards less air under all operating conditions. The CO edge towards excess air must not be exceeded.
The following figure depicts this once more.
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CO/O2 Control
Fig. 8-1 Correction range of the CO controller
The upper limit of the correction range ensures that all errors leading to a movement of the
controller in the direction of excess air only move the actuating devices up to an upper limit
that is still safe.
If this upper limit is exceeded in spite of this, and the correction range is violated, the controller
recognises this problem.
In contrast, errors that lead to the CO controller regulating in the direction of a lack of air must
be detected beforehand.
To handle this error, two additional monitors are implemented, which detect in a variety of
ways by means of the O2 and CO sensor when the exhaust gas falls below a critical O2 minimum value or exceeds a COe value (O2 minimum monitor /U-COe maximum monitor).
A "COe dynamics test" and "O2 dynamics test" ensure that these monitors are working correctly. These tests check whether the probes still react to changes of the fuel-air mixture by
means of a short modification of the exhaust gas composition.
Monitors for limit values have a timeout of < 20 s (<0.4 % O2). This is due to the long running
time of the exhaust gas flow from the burner to the exhaust gas sensor system and the thus
very slow control function.
8.3
Requirements
To use CO/O2 control, one of the following systems must be implemented:
8.4
8.5
•
LT3-F in combination with KS1D
•
LT1/LT2 for O2 measurement in combination with LT2 and KS1D
Required Inputs/Outputs
•
Corrections to the electronic ratio control
•
Sensor input to LT3
Required Parameters
All parameter groups for CO controller and CO monitoring are required for CO/O2 control.
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CO/O2 Control
8.6
Why Control CO?
8.6.1
Where Can CO Control be Used?
For the combustion of gaseous fuels, such as:
•
Natural gas H, L
•
Biogas
•
Process and exhaust gases
•
Hydrogen
And for fuels for which a reduction in the combustion air forms a CO edge, such as:
•
Lignite dust
•
Coal firing
For liquid fuels such as light fuel oil, control is possible on the basis of the CO concentration
in the exhaust gas only for so-called ’blue burners’ (blue flame).
For technical reasons, however, these are only available in the output range up to several 100
kW. For industrial furnaces, so-called ’yellow burners’ (yellow flame) are therefore used exclusively today for liquid fuels. In the combustion of liquid fuels with a yellow flame, soot normally
forms first before the CO concentration rises noticeably. For this reason, CO control is not possible with oil burners with a yellow flame.
In the case of LAMTEC CO/O2 control, you can regulate on the basis of either CO or O2, alternatively. This can be done depending on the fuel or firing rate. Firing rate-dependent switching from CO control to O2 trim may be necessary if, for example, the stability of the flame or
the NOx concentration in the exhaust gas makes it necessary to have a higher level of excess
air. ’On-the-fly’ switching from CO control to O2 trim is possible in a firing rate-dependent manner without the need to interrupt control.
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8
8.6.2
CO/O2 Control
Overview of Functions
The LAMTEC CO/O2 control consists of the following components:
•
CMS Combustion Management System with the option CO/O2 control
•
LT3-F Lambda Transmitter with KS1D combination probe
The LAMTEC SYSTEM BUS (LSB) transmits the measured values and operating states to
CMS.
NOTICE
The CO/O2 control only takes over when the probe is ready for operation.
Fig. 8-2 System overview CO/O2 control Gerät
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8.6.3
CO/O2 Control
Optimisation Strategy
The optimisation strategy includes searching for the optimum working point of the furnace
near the emission edge, adjusting this accordingly, maintaining it, optimising further, if necessary, and monitoring.
To do this, the fuel-air mixture is dynamically modified without influencing the power control
unit in the direction of a lower lambda value (less air, more fuel). The beginning of incomplete
combustion is shown by a strong signal increase and signal dynamics.
From this point on, the air-fuel mixture is slightly modified again in the direction of a greater
lambda value (more air/less fuel). The optimum working point is found.
The working points determined in this way are subjected to a plausibility analysis. Working
points outside of this are discarded and recalculated. This procedure is repeated cyclically so
that the optimum working points are always maintained even in changing weather and systemrelated conditions.
If the KS1D Combination probe detects unburned residue (CO/H2), for example as a result of
changed, system-specific conditions, the working point is immediately shifted in the direction
of a greater lambda value (more air, less fuel).
The simultaneously measured O2 value is not required for CO control itself. It is only required
for monitoring and visualisation purposes. If it is not possible for combustion-related reasons
to run to the CO edge over the entire firing range, there is the option of switching smoothly
from CO control to O2 trim depending on the firing range. With multi-fuel burners, you can select whether CO control or the O2 trim is active depending on the fuel.
8.6.4
Advantages of CO Control over O2 Trim
•
Higher energy savings through continuous self-optimisation in every firing-rate point
•
Better control performance through significantly shorter setting times
•
Excess air independent
•
Failsafe
•
Higher operating safety
•
Robust
•
Low-maintenance
8.7
Operating Control and Displays
8.7.1
Is CO Control or O2 Trim Activated?
Factory settings
Oil

O2 trim
Gas

CO control
P 100
AL 1
=
1
O2 standard trim with optimisation curve
P 101
AL 0
=
0
1
O2 trim OFF
O2 trim ON
P 200
AL 1
=
1
CO controller type: Gas = CO control, oil = O2 trim
P 203
AL 0
=
0
1
CO controller OFF
CO controller ON
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AL = access level
If CO regulation is deactivated or malfunctioning, the O2 trim takes over depending on the
curve set.
Curve set-dependent activation of CO regulation is possible via P 200/P 201 (access level 4).
For firing rate-dependent activation/deactivation of the CO regulation, AL 3 is required via
UI400 or CMS Remote Software.
NOTICE
The CO or O2 regulation is active only if the CO/O2 measurement is in the ’Measure’ mode
and the adjustment mode is OFF.
NOTICE
To be on the safe side, the CO optimisation curve must be deleted before initial commissioning.
NOTICE
If O2 regulation is activated, O2 regulation takes over automatically when CO regulation is deactivated or malfunctioning.*****
CO regulation always requires a stored O2 setpoint curve.
No CO regulation without an O2 setpoint curve!******
O2 regulation inactive
If O2 regulation is inactive, excess air is set, depending on the cause.
Basic value for deactivated O2 regulation and air deficiency
In the CMS, the value for an inactive O2 trim and air deficiency value must be set as an offset
to the neutral value, so that this value always tends in the direction of excess air.
Factory setting:
Basic offset with ’inactive O2trim’ = 100
Basic offset with ’Air deficiency’ = 200
Via the burner efficiency, the following overall picture results:
Fig. 8-3 Base values for ’Air deficiency’ and ’Deactivated O2 regulation’
*****Can
be configured via P 202 depending on the curve set.
2 setpoint curve is only regarded as present when there are at least 3 programmed
O2 setpoint values.
******The O
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8.7.2
CO/O2 Control
Display in the Case of Active CO/O2 Control
8.7.2.1 Display with Active CO Control
The CO display replaces the O2 display as soon as CO control is active.
1
CO actual value [ppm]
2
– = air is reduced
+ = air is increased
3
C = increasing firing rate
c = falling firing rate
4
Number of optimisation steps
5
O2 actual value – in this case 1.1 vol. %
O2
Fig. 8-4 Display for active CO control
NOTICE
re Items 2 and 4:
If this display value reaches -32 in case of air reduction (display of Item 2 = – and Item 4 = 32)
and +52 or +54 in case of air increase (display of Item 2 = + and Item 4 = 52 or 54), the CO
control has detected the CO edge and the optimisation point is saved.
8.7.2.2 Display for Active O2 Trim
1
O2 actual value
2
O2 setpoint value
3
Status display
Fig. 8-5 Display for active O2 trim
8.7.2.3 Status Display in Case of O2 Trim
op
O2 trim ready (at burner startup) or O2 trim switched off temporarily depending on firing rate (see Chapter Activating O2 Trim
or
O2 trim active (see Chapter 8.7.2.2 Display for Active O2 Trim).
ot
O2 trim temporarily deactivated (insufficient air, O2 value under the monitoring bands,
etc.)
od
O2 trim permanently deactivated (malfunction), e.g., test routines at burner startup
not passed, dynamics test negative, O2 trim temporarily deactivated for longer than
an hour, etc. (see chapter 8.7.2.4 Resetting Faults).
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CO/O2 Control
8.7.2.4 Resetting Faults
Also see Chapter 8.10.8.1 Resetting Faults.
Manual
NOTICE
For the manual reset of the fault, the fault display absolutely must be opened (call the fault
text)!
After that, acknowledge with the ENTER key.
Automatic
Automatic reset whenever the burner starts up
8.8
Electrical Connection - Connection via LSB
8.8.1
Electrical Connection
Electrical connection according to the connecting diagrams in the Appendix (see Chapter 12.3
Circuit Diagrams).
8.8.2
LAMTEC SYSTEM BUS (LSB)
Fig. 8-6 CMS MCC with CO/O2 trim
All data and operating states relevant for the control are transferred by LSB.
For more information refer to the documents in chapter 1.1 Validity of these Instructions).
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8.9
CO/O2 Control
Settings
NOTICE
Whenever CO control malfunctions, you can switch smoothly to O2 trim. That means you have
to set and activate both CO control and O2 trim (see Chapters 8.9.1 Activating CO/O2 Control
Activating CO Control).
You need access level 1 for this purpose.
Factory setting:
CO control is an adaptive optimisation of the electronic ratio control. Control parameters and
setpoint values do not have to be set.
8.9.1
Activating CO/O2 Control
Activate CO/O2 trim with User Interface (UI400), see chapter 7.1.5.6 Adjusting Controller,
Setting the Correction Range and the Spread Factor and chapter Setting the Correction
Range and the Spread Factor
Activate CO/O2 trim with CMS Remote Software, see chapter Activating O2 Trim and chapter
Setting the Correction Range and the Spread Factor
8.9.2
Access Levels
The parameters are subdivided into four different access levels depending on their function or
security classification:
Operating level (level 0)
No password required. Parameters which are not security-related and that can be changed
during operation.
