LC2250 Level Controller Installation and Maintenance Guide

Installation and Maintenance