Commissioning level (level 1)
Accessible using a password which can be changed. Access to parameters which require specialist knowledge, are set for the specific system and cannot be changed during operation.
Factory setting = 0000
Service level (level 2)
Accessible with a fixed password but only to personnel specifically trained in parameter assignment. Access to all parameters which are not set on the basis of standards and technical
rules.
Password = customer-specific (if necessary ask the supplier/manufacturer of the burner software; LAMTEC identification code for customers is required).
Production level (level 4)
Access to all parameters (by LAMTEC only).
NOTICE
Each parameter level is protected by means of a separate checksum. We recommend that
you note these checksums on completion of commissioning. They serve as proof that no
changes have been made. Alternatively, back up the data set.
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8.9.3
Password Entry
Information regarding password entry for the connected devices can be found in the corresponding basic documents in Chapter 1.1 Validity of these Instructions.
Information regarding password entry with UI400 see chapter 7.1.5.1 Password
Information regarding password entry with GUI60x see chapter 7.2.2 Password
Information regarding password entry with CMS Remote Software see chapter 7.3.3.3 Access
Rights Menu
8.10
Installation and Commissioning
8.10.1
Guidelines for Commissioning CO/O2 Controller
Commissioning of the CO/O2 control
1. Check terminal resistances on LT and the devices connected to the LSB
and reset if necessary.
2. Activate CO/O2 control on CMS.
8.10.8 Commissioning the CO/O2 Control
alternatively by UI400 (8.10.8.1 Commissioning with UI400) or CMS Remote Software
(8.10.8.2 Operating with PC Remote Software)
3. Compare the CO/O2 measurement device (LT3-F) offset (air) and operating point.
See basic document LT3-F: Offset calibration (publication no. DLT3140)
See basic document LT3-F: O2 calibration (publication no. DLT3140)
See basic document LT3-F: COe calibration (publication no. DLT3140)
4. Check or enter O2 setpoint curve on CMS
Entering the O2 Setpoint Curve
NOTICE
No CO control without an O2 setpoint curve!*******
5. Set correctional range on CMS.
Recommendation for CO control:
Speed  300
Air damper  100
Recommendation for O2 trim:
Speed  150
Air damper  50
*******The
O2 setpoint curve is only regarded as present when there are at least 3 programmed O2 setpoint values.
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NOTICE
See safety concept in chapter 8.2 Safety Concept
6. Set response threshold of the CO detection on the LT3-F.
8.10.7 Set and Optimise the CO Response Threshold on LT3-F
7. Put CO control into operation.
8.10.8.1 Commissioning with UI400.
8.10.8.2 Operating with PC Remote Software.
8. Set control parameters and dead time of the O2 trim on CMS.
Setting the 'Proportional Factor' and 'Dead Time' Control Parameters.
Setting the 'Proportional Factor' and 'Dead Time' Control Parameters.
9. Check settings on CMS and LT.
Activating CO Control – via UI400
Exiting SETTING Mode – via CMS Remote Software
10. Back up dataset from CMS and LT3-F using CMS Remote Software (download).
Information on this is included in the basic documentation (publication no. DLT3140)
The commissioning of CO/O2 control is now complete.
8.10.2
Putting the Electronic Ratio Control System into Operation
Commissioning of the electronic ratio control system and O2 measurement, as described in
the device-specific instructions referred to in Chapter 1.1 Validity of these Instructions.
The integrated CO/O2 control remains deactivated.
7 Operating Control and Displays
P 200 = 0  CO control is deactivated.
P 200 = 1  Standard (O2 = OIL/CO = Gas)
(see chapter 8.10.8.2 Operating with PC Remote Software)
WARNING!
An incorrect setting can result in explosion.
This can result in severe injuries or death.
 Note the burner manufacturer's instructions with regard to settings.
The burner (basic setting without O2 trim or CO control) must be set so that it burns stably
under all operating conditions and the emission limit values are observed. For the ’Deactivated
CO/O2 control’ operating condition, a correct offset for inactive control with excess air must be
set (at the factory).
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8
CO/O2 Control
CO control:
Correct offset at 0 % correction = +50
P 120 = 100 (Air offset in correction digit with
Correct offset at 100 % correction = -50
deactivated O2 trim)
This results in a neutral correction of 500
(permanently factory-set)
P121 = 200 (Air offset in correction digit with air
deficiency)
With O2 trim, the offsets must be converted accordingly.
O2 trim:
Correct offset at 0 % correction = +60
P 120 = 500 (Air offset in correction digit with
Correct offset at 100 % correction = -40
deactivated O2 trim)
This results in a neutral correction of 500
(permanently factory-set)
P121 = 400 (Air offset in correction digit with air
deficiency)
8.10.3
Combined O2/CO/H2 Measurement LT3-F
Information in the corresponding basic documents (see Chapter 1.1 Validity of these Instructions).
8.10.3.1 Checking the Connection from LT3-F to BT300 by LAMTEC SYSTEM BUS.
NOTICE
The CMS then only has a connection via the LAMTEC SYSTEM BUS if the CO, or O2 value
is displayed in the display window of the controller.
Fig. 8-7 Display for active CO control
218
1
CO actual value [ppm]
2
– = air is reduced
+ = air is increased
3
C = increasing firing rate
c = falling firing rate
4
Number of optimisation steps
5
O2 actual value – in this case 1.1 vol.%
O2
8
CO/O2 Control
1
O2 actual value
2
O2 setpoint value
3
Status display
Fig. 8-8 Display for active O2 trim
8.10.3.2 Operating and Comparing O2 and COe Measurements
Information in the corresponding basic documents (see Chapter 1.1 Validity of these Instructions).
8.10.4
Setting the CMS Correction Range
Spread factor in case off correction of air actuator
Fig. 8-9 Correction with a spread factor of 10 (unchanging correction)
219
Spread factor (P725 seq.)
= 10
Increase
= 1.0
Mode
+50 ... -50
Input
0 % ... 100 %
Neutral value
50 %
Correctional range*
P 705 ff.
8
CO/O2 Control
Spread factor (P725 seq.)
20
Increase
2.0
Mode
+50 ... -50
Input
0 % ... 100 %
Neutral value
50 %
Correctional range*
P 705 ff.
Fig. 8-10 Correction with a spread factor of 20
Factory setting:
Spread factor
10 Corresponds to 1.0 (i.e. no weighting)
Spread factor
>10 Correction effect increases as the burner efficiency increases
Spread factor
<10 Correction effect decreases as the burner efficiency decreases
WARNING!
An incorrect setting can result in explosion.
This can result in severe injuries or death.
 Note the adjustment instructions of the burner manufacturer with regard to the combustion-related limit values.
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8
CO/O2 Control
Spread factor in case off correction of air actuator
Spreading factor
(P701)
= 10
Amplification
+50 - -50
Mode
0% 100%
Input
50 %
Neutral value
P 702
= 1.0
Correction range*
Fig. 8-11 Correction with a spread factor of 10 (unchanging correction)
Spreading factor
(P701)
20
Amplification
+50 - -50
Mode
0% 100%
Input
50 %
Neutral value
P 702
2.0
Correction range*
Fig. 8-12 Correction with a spread factor of 20
Factory setting:
Spread factor
10 Corresponds to 1.0 (i.e. no weighting)
Spread factor
>10 Correction influence increases as the burner output increases
Spread factor
<10 Correction influence decreases as the burner output decreases
WARNING!
An incorrect setting can result in explosion.
This can result in severe injuries or death.
 Note the adjustment instructions of the burner manufacturer with regard to the combustion-related limit values.
221
8
8.10.5
CO/O2 Control
CO Control: Start-up O2 Monitoring Shut-off Limits
It is essential to check and ensure that the burner burns stably in every firing rate range at the
shut-off limit of O2 monitoring, taking into account all environmental influences.
Factory setting of the shut-off limit of O2 monitoring with CO control activated = 0.4 vol.%.
Testing the Correction Effect
NOTICE
If the factory-set shut-off limit at 0.4 Vol.% O2 is too low for your application, there is an option
to raise this via the CMS Remote Software (FE4 required). The LAMTEC Support department
is available for support queries (support@lamtec.de or +49 (0) 6227 6052-33).
 P206
Fig. 8-13 Setting the shut-off limit of O2 monitoring
NOTICE
Before the shut-off limit is traversed, the O2 measurement must be calibrated in accordance
with the specifications in the basic documentation (see chapter 1.1 Validity of these Instructions).
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8
CO/O2 Control
Deactivating CO control depending on the O2 value
For a description, see chapter Optimising the CO Control
NOTICE
This function is only available via CMS Remote Software.
8.10.6
Checking the Combustion-related Limit Values
NOTICE
With O2 trim is it essential to ensure that the burner burns safely and stably at maximum correctional intervention (0 % and 100 %), taking into account all environmental influences and
in every burner firing-rate range.
To do this, transverse the correction value both to 0 % and to 100 % at different firing-rate values (for CMS Remote Software see chapter Testing the Correction Effect).
8.10.7
Set and Optimise the CO Response Threshold on LT3-F
The basis for CO regulation is a digital signal  CO greater/less than threshold value.
This signal is formed in the LT3-F and transferred to the burner controller via the LAMTEC
SYSTEM BUS (LSB).
1. Run the burner to a firing-rate between base fire and half fire.
2. Change the electronic ratio towards less air and/or more fuel (correction values  100%)
until the CO edge is detected; if necessary, increase the correctional range again.
Alternatively, you can keep it regulated at the CO edge. You must not change the firingrate for this purpose (MANUAL burner firing-rate controller). On the display of the CMS,
the signal dynamics must rise continuously.
NOTICE
If this display value of CMS reaches -32 in case of air reduction (display of Item 2 = – and Item
4 = 32) and +52 or +54 ( in case of air increase (display of Item 2 = + and Item 4 = 52 or 54),
the CO regulation has detected the CO edge and the optimisation point is saved.
Repeat at another firing-rate point.
Can only be set in access level 2!
COe trigger threshold. Switching threshold of
the COe detection for LAMTEC CO/O2 regulation. Evaluation of the signal dynamics.
Settable in a range from 0 ... 100 %.
Factory setting: 40 %
< 40% trim becomes more sensitive
Fig. 8-14 ’Settings’ menu in the LT3-F
223
> 40% trim becomes less sensitive
8
CO/O2 Control
O2
 O2 in humid flue gas
COe
 evaluated COe signal
COe
 Signal dynamics UCO/H2
 CO edge signal reached/
exceeded
Fig. 8-15 Main menu in the LT3-F
The factory-set response threshold is 40%. The display of the LT3-F shows whether or not the
response threshold has been reached. When the response threshold is reached, the CO edge
signal is present, and the CO regulation becomes active. This is indicated by a symbol on the
display of the LT3-F
or can be exported via the LSB remote software of the LT3-F in parameter 444. The desired response threshold can be set on the display of the LT3-F or using
Parameter 453 of the LSB remote software of the LT3-F. Access level 2 is required for service!
Setting recommendation:
8.10.8
–
For burners without a CO base level, the response threshold in the LT3-F should be set in
such a way that the CO edge is at 20  10 ppm CO (measured using a CO reference
measuring device).
–
For burners without a CO base level, the response threshold value should be set to values
 80 ppm CO (measured using a CO reference measuring device).
–
Setting increments 10%
Commissioning the CO/O2 Control
8.10.8.1 Resetting Faults
Faults are reset in different ways:
Resetting temporary faults (ot):
The fault is displayed for as long as it is present. Once the cause of the fault is eliminated, the
fault is deleted, and the fault status signal no longer displayed.
Resetting permanent faults (od) at startup of the burner:
Each time the burner starts up, a fault is automatically reset, even if the cause of the fault has
not yet been eliminated. If the cause has not yet been eliminated, the fault will re-occur.
Resetting permanent faults (od) manually:
You can also reset permanent faults (od) manually after eliminating the cause.
UI400: Open the fault status signal using the arrow keys (see chapter Calling the CO/O2 Fault
History) and acknowledge the fault with
.
CMS Remote Software: Use the RESET buttons in the header bar of the CMS Remote Software.
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8
CO/O2 Control
8.10.8.2 Operating with PC Remote Software
The CO and O2 trim can be conveniently configured, set, evaluated and monitored using the
CMS Remote Software (option) developed by LAMTEC.
Article number 667R0300-1
Activating O2 Trim
For more information refer to the following chapters:
•
Activating CO Control
•
Optimising the CO Control
Fig. 8-16 O2 trim parameter menu
NOTICE
At least access level 1 is required for activation.
A = Activation/deactivation of the
O2 trim, depending on the firing
rate
Fig. 8-17 Activation of the O2 trim in the drop-down menu
Settings/O2 trim
1
Default O2 trim with optimisation curve and firing rate shifting with feed forward control
2
Without optimisation curve and firing rate shifting with feed forward control :
Setting 2 is recommended whit ongoing changes of the fuel (calorific value) p.ex. the
plat runs on bio gases or process gases
225
8
CO/O2 Control
3
O2 trim is inactive
Measured O2 value is indicated.
4-7 inactive
8
The correction value for an inactive control is preset.
9
The correction value for air deficiency is preset.
Affected parameters
P100 = Type of O2 trim
P101 = Activation of the O2 trim
P109 = Bit pattern of the curve set
P120 = Offset value of excess air for inactive CO/O2 control
P121 = Offset value of excess air for air deficiency
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8
CO/O2 Control
Setting the Correction Range and the Spread Factor
NOTICE
The spread factor can only be set or changed when the burner is switched off.
 Access level 1 is required.
1. Open the correction window
2. Select the channel to be corrected. Enter the correction shift and the correction range into
the text boxes.
Deleting the O2 and CO Optimisation Curve
NOTICE
To delete O2 and CO optimisation curve access level 1 is required.
NOTICE
Recommendation:
Delete optimisation curves if:
– The optimisation curve of the O2 trim is no longer valid (e.g. after a longer burner standstill).
– The burner starts to run into a air deficiency when the firing rate changes.
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8
CO/O2 Control
1. Select CO/O2 curves
Fig. 8-18 CO/O2 data menu
The diagram of the optimisation curve CO (tab O2 optimisation curves) opens.
2. The tab CO optimisation curve
228
leads to the diagram.
8
CO/O2 Control
3. Delete the CO and O2 optimisation curve by the buttons as shown below.
Fig. 8-19 Button for clearing O2 curves
Fig. 8-20 Button for clearing CO curves
CO and O2 optimisation curves are; the respective curve is deleted from the diagram. The display shows an empty diagram.
Deleting the optimisation curve by UI400 is described in chapter Deleting the O2 and CO Optimisation Curve.
Entering the O2 Setpoint Curve
Optimisation through adjustment of O2 curves
1. Click the button
.
2. Set the firing rate value using the arrow buttons
3. Adjust the O2 value using the arrow buttons
4. Save the point using the button
and
and
.
.
.
5. Set the O2 setpoint value for all the supporting points of the fuel-air ratio curve.
You will find the recommended procedure for setting the fuel-air curve in the basic documentation for this device (see Chapter 1.1 Validity of these Instructions).
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8
CO/O2 Control
Testing the Correction Effect
Manual adjustment of the correction value can be used to check the switch-off limit of the O2
monitoring for CO control.
Moving the correction value
1. Open the CO/O2 curve window.
Fig. 8-21 CO/O2 data menu
NOTICE
This manual adjustment of the correction value is only possible in the O2 SETTINGS mode,
’O2 EI mode active’.
The window ’CO/O2 curves’ opens.
Fig. 8-22 CO/O2 curves
230
8
CO/O2 Control
2. Click the button Button correction presetting
.
NOTICE
999 = maximum correction in direction air deficiency.
NOTICE
Move slow!
3. Adjust the correction with the arrow keys
.
4. Observe O2 and COe values.
5. Check that the combustion is stable. Are abnormal noises being heard?
If, for combustion reasons, it is not possible to approach 0,4 Vol.% O2, it is possible to increase the O2 switch-off value. (see chapter 8.10.5 CO Control: Start-up O2 Monitoring
Shut-off Limits).
NOTICE
Alternatively, the CO control can be limited depending on O2. (see chapter Optimising the CO
Control).
6. Set the correction input value back to a medium position (500).
7. Repeat the procedure on a medium firing rate position.
8. Repeat the procedure on the maximum firing rate position.
NOTICE
If the correction effect is too small at medium and maximum burner firing rate, the correction
effect can be adjusted firing rate-dependently by the correction effect.
Switch OFF the burner to adjust the correction shift.
The correction shift is set in access level 1.The correction shift is set in access level 1 and can
only be adjusted using the CMS Remote Software.
9. Click the button ’Back’
, to finish this procedure.
NOTICE
These settings are not saved. They are only used to check the correction range.
NOTICE
To activate the SETTING mode, the commissioning engineer must specify the firing-rate manually. The analogue firing-rate input, regular firing rate input via LSB and manual specification
on the device are not taken into account.
NOTICE
The responsibility for the set burner efficiency passes to the commissioning engineer or user.
231
8
CO/O2 Control
Setting the 'Proportional Factor' and 'Dead Time' Control Parameters
NOTICE
To adjust control parameters access level 1 is required.
P 100
P 109
P 110
P 120
P 121
Set parameter P 109 so that the next setpoint/actual value comparison (control pulse) does
not take place until the O2 actual value has visibly changed – best seen in the window ’Analogue measured values"’ (see Fig. 8-23 Analogue measured values menu and Fig. 8-24 Analogue measurement values window).
Fig. 8-23 Analogue measured values menu
232
8
CO/O2 Control
Fig. 8-24 Analogue measurement values window
No change or change is too small  increase P term in P 110.
NOTICE
The new correction is determined as a function of the actual/setpoint deviation of the O2 value,
the P factor and the spread factor. This is then sent to the CMS. The procedure is repeated
after the dead time has elapsed. If the internal firing rate changes during this time, the O2 trim
switches to the FEED FORWARD CONTROL mode. The correction value follows the stored
optimisation curve.
Activating CO Control
Fig. 8-25 Open the CO controller menu
NOTICE
To open the menu at least access level 1 is required. (CMS, V1.0.3).
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8
CO/O2 Control
Fig. 8-26 Activation of the CO control in the drop-down menu
NOTICE
No CO control possible without stored O2 setpoint curve!
Without activated O2 trim (setting 1 ... 4) no CO control!
If the CO control is switched off or malfunctioning, the O2 controller takes over depending on
the fuel.
For more information see chapter Activating O2 Trim
Optimising the CO Control
NOTICE
Access level 1 is required.
Enter the password for access level 1, see chapter 7.3.3.3 Access Rights Menu.
Fig. 8-27 Open the CO controller menu
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8
CO/O2 Control
Behaviour during optimisation
Fig. 8-28 Parameter of the CO controller - behaviour during optimisation
Description of the window ’Parameter of the CO controller - behaviour during optimisation’
1
CO controller type
0 = OFF
1 = ON (default)
2
Smallest permissible O2 value/tolerance time during monitoring
Smallest permissible O2 value (1/10 %) until the CO controller is switched off. If the
O2 value remains below this parameter set limit (P 204) for longer than the time set in
P 205, the CO control switches off.
3
Low fire
Enter the firing rate value at which CO control is activated. The entry is made in digit.
Factory setting: 000
High fire
Enter the firing rate value at which CO control is deactivated. in digit.
Factory setting: 999
NOTICE
Special situation: P 202 (low fire) > P 203 (high fire). In this case, the CO controller is only
activated outside the parameter set firing rate values.
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8
CO/O2 Control
4 Tab ’Behaviour during optimisation’
5 Maximum firing rate difference for static optimisation
During static optimisation, the internal firing rate is frozen. As soon as the requested firing rate exceeds the set value, the optimisation is stopped and the firing rate adjustment
is enabled again. Value range 0 ... 999 digit.
6 Time [s] to cancel a completed optimisation while the burner is running
Validity of the optimisation points adjustment.
Time value to start a new optimisation after a successful completion in hours.
Value range = 0 ... 17780 s.
Each optimisation point is treated individually. The time begins to run as soon as the
optimisation in the affected firing rate segment has been completed.
Factory setting: 28800 8 h.
7 Burner down time [Min]: After expiry the CO optimisation is released immediately after
the start of the controller
Factory setting: 60 Min*
* i. e. If the burner remains switched OFF for longer than 60 Min, the CO control is enabled immediately after burner ON in order to counteract an earlier formation of CO in a
cold combustion chamber.
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8
CO/O2 Control
Behaviour during CO detection
Fig. 8-29 Parameter CO- controller - Behaviour during CO detection
1
Increasing air: Initial value at upcoming CO detection [digit]
Number of optimisation points that raise the current correction signal in the direction
of excess air immediately after the CO threshold has been detected.
Factory setting and value range 0 ... 300 corresponds to 0 ... 300 digit.
2
Increasing air: Speed gradient after CO detection [digit/s]
Number of optimisation points that increase the current correction signal in the direction of excess air during a direction change of the firing rate.
Factory setting and value range 0 ... 400 corresponds to 0 ... 400 digit.
3
Decreasing air: (Falling) speed gradient after decreasing CO correction [digit/s]
After a completed optimisation, the correction signal leaves the associated optimisation point by the set number of digit in the direction of excess air.
Factory setting and value range 0 ... 200 corresponds to 0 ... 200 digit.
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8
CO/O2 Control
Threshold signal/optimisation point
A graphical representation of the behaviour during CO detection can be found in chapter Fig.
8-29 Parameter CO- controller - Behaviour during CO detection.
Fig. 8-30 CO threshold tab
1
Maximum permissible effective UCOe [mV] below the CO edge
In addition to the binary edge signal, the CO edge is also evaluated as exceeded if
UCOe has exceeded the threshold value set in P 234.
NOTICE
If the COe probe dynamic test is active, this value can be undershot.
This value is not controlled, therefore lower O2 values are possible.
2
O2 value [forces the completion of the optimisation (condition: value > P235)
When the O2 value in P 235 is reached in 0.1%, the optimisation is forcibly completed. When the O2 value in P 235 is reached in 0.1%, the optimisation is forcibly
completed. During the dynamic test the value can be undershot!
3
Maximum O2 value to accept an optimisation [%]
The optimisation is only completed and the new point entered in the CO optimisation
curve if the current O2 value is smaller than the parameter set threshold value in
P 236. O2values above this threshold value are not entered in the visualisation curve
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8
CO/O2 Control
Threshold signal/optimisation point
A graphical representation of the behaviour during CO detection can be found in chapter Fig.
8-29 Parameter CO- controller - Behaviour during CO detection.
Fig. 8-31 Behaviour during firing rate change
CO Threshold: Increasing air while changing the direction of the firing rate
Number of optimisation points which change the current optimisation value in the direction of
increasing air pressure immediately after changing the firing rate direction (P231).
CO Threshold: Increasing air while changing firing rate (without the direction of the firing rate)
Number of optimisation points which change the current optimisation signal in the direction of
increasing air pressure immediately after a firing rate change (P248).
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8
CO/O2 Control
Assessing CO/O2 Control Behaviour
NOTICE
Recommendation:
Use the Chart/Trace recording tool to evaluate the control mode
(see chapter Chart/Trace (Recording Tool).
The LAMTEC CO regulation is an adaptive, self-optimising fuel-air composite regulation. The
goal is to implement optimum burner adjustment at or just before the CO edge without manual
intervention.
To prevent CO spikes in extreme systems (burners) that, for example, have a large mechanical hysteresis, you have the option of making the following adjustments using the CMS Remote Software.
Possible optimisations:
–
Activate/deactivate CO regulation depending on the firing rate (see Chapter Activating O2
Trim).
–
Amount of air increase in the case of a change of firing rate direction (see Chapter Optimising the CO Control).
–
Amount of air increase between the CO edge and CO optimisation curve.
Also see chapter Optimising the CO Control.
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8
CO/O2 Control
Calling the CO/O2 Fault History
CO/O2 fault history
•
When the data sets are saved, the log of the last 20 faults is also saved. The faults are
indicated by a mouse click on the flag of the tabs.
Fig. 8-32 CO/O2 fault history menu
Fig. 8-33 CO/O2 fault history
•
Display of the fault and its duration.
The current curve set and the firing rate value at the time the fault occurred are also displayed. In online mode, the time at which the fault occurs is calculated and displayed. Due
to power failures or "Power OFF", the calculated time may deviate from the actual time.
•
The activated LED symbols indicate the cause of the fault.
241
8
CO/O2 Control
Resetting Faults
Faults are reset in different ways:
Resetting temporary faults (ot):
The fault is displayed for as long as it is present. Once the cause of the fault is eliminated, the
fault is deleted, and the fault status signal no longer displayed.
Resetting permanent faults (od) at startup of the burner:
Each time the burner starts up, a fault is automatically reset, even if the cause of the fault has
not yet been eliminated. If the cause has not yet been eliminated, the fault will re-occur.
Resetting permanent faults (od) manually:
You can also reset permanent faults (od) manually after eliminating the cause.
UI400: Open the fault status signal using the arrow keys (see chapter History) and acknowledge the fault with
.
CMS Remote Software: Use the RESET buttons in the header bar of the CMS Remote Software.
Chart/Trace (Recording Tool)
The recording tool can be used to record and store various values for evaluation and documentation purposes.
Fig. 8-34 Chart/Trace menu
Fig. 8-35 Chart view
242
8
CO/O2 Control
1. Start/Stop Trace button
Click this button to start and stop tracing.
After stopping the tracing process the system asks whether the recording should be saved.
Click this icon to store the result.
NOTICE
The Chart/Trace tool always records all values, but displays only the values selected in the
options window.
Fig. 8-36 The Options window
Zoom functions:
Fig. 8-37 Zoom functions
243
8
CO/O2 Control
With the zoom function, the scaling of the display can be enlarged and reduced.
Enlarging
1. Set the cursor to a point (20 % in this case).
2. Keep the left mouse button pressed and drag the cursor to the X-axis.
3. Release the left mouse button at the desired position.
The selected area is enlarged.
Reducing
1. Proceed in reverse order as to enlarge.
8.11
Monitoring Routines
8.11.1
Dynamic Monitoring Routines
Fault display UI400
Fault description
0004
O2 probe dynamics response
0045
COe probe dynamics response
These dynamic monitoring routines continuously check whether the probe voltage or O2 value
has changed by more than the parametrised threshold value. If the CO controller does not detect any change (dynamics) after expiration of the monitoring time, an active dynamics test is
started. This dynamics test changes the correction signal, which changes the probe signal and
the O2 value. If the set dynamics threshold is not reached despite this, CO regulation switches
off. This fault must be reset manually.
Possible causes:
8.11.2
•
Parametrisation of the O2 correctional range or CO correction range too small.
•
Parametrisation of P-term for O2 regulation too small
•
Probe/actuator faulty
CO/O2 Controller Information
O2 information example:
O2 trim is deactivated. Firing rate value is
outside the control range.
Fig. 8-38 Display of an O2 information
No.
Fault/
information
Comment
0014
O2 information
½ air shortage: Countermeasures are inactive.
0015
O2 information
O2 probe dynamics missing. Increase excess air.
0016
O2 information
Correction at stop - O2 trim is inactive.
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8
CO/O2 Control
No.
Fault/
information
Comment
0024
O2 information
O2 trim is on standby.
0025
O2 information
O2 trim is deactivated. Firing rate value is outside the control range.
0026
O2 information
O2 trim is deactivated. Burner is switched off.
0031
O2 information
O2 trim was switched off via LSB (maintenance/fault in O2 measurement).
0032
O2 information
Correction value set manually
0034
O2 information
O2 trim is active.
0046
CO information
CO control deactivated. firing rate value is outside the control range.
0048
CO information
CO control was deactivated by the SYSTEM BUS (maintenance/fault in
CO/O2 measurement)
0051
CO information
CO curve is active.
0061
O2 information
Curve set change is running.
0062
O2 information
O2 adjustment is in operation after burner OFF.
0063
O2 information
O2 trim is inactive in this curve set.
0064
O2 information
O2 trim is inactive in ADJUST mode.
0065
O2 information
O2 trim is active.
0066
O2 information
O2 trim is inactive.
0067
O2 information
O2 trim is only available in READ mode.
0068
O2 information
O2 ADJUST mode is active at burner startup.
0069
O2 fault
O2 setpoint curve is incorrect.
0070
O2 fault
O2 correction curve is incorrect.
0071
O2 information
O2 trim – waiting period after curve set change in progress.
0072
O2 information
O2 trim has been deactivated by parameters.
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8
8.11.3
CO/O2 Control
CO Controller Faults
CO fault example:
The plausibility check of the sensor voltage
of the COe measuring cell with O2 trim has
been activated.
Fig. 8-39 Display of a CO monitoring fault
When the following monitoring routines are activated, CO control is deactivated. Depending
on the settings made, CO optimisation is completely deactivated (factory setting) or switched
to O2 trim online.
No.
Fault/
information
0040
CO fault
Comment
ot
There is no CO edge information available on the LAMTEC SYSTEM
BUS.
Lambda Transmitter is incorrectly configured or not connected to LSB.
LSB connection is twisted.
(see chapter 8.8 Electrical Connection - Connection via LSB)
Lambda Transmitter is not in measuring mode (malfunction/cold start).
Lambda Transmitter is in adjustment mode.
The correction range is set too small. As a result, the control
cannot approach the CO edge.
– Check correction range (P703) and adjust if necessary.
The electronic ratio curve is set in such a way that the CO edge cannot
be reached.
– Check curve setting and adjust l if necessary.
With CO, the LT does not achieve the necessary probe dynamics for
triggering the CO edge.
– Check the trigger threshold for the edge signal in the LT and
adjust it if necessary.
0041
CO fault
ot
CO probe voltage is outside the monitoring window (UCO/H2).
Incorrect polarity of probe connection (signal).
The probe is defective.
Permissible probe voltage range in Lambda Transmitter is too small.
Range: +10 ... + 500 mV
0042
CO fault
ot
CO probe offset is outside the monitoring window.
During the offset calibration process 21 % O2 (air) were not present at
the measuring point.
– Repeat offset calibration
The probe heats up.
– Check internal probe resistance Ri in LT
– Check wiring and correct if necessary
The probe is defective.
Fault in the wiring (incorrect polarity)
Range: -25 ... +10 mV/20 s
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8
CO/O2 Control
No.
Fault/
information
0043
CO fault
0044
Comment
ot/
od
CO fault
Cell resistance of the CO sensor is outside the monitoring window.
The probe is too cold.
Heating capacity is too low
– Check wiring for probe heating and correct if necessary.
– Check internal probe resistance Ri in LT
Cable cross-section is too small for probe heating.
PH = ... W
Range: <100 
Cell temperature of the CO sensor is outside the monitoring window.
A fault occurred during O2 measured value calibration in air.
– Repeat O2 measured value calibration in air.
– Check and correct wiring.
– Probe is defective. Range: 700 bis 1.300 K
0045
0047
CO fault
CO fault
ot/
od
ot
Dynamics of the CO probe too low.
The correction range in the BT300 is too small or set to ’0’.
– Check and correct the correction range.
– Check and correct the electronic ratio curve.
The correction in BT300 is at its limit:
– Correction channel is at limit stop.
Check and correct the electronic ratio curve.
– With CO, the LT does not achieve the necessary probe
dynamics for triggering the CO edge.
Check the trigger threshold for the edge signal in the LT and
adjust it if necessary.
The probe is defective.
CO control has been switched off by the monitoring processor.
– Reset fault
– If the fault still exists:
Send error number and diagnostic code to the technical
support.
– Replace the device
0049
CO fault
CO control has been switched off by the O2 monitoring system.
The smallest permissible O2 value (<0.4 Vol.%) has been exceeded.
– Check whether the burner at which the fault occurred is
running COe free (no CO edge) at the firing rate value and with
less than 0.4 % O2.
If yes: Reduce P204. FE 4is required.
If no: Activate increasing air on firing rate change (P232).
AL2 is required.
0050
CO fault
ot
The effective CO probe voltage UCOe is incorrect.
Is the probe defective?
Value is outside the monitoring window.
Range: 0 ... 100 mV for 20 s
– Remove probe and recalibrate in air.
(see base documentation 1.1 Validity of these Instructions).
If this is not possible, the probe is defective (toxic).
247
8
CO/O2 Control
No.
Fault/
information
0052
CO fault
Comment
ot
The CO edge signal is not plausible.
The CO edge signal was present constantly for more than 60 s.
The controller cannot control out of the CO.
– Check/adjust the triggering threshold for the CO edge on the
LT.
– Check/adjust correction range (P703).
– Check/adjust electronic ratio curves.
– Check/replace probe for correct function.
– Check/replace LT
0053
CO fault
ot
The CO edge signal is not plausible.
Permanent CO controller switch-off.
CO edge signal persisted for more than 300 s.
– Reset fault by a manual acknowledgement of the fault
or with a burner restart
– Check/adjust correction range (P703).
– Check/adjust electronic ratio curves.
– Check/replace probe for correct function.
– Check/replace LT
0054
CO fault
ot
The CO edge has been exceeded for too long after ignition.
The CO edge has been exceeded permanently for more than 120 s. The
controller cannot control out of the CO.
– Check/adjust the triggering threshold for the CO edge on the
LT.
– Check/adjust correction range (P703).
– Check/adjust electronic ratio curves (ignition point).
– Check/replace probe for correct function.
– Check/replace LT
0055
CO fault
od
The CO edge has been exceeded for too long after ignition.
The CO edge has been exceeded permanently for more than 240 s.
The controller cannot control out of the CO.
The CO detection can be switched off after ignition by P234
(P 234  0)
– Check/adjust the triggering threshold for the CO edge on the
LT.
– Check/adjust correction range (P703).
– Check/adjust electronic ratio curves (ignition point).
– Check/replace probe for correct function.
– Check/replace LT
248
8
8.11.4
CO/O2 Control
O2 Trim Faults
NOTICE
Depending on the parameter settings, either O2 trim is deactivated or a fault switching of the
burner is triggered (P 142).
Factory setting: P 142 = 0 (CO/O2 control is inactive, burner is not switched off)
O2 fault example:
O2 measured value at pre-purge is too large
24%
Fig. 8-40 Display of an O2 monitoring fault
No.
CO faults information
0001
O2 fault
Fault description
od
O2 measured value during pre-purge is too low (P104).
O2 actual value at pre-purge too low.
Setpoint: > 16.0% O2
– Check the probe.
– Perform an offset calibration
0002
O2 fault
od
O2 measured value during pre-purge is too high (P103).
O2 actual value at pre-purge too high
Setpoint: <24.5 vol. % O2
Probe is too cold or the offset calibration is not performed.
– Check the probe’s internal resistor.
– Perform an offset calibration.
0003
O2 fault
od
O2 measured value after ignition is too high (P105).
The probe dynamics cannot be detected.
Setpoint: <14.0 vol. % O2 (factory setting)
The fault occurs after a timeout if no O2 value is transmitted by
LSB.
– Check if Lambda Transmitter is in adjustment mode.
If yes: Finish adjustment mode.
– No value is indicated:
Check LSB.
– Is the probe hot enough?
0004
O2 fault
ot
od
249
No probe dynamics - O2 trim is deactivated (P118)
No probe dynamics can be detected.
–Correction range in CMS too small or set to ’0’
0 = Default setting. The value must be set by the customer
for each specific system.
– Set the correction range.
– Is the servomotor at the upper range limit?
Reprogram the electronic ratio control.
8
CO/O2 Control
No.
CO faults information
0006
O2 fault
No.
0008
0009
Fault description
ot
od
O2 faults –
information
O2 fault
O2 measured value is outside the upper monitoring band.
The first upper monitoring band was exceeded for too long.
– Check the following and adjust if necessary:
– Correction range
– Electronic ratio control
– Setpoint curve
Fault description
od
ot
O2 measured value is outside the 1st lower monitoring band.
The first monitoring band was undershot for too long.
– Check the following and adjust if necessary:
– Correction range
– Electronic ratio control
– Setpoint curve
Half air shortage reached.
O2 fault
O2 value is too small
– Expanded control strategy: Air supply is increased.
The automatic, expanded control strategy increases the air
supply.
0011
O2 fault
Invalid O2 measured value on LSB.
Lambda Transmitter is in cold start, adjustment mode or calibration mode (do not measure).
– Wait until cold start has finished or leave adjustment mode
or calibration mode.
– Is LSB connected to Lambda Transmitter?
– Is Lambda Transmitter switched ON?
– Is LSB in fault condition (ERR LED is ON on LCM100)?
O2 setpoint curve is incorrect.
0012
O2 setpoint curve is empty or contains less than 3 points.
– Check and correct setpoint curve.
0013
O2 fault
ot
Air deficiency: O2 trim has been deactivated.
O2 actual value is permanently too small.
Due to insufficient air the control was deactivated.
A Replacement value for insufficient air is indicated as the correction.
0018
O2 fault
od
Internal fault: O2 setpoint curve is incorrect.
– Reset fault
– If the fault still exists:
Send error number and diagnostic code to the technical
support.
– Replace the device
0020
Internal fault: O2 trim fault
O2 fault
– Reset fault
– If the fault still exists:
Send error number and diagnostic code to the technical
support.
– Replace the device
250
8
CO/O2 Control
No.
0060
O2 faults –
information
O2 fault
Fault description
ot
The watchdog processor has detected a fault. O2 trim has
been switched off after a timeout.
– Reset fault
– If the fault still exists:
Send error number and diagnostic code to the technical
support.
– Replace the device
Content of the O2 setpoint curve is invalid.
0069
– Enter a valid O2 setpoint curve.
Unknown CO/O2 operating state
0073
– Reset fault
– If the fault still exists:
Send error number and diagnostic code to the technical
support.
– Replace the device
Prohibited O2 operating mode
0074
– Reset fault
– If the fault still exists:
Send error number and diagnostic code to the technical
support.
– Replace the device
0363
Burner deactivation after the O2 deactivation limit is undershot;
see chapter 8.11.5 Burner Fault Shut-down when Falling below
the Absolute O2 Minimum
O2 fault
ot = O2 trim temporarily deactivated – automatic reset if values are OK again
od = O2 trim permanently deactivated – manual reset required or automatic reset at
burner start
For more information, refer to chapter 8.7.2.3 Status Display in Case of O2 Trim.
8.11.5
Burner Fault Shut-down when Falling below the Absolute O2 Minimum
•
Can only be set via CMS Remote Software P 224 and P 225
– If the O2 value set in P 224 is continuously undershot beyond the time specified in P
225, CO regulation triggers a fault shut-down of the burner ’0363’.
NOTICE
The absolute O2 minimum fault shut-down of the burner was introduced on the request of the
customer. It is not part of the TÜV design test certificate and thus also switched off at the factory.
You will find information on the fault history in the following chapters:
•
Calling the CO/O2 Fault History - for LSB remote software
251
9
9
Faults
Faults
The fault status signal is also written to a separate document (publication no. DLT7201).
Restarts
For some faults automatic restarts can be configured in the CMS. In this context, it is important
to ensure that the set restarts comply with the normative and safety-related requirements of
the system.
No.
Description
001 - 019 Internal fault
D1
D2
0
0
0
0
Affected motor(s),
bit coded:
0
Extra
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
020 - 067 Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
068
IO: Motor overload shutdown has been triggered
Overload shutdown of a TPS motor output or the VS
relay output has been triggered.
R=0
Power ON Reset
AEC-TPS:
Bit0: TPS motor 1
Bit1: TPS motor 2
069 - 096 Internal fault
0
0
Potentiometer no.
0
R=0
Reset
Reference voltage
Potentiometer
current
R=0
Reset
Reference voltage
Potentiometer
current
R=0
Reset
Bit mask of potentiometer current:
Potentiometer 1
Bit 0 = 1
Bit 1 = 2
Potentiometer 2
Bit 2 = 1b
Bit 3 = 2b
Bit mask of
reference voltage
Potentiometer 1
Bit 0 = 1
Bit 1 = 2
Potentiometer 2
Bit 2 = 1b
Bit 3 = 2b
R=0
Power ON Reset
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
097
Short circuit in potentiometer 1
Plausibility test of potentiometer 1 during operation:
Short circuit between potentiometer reference and
ground.
098
Failure in potentiometer 1: Reference voltage or reference current
Plausibility test of potentiometer 1 during operation:
Fault in reference voltage or potentiometer current
099
Failure in potentiometer 2 reference current or reference voltage
Plausibility test of potentiometer 2 during operation:
Fault in reference voltage or potentiometer current
100
Invalid potentiometer configuration
The potentiometer plausibility check at Power ON
detected an invalid configuration.
Problem:
– Reference voltage is missing
– Current in potentiometer without reference voltage
– Variant with redundancy but only one
potentiometer is connected
252
9
Faults
No.
Description
101
D1
D2
Extra
Current relay
number
0
R=0
Power ON Reset
0
0
Input number
0 = no current
measurement
1 = configuration
of SafetyRAM is
not plausible
R=0
Reset
Input number
Reference voltage
R=0
Reset
Input number
Input current
R=0
Reset
Input number
Own signal
R=0
Reset
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
102
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
103
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
104
Main relay failure
Phase or Neutral is missing at the power supply of
the digital output
105 - 114 Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
115
Invalid configuration of the analogue input
Additional info 2:
0 = Configuration of the analogue input for current
measurement is not possible. The voltage at the current input is currently too high, which leads to the
destruction of components.
1 = SafetyRAM contains an invalid configuration and
returns an invalid value if the configuration is redundant.
116
Analogue input: The reference voltage exceeds its
tolerance
The reference voltage of a safe analogue input
exceeds its tolerance.
117
Analogue input: Input current is too high
The voltage at the analogue input is at such a high
level after a self-test that the configuration as a current input (activate shunt) leads to the destruction of
components.
118
Different measured values at the analogue input
between main processor and watchdog processor.
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
253
9
Faults
No.
Description
119
D1
D2
Extra
Input number
Own reference
R=0
Reset
Logic signal
HI Byte: ModuleID
LO Byte: Terminal
R=0
Power ON Reset
Logical signal
HI Byte: ModuleID
LO Byte: Terminal
R=0
Power ON Reset
0
0
Internal
information
0
Analogue input: Invalid measurement value of the
reference voltage
The measured values of the reference voltage outputs of the fail-safe analogue inputs do not match on
the main processor and watchdog processor.
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
120 - 183 Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
184
Too many signals at one terminal
Several logical signals are mapped to one physical
terminal.
– Check the I/O configuration.
185
An invalid logical signal is pending at the module.
The signal type does not match the configuration of
the module
– Check the I/O configuration.
186 - 200 Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
201
Parasitic light fault
– Check parasitic light detection (outside door)
– Check flame sensor
– Check positioning of the flame sensor
– Check flame sensor cable for short circuits/broken
wire
– Check grounding of sensor cable
– Check spark igniter and pilot burner
– Check parameter 800 (FE1)
– Check fuel supply
– Check wiring
254
R = 0, 0, 0, 0
9
Faults
No.
Description
202
Extra
Internal
information
Fuel train
R = 3, 3, 3, 3
Reset
Flame fault during operation
– Check curve settings
– Check flame sensor
– Check flame stability
– Check positioning of the flame sensor
– Check fuel valves
– Check fuel supply
– Check stability of the fuel pressure
– Check grounding of sensor cable
– Check flame sensor cable for short circuits/
broken wire
– Check wiring
– Check parameter 800
204
D2
Flame fault during ignition process
Flame is lost during ignition process.
The fault is caused by invalid ignition settings.
– Check ignition point
– Check spark igniter and pilot burner
– Check flame sensor
– Check flame stability
– Check positioning of the flame sensor
– Check fuel valves
– Check fuel supply
– Check stability of the fuel pressure
– Check grounding of sensor cable
– Check flame sensor cable for short circuits/
broken wire
– Check wiring
– Check parameter 302, 303 and 800
203
D1
Internal
information
R = 1, 1, 1, 1
Reset
Invalid configuration
Cold check cannot be deactivated.
205
R = 0, 0, 0, 0
Reset
Not permitted fuel changeover while burner is operating.
A fuel change was requested although a change via
OFF is not configured (P807, FE4).
208
0
0
R = 0, 0, 0, 0
Reset
0
0
R=0
Reset
0
0
R = 0, 0, 0, 0
Reset
Internal
information
Fuel train
R = 0, 0, 0, 0
Reset
Internal
information
Fuel train
R = 1, 1, 1, 1
Reset
Remote shut-down was triggered.
The Remote shut-down can be triggered by:
Press the BACK button for too long.
Press the ENTER and BACK button simultaneously.
Disconnect the CMS Remote Software in SETTING
mode (after a waiting time of 45 s)
Clicking the icon
in the CMS Remote Software
– Switch off the burner and restart.
209
Program monitoring times
The Program monitoring time exceeded (P304, FE0)
(FAT).
210
211
Invalid CPI signal
Ignition position acknowledgement is dropping
The signal ’Ignition position acknowledgement’ is
dropping
255
9
Faults
No.
Description
212
R = 0, 0, 0, 0
Reset
Internal
information
Fuel train
R = 0, 3, 0, 0
Reset
Internal
information
Fuel train
R = 0, 0, 0, 0
Reset
Internal
Information
0
R = 0, 0, 0, 0
Internal
information
0
R = 0, 0, 0, 0
Internal
information
0
R = 0, 0, 0, 0
Internal
information
0
R = 0, 0, 0, 0
0
0
R = 3, 3, 3, 3
Reset
Invalid signals from the spark igniter
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
225
Fuel train
Invalid readback values of the fuel valve 2.
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
221
Internal
information
Invalid signals from the fuel valve 1
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
220
R = 0, 0, 0, 0
Reset
Invalid signals from the pilot valve.
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
219
Fuel train
Air pressure is missing
– Check air pressure switch
– Check fan
218
Internal
information
Gas pressure too low
– Check gas pressure
– Check gas pressure switch
– Is fuel available?
216
Extra
Invalid signal of the safety interlock chain fuel
Safety interlock chain is interrupted
– Check contacts and wiring of safety interlock chain
215
D2
Invalid signal of the safety interlock chain system
Safety interlock chain is interrupted
– Check contacts and wiring of safety interlock chain
213
D1
The flame signal is missing during the 1st safety time.
– Check ignition point
– Check spark igniter and pilot burner
– Check flame sensor
– Check flame stability
– Check positioning of the flame sensor
– Check fuel valves
– Check fuel supply
– Check stability of the fuel pressure
– Check grounding of sensor cable
– Check flame sensor cable for short circuits/broken
wire
– Check wiring
– Check parameter 302, 303 and 800
256
9
Faults
No.
Description
226
Extra
Internal
information
0
R = 3, 3, 3, 3
Reset
Internal
information
0
R = 3, 3, 3, 3
Internal
information
0
R = 3, 3, 3, 3
Reset
The (pilot) flame signal drops during the 2nd safety
time.
– Check ignition point
– Check spark igniter and pilot burner
– Check flame sensor
– Check flame stability
– Check positioning of the flame sensor
– Check fuel valves
– Check fuel supply
– Check stability of the fuel pressure
– Check grounding of sensor cable
– Check flame sensor cable for short circuits/broken
wire
– Check wiring
– Check parameter 302, 303 and 800
229
D2
The flame signal drops during the stabilisation time.
– Check ignition point
– Check spark igniter and pilot burner
– Check flame sensor
– Check flame stability
– Check positioning of the flame sensor
– Check fuel valves
– Check fuel supply
– Check stability of the fuel pressure
– Check grounding of sensor cable
– Check flame sensor cable for short circuits/broken
wire
– Check wiring
– Check parameter 302, 303 and 800
228
D1
The flame signal is missing during the safety time.
– Check ignition point
– Check spark igniter and pilot burner
– Check flame sensor
– Check flame stability
– Check positioning of the flame sensor
– Check fuel valves
– Check fuel supply
– Check stability of the fuel pressure
– Check grounding of sensor cable
– Check flame sensor cable for short circuits/broken
wire
– Check wiring
– Check parameter 302, 303 and 800
257
9
Faults
No.
Description
230
D1
D2
Extra
Internal
information
Fuel train
R = 1, 1, 1, 1
Reset
Internal
information
0
R = 1, 1, 1, 1
Reset
Internal information
Fuel train
R = 0, 0, 0, 0
Reset
0
0
R = 0, 0, 0, 0
Reset
0
0
R=0
Reset
The flame signal is missing after the safety time.
If flame OFF appears within 3 s after ignition, fault 10
is indicated; after that, fault 4 is indicated subsequently.
– Check curve settings
– Check flame sensor
– Check flame stability
– Check positioning of the flame sensor
– Check fuel valves
– Check fuel supply
– Check stability of the fuel pressure
– Check grounding of sensor cable
– Check flame sensor cable for short circuits/broken
wire
– Check wiring
– Check parameter 801
231
Loss of the permanent pilot flame during operation.
– Check curve settings
– Check flame sensor
– Check flame stability
– Check positioning of the flame sensor
– Check fuel valves
– Check fuel supply
– Check stability of the fuel pressure
– Check grounding of sensor cable
– Check flame sensor cable for short circuits/broken
wire
– Check wiring
– Check parameter 801
232
Oil pressure is too low.
– Is fuel available?
– Check oil filter
– Check oil pressure switch
– Check oil pressure
– Check oil controller
233
Carry out burner maintenance
A missing burner maintenance causes a fault shutdown.
– A reset of the maintenance counter occurs due
to a change of parameter P10 or P11.
FE2 is required.
234
The signal BURNER ON/OFF from the operating unit
drops without permission.
– A restart is required
235
The remote fault reset was performed in a too short
interval.
258
9
Faults
According to EN 14459, remote fault release is permitted only 4 times within 15 minutes.
The fault release is monitored by CMS Remote Software, LAMTEC SYSTEM BUS and fieldbus.
Exceeding the number of fault releases causes the
fault shot-down and further remote fault releases are
ignored.
After a waiting period, another remote fault release is
possible.
The fault shut-down also occurs, if a fault release
was send, although none is existing!
A reset by terminal is always possible.
Reset fault:
– Wait for 15 minutes until you try to reset the
fault again
– Disconnect the power supply voltage of the CMS
for a moment, reconnect it and reset the fault
subsequently.
259
0
0
R=0
Reset
9
Faults
No.
Description
236
D1
D2
Extra
Internal
information
0
R = 0, 0, 0, 0
Reset
0
0
R=0
Reset
Internal
information
0
R = 0, 0, 0, 0
Reset
The main flame is detected during ignition.
If parameters 302 is set to value 3 or 4, only the ignition flame may be present during ignition (up to the
beginning of the 2nd safety time). If the main flame is
detected during this period, the following fault will be
indicate:
– Check main fuel valves
– Check position of main flame sensor
– Check main flame sensor
The main flame sensor must detect only the main
flame and not the pilot flame.
– Check grounding of sensor cable
– Check flame sensor cable for short circuits/
broken wire
– Check wiring
237
Secure writing of the parameter cannot be finished.
The device is blocked.
– Rewrite the parameter.
– Write the backup dataset into the CMS using
UI400 or CMS Remote Software.
240
Loss of flame in STANDBY
Pilot flame OFF during operation mode STANDBY.
– Check spark igniter and pilot burner
– Check flame sensor
– Check flame stability
– Check positioning of the flame sensor
– Check fuel valves
– Check fuel supply
– Check stability of the fuel pressure
– Check grounding of sensor cable
– Check flame sensor cable for short circuits/broken
wire
– Check wiring
– Check parameters 302, 303 and 801
241
Internal fault
R=0
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
242
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
244
Internal
information
0
R=0
Power ON Reset
2
Code position
R = 0, 0, 0, 0
Reset
Time-out failure in COLD CHECK
The time-out for a retrigger in the operating mode
COLD CHECK has expired.
260
9
Faults
No.
Description
245
Internal
information
0
R=0
Power ON Reset
Internal
information
0
R=0
Power ON Reset
Internal
Information
0
R = 0, 0, 0, 0
Reset
Internal
Information
Fuel train
R = 0, 0, 0, 0
Reset
Internal
information
Fuel train
R = 0, 0, 0, 0
Reset
Pilot air pressure is missing.
No air pressure for the pilot burner.
– Check air pressure switch
– Check fan
248
Extra
No fault shut-down of the FAT although a fault is
pending.
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
247
D2
Fuel valves are OPEN in spite of malfunction.
The fuel valves are open although a fault is pending.
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
246
D1
Valve leakage test: Gas pressure is still present.
Main valve 1 is leaking
– Check gas pressure switch for function
– Is main valve 2 opened during the test?
No: check the valve, replace if necessary
check wiring
– Check output pressure at the main valves during
the venting of the test line.
If the outlet pressure is higher than the adjusted gas
pressure at the pressure switch, take the following
measures:
– Re-adjust the pressure switch and recalculate the
detected leakage rate (observe local standards
and guidelines).
– Reduce the aperture of the air damper for venting
– If the fault still exist: change main valve 1
249
Valve leakage check: Gas pressure is still present.
Main valve 2 is leaking
– Check gas pressure switch for function
– Is main valve 1 opened during the test?
No: check the valve, replace if necessary
check wiring
– Check output pressure at the main valves
during the venting of the test line.
If the outlet pressure is higher than the
adjusted gas pressure at the pressure switch,
take the following measures:
– Re-adjust the pressure switch and recalculate
the detected leakage rate (observe local
standards and guidelines).
– Reduce the aperture of the air damper for
venting
– If the fault still exist: change main valve 2
261
9
Faults
No.
Description
250
0
WA = 0
Power ON Reset
Internal
information
Fuel train
R = 0, 0, 0, 0
Reset
Valve leakage test
control line
Code position
R = 0, 0, 0, 0
Internal
Information
0
R = 0, 0, 0, 0
Internal
information
Fuel train
R = 0, 0, 0, 0
Reset
Internal
information
Fuel train
R=0
Reset
Internal
information
Fuel train
R=0
Reset
Invalid feedback of the atomiser valve
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
254
Internal
information
Valve leakage test: Unknown control line
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
253
Extra
Invalid feedback of the purge valve
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
252
D2
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
251
D1
Fuel pressure is too high
The maximum fuel pressure has been exceeded
When burning fuel is oil:
– Check availability of the fuel
– Check oil filter
– Check oil pressure switch
– Check oil pressure
When burning fuel is gas;
– Check availability of the fuel
– Check oil controller when using fuel gas:
– Check gas pressure
– Check gas pressure switch
255
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
256
Invalid operating mode
Fault in an internal self-test.
MP and WD recognise the digital input signals at
slightly different times. This may cause an incorrect
change of operating modes.
– Check signal sequence.
– Reset fault and if necessary switch mains OFF and
ON again.
262
9
Faults
No.
Description
257
D1
D2
Extra
0
0
R=0
Reset
Curve set change has failed
A curve set change was not completed until the timeout expired.
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
258
Internal fault
R=0
Power ON Reset
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
259
Internal fault.
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
260 - 278 Internal fault
0
Fuel train
0
0
R=0
Power ON Reset
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
281
285
Invalid curve data
Channel number
R=0
Reset
Fuel train
Internal
information
R = 1, 1, 1, 1
Reset
Channel number
(starting at 0)
Setpoint feedback
R = 0, 0, 0, 0
Reset
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
286
Ignition position was left in IGNITION mode.
When using continuous output:
– Check the position-and speed of the channel which
is indicated in D1.
– If position and speed of the channel is OK:
Check EMC influences by ignition transformer. .
– If the speed and position are incorrect:
Check the settings of the frequency inverter
(analogue output)
– Check the smoothness of the control dampers
287
Band failure: Setpoint is not in the expected range.
The system detects a band failure. The setpoint
value has been exceeded.
263
9
Faults
No.
Description
288
– Check air damper and gas damper for
jamming
– Replace the affected actuator
Extra
0 = Actuator’s
dynamics
1 = Correction
channel’s
dynamics
Channel number
for actuator or
correction
(starting at 0)
WA = 9
Reset
Curve set
0
R=0
Invalid curve ID of the actual curve set
Reason:
– Wrong curve set loaded
– EEPROM defect
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to
the technical support.
– Replace the device
290
D2
Required dynamics for at least one actuator is missing
The actual position of the actuator has not changed
for more than 24 h.
289
D1
Power ON
Reset
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
291
Invalid configuration
Incorrect parameter setting
300 - 313 Internal fault
Code position
Value
0
0
measured time in
steps of 20 ms
0
0
0
Internal
information
0
0
0
R = 0, 0, 0, 0
Reset
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
314
Duration of ambient light monitoring was not met [s]
Duration (5 s) of the ambient light monitoring was not
met. The fault may occur during an internal self-test
R=0
Power ON Reset
.– Reset fault and switch mains OFF and ON if
necessary
– If the fault still exists replace the device.
315 - 347 Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
348
Ignition air is missing
349 - 354 Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
264
R=0
Power ON Reset
9
Faults
No.
Description
355
Fuel train
R=0
Reset
Internal
information
0
R=0
Power ON Reset
Internal
information
0
R=0
Power ON Reset
Setpoint minimum
lower 12 bits: setpoint maximum
Channel number
in the bits above
bit 12
R = 0, 0, 0, 0
Reset
0: Actuator
dynamics
1: Correction
channel dynamics
Number of actuator or correction
channel (starting
with 0)
R=0
Reset
1: Actual curve
set
3: Actual value,
channel no. in
P2
4: Setpoint value,
Channel no. in
P2
5: Firing rate
value
P 1 = 3 or 4,
Channel no.
(starting at 0)
P 1 = 5,
special fault code
R=0
Power ON Reset
0
0
R=0
Power ON Reset
Band failure: Setpoint is outside the expected range
The watchdog processor detects a band failure.
Setpoint or actual value of an actuator is not in the
expected range.
381
Internal
information
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
380
Extra
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
357
D2
Ignition in mixed operation
FAT tries to ignite in a mixing curve
356
D1
Actuator dynamics is missing
The ÜP has not detected the required dynamics for
at least one actuator.
Problem: The actual position of the actuator has not
changed in the last 24 hours.
– Check air damper and gas damper for jamming.
– In case of stiffness, clean the damper and
make it smooth running again.
– Check the function of the actuator without
damper and replace if necessary.
– Reset fault and switch mains voltage OFF
and ON again.
– If the error still exists, replace the device.
382
Monitoring data from the bus are missing
The watchdog processor requires certain data for
monitoring. These are read at the bus. Currently
required data are missing
Reason:
– Invalid channel configuration
– A non-existing channel is activated
– An inactive channel is marked in the channel
enable mask
383
Invalid curve set selection
– Ensure that there is no fuel change during curve
set programming.
– Reset fault
265
9
Faults
No.
Description
384
Required action
0
R=0
Power ON Reset
Firing rate at
which it is to be
programmed
Index at which it is
to be programmed
R=0
Power ON Reset
0
0
R=0
Power ON Reset
0
0
R = 0, 0, 0, 0
Reset
Inconsistent values in SETTING mode
– Reset fault
– If the fault still exists:
Transfer fault number and diagnosis code
to the technical support.
– Replace the device.
387
Extra
Inconsistent values between main processor and
watchdog processor
Fault in an internal self-test.The digital input signals
for main and watchdog processor are compared and
are not the same.
– Reset fault and switch mains OFF and ON again if
necessary
– Check all fuses in the device. A bouncing signal
can cause different states to be detected between
the main processor and the watchdog processor.
– The main processor and the watchdog processor
detect the digital input signals at slightly different
times. A signal change only occurs so briefly that
the main processor detects it, but the watchdog
processor does not.
– Check signal sequence
– Reset error
– If the fault still exists:
Transfer fault number and diagnostic code to the
technical support
386
D2
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
385
D1
Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
388 - 392 Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
400
Permanent air deficiency
The air deficiency cannot be corrected by countermeasures.
– Reset fault.
– If the fault still exists:
Transfer fault number and diagnosis code to the
technical support.
– Replace device
266
9
Faults
No.
Description
401
D1
D2
Extra
O2 actual value in
0,1 % O2
23;1
R = 0, 0, 0, 0
Reset
Probe voltage
(mV with an offset of +1 V)
0
R=0
Reset
0
0
R=0
Reset
Probe voltage
(in mV with an offset of +1 V)
0
R=0
Reset
CO actual value in
ppm
0
R=0
Reset
O2 actual value
in 0,1 % O2
0
R=0
Reset
Fallen below the smallest, permissible O2 value
The O2 trim does not work on this burner.
– Check the electronic ratio control curve
402 - 425 Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
426
Exceeding the maximum, valid CO probe voltage
Probe voltage (in mV with an offset +1 V)
427
Exceeding the maximum, valid CO actual value
428 - 457 Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
458
Exceeding the parameter set UCO-MAX-value
The main processor has not detected that the maximum permissible CO probe voltage has been
exceeded.
459
Exceeding the parameter set COe-MAX-value
The main processor has not detected that the maximum permissible CO actual value has been
exceeded
461
Exceeding the parameter set O2-MIN-value
The main processor has not detected that the minimum permissible O2 value has been exceeded
470 - 820 Internal fault
– Reset fault
– If the fault still exists:
Send fault number and diagnostic code to the
technical support.
– Replace the device
267
10
Maintenance
10
Maintenance
10.1
Firmware Update
NOTICE
A firmware update on the CMS concerns the respective firmware numbers of the entire system. All CMS components used must be observed. Only versions that are compatible within
the system may be put into operation.
NOTICE
Only LAMTEC is authorised to configure the appropriate software package for an update of
the components.
The safety functions are no longer guaranteed if software versions that differ or do not correspond together are used.
During a firmware update, parameters can be omitted or added. This leads to a change in the
CRC checksums of all release levels. This change is documented in the software.
Establish connection between PC and CMS
1. Connect the PC to CMS
NOTICE
The IP addresses must not be equal.
The IP addresses must be in the same subnet.
Factory setting: 192.168.001.111 – 255.255.255.0
2. Open the CMS Remote Software.
268
10
Maintenance
The IP address of
the CMS is independent of the computer's IP address.
3. Open the connecting data.
4. Set the IP address.
The IP addresses must be equal.
5. Establish connection.
269
10
Maintenance
Connection between PC and CMS is
established.
6. Close the window.
Indication of
the connected CMS
270
10
Maintenance
How to update the firmware in the CMS (AL2)
1. Open the menu ’Firmware update’
2. Prepare firmware update.
271
10
Maintenance
3. Flash firmware.
The firmware update is successfully completed.
Update the remaining modules in the system in the same way after the successful update.
If the CMS does not reach the operating mode OFF after a successful update, the system
must be restarted by a cold start.
NOTICE
After the firmware update of the CP, wait at least 1 minute until all of the CP software is written
to the flash memory.
Otherwise, the program of the communication processor may be damaged.
With a bootloader from version 2.1.0.2 on, the application of the MCC-CP restarts - LEDs for
PLC and LSB start flashing.
272
10
Maintenance
Activating the Debug Data
1. Start CMS Remote Software.
2. Set device online.
3. Show debug data.
273
10
Maintenance
Updating the Soft-SPS
1. Stop Middleware.
Not confirming the ’Stop middleware’ dialogue box with OK within a certain time window,
aborts the process. The process can be repeated immediately.
2. Run Soft-SPS Update.
274
10
Maintenance
3. Restart CMS to complete the update.
275
10
10.2
Maintenance
Maintenance Tasks
In normal operation, no maintenance tasks or configurations are necessary on the CMS. This
will only be the case if the CMS or its components fail.
Repeating System Tests
System tests are mandatory if:
•
Parameters have been changed.
This applies to parameters with requirements that have to be checked during system tests.
•
After completing a software update.
It is necessary to check whether the changes have an effect on the safety of the plant.
•
Components connected to the CMS have been replaced
In this case, only the related system tests need to be carried out again.
The table for approving the system see chapter 12.2 Acceptance and Inspection
276
11
Decommissioning
11
Decommissioning
11.1
Important Notes on Shutdown/Return to Service
NOTICE
 These instructions are required in particular for systems according to EN 61508
The plant owner must observe/execute the following during decommissioning:
•
Influence analysis with the evaluation of the influences on each connected system.
•
Hazard and risk analysis for the connected systems.
•
The routine for decommissioning must be documented. To do this, a template must be
created and made available for recording the individual steps during decommissioning.
•
Ensure that decommissioning/disposal may only be initiated by making an authorized request using the procedures for managing functional safety.
•
Permission to carry out the required decommissioning/disposal depends on the results of
the influence analysis.
•
Before decommissioning/disposal, a plan must be created containing procedures relating
to the following points:
• Decommissioning of safety-related E/E/PE systems
• Dismounting of safety-related E/E/PE systems
•
Return to the phase of the plant's safety life cycle to the safety-related E/E/PE systems
that were influenced by the decommissioning.
At least the following specifications of the PE system manufacturer (LAMTEC) apply to the decommissioner:
11.2
•
For decommissioning, the system must be switched to the safe state and the CMS and its
components must be disconnected from the power supply on all poles.
•
Observe the instructions of the burner or boiler manufacturer for disassembly.
•
The device itself must either be sent to the electronics disposal or returned to the burner
or boiler manufacturer.
•
LAMTEC GmbH must be informed about the decommissioning. The serial number of the
decommissioned device must also be transmitted.
Disposal Notes
The device contains electrical and electronic components and must not be disposed of as domestic waste. The local and currently valid legislation absolutely must be observed.
277
12
Appendix
12
Appendix
12.1
CP Default Configuration
For the general functionality of the communication processor (CP), a standard configuration
is required, which becomes effective in case of invalid CP parameter queries or invalid CP parameter configurations. This is listed below:
Parameter
Default Value
Remarks
SPS name
PLC <host name>
Everything is valid, up to 32 characters
IP address
192.168.11.200
Invalid: X.X.X.0 or X.X.X.255
Subnet mask
255.255.255.0
Invalid: 0.0.0.0
Gateway
192.168.11.4
Everything is valid
Primary DNS
192.168.11.1
Everything is valid
Secondary DNS
192.168.11.4
Everything is valid
Host name
cms00
Everything is valid, ASCII,
up to 15 characters
DHCP
Enabled
Valid: 0, 1
If DHCP is enabled but no DHCP server is
available, ’AutoIP’ is activated after a timeout
of 60 s. Random IP in the range of :
169.254.1.0 - 169.254.254.255
Subnet mask: 255.255.0.0
SNTP
217.79.179.106
Everything is valid, without SNTP = 0.0.0.0
SNTP interval
720 Min.
-32768 ... 32767
LSB termination
Enabled
0,1
LSB family
1
1, 2, 3, 4
Time zone
UTC (0)
-32768 ... 32767
278
12
12.2
Appendix
Acceptance and Inspection
NOTICE
The following table on system acceptance is only an example and does not imply completeness. Local regulations or special configurations may require further testing or may not require
listed testing.
Table on system acceptance
The following table must be completed when completing the commissioning process.
Tools,
equipment
incl. calibration data
Configuration of test object
Hardware version
Software version
Test description
Date/Tester
Extra low voltage conductors are correctly laid so that they are not positioned in
one channel together with the supply and outgoing conductors from the power
electronic board.
For conductor lengths <10m, shielded cable is used.
When using an insulation electrode, ensure the reinforced insulation of the connecting pipework in accordance with DIN EN 601730-2-5 section 20 (protection
against contact).
All electrical plug-in connections have been checked.
The current software version number and all CRCs for the user levels has been
documented.
The plant has at least IP40 contact protection indoors and IP54 outdoors.
For access level 1, a password not equal to 00000 has been entered.
All security relevant parameters for each function to be monitored have been set in
accordance with the standards that apply to the plant.
The actuators conform to the approved types.*
In SETTING mode, the actuators can be traversed manually across the entire setting range.
The switch-off tests of the LAMTEC FFS07/FFS08 flame sensor have been correctly
performed.
Information on the switch-off tests e.g. for flame scanners from other manufacturers, see manufacturer's documentation.
The setting values for the actuators to control the fuel quantity, air quantity, recirculation gas quantity and all other, safety-relevant actuating combustion variables
are stored in sufficient numbers across the performance range of the burner.
279
Result
/
12
Appendix
Test description
Date/Tester
Result
/
Measurement of the combustion process characteristics:
This must be documented by measuring the characteristic values for an operation
of the furnace at the shut off limits of the ratio control, as well as the set limits of
the correction circuits (e.g. an O2 trim) see chapter 2 Safety.
The combustion is safe at maximum correctional intervention.
The tolerance time for a deviation between the setpoint and actual value of an
actuator greater than B-Band has been set to 3 s by default for the electronic ratio
control (see prEN12067:2012).
Each actuator is then checked that it does not cause any dangerous process condition at its max. speed within 3 s.
Safe burner operation is checked taking into account of the system tolerances
(notes in prEN 12067-2-2012 Annex CC).
Combustion values (exhaust gas measurement) have been checked and corrected where necessary
* If any servo motors not mentioned in the test report are used, an assessment of the input of the alternative servo motors shall
be available.
12.3
Circuit Diagrams
NOTICE
in progress
12.4
Accessories
12.4.1
Power Supplies
Power Supply
Description
Type
PSU2415 Power supply 100 ... 240 VAC/24 VDC, 15 W
668R0105
PSU2430 Power supply 100 ... 240 VAC/24 VDC, 30 W
668R0030
PSU2460 Power supply 100 ... 240 VAC/24 VDC, 60 W
668R0060
PSU24150 Power supply 100...240VAC/24VDC, 150 W
668R0150
280
12
12.5
Appendix
EU Declaration of Conformity
281
12
Appendix
282
The information in this publication is subject to technical changes.
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
Printed in Germany | Copyright  2019
info@lamtec.de
www.lamtec.de
Publication no. DLT7200-19-aDE-002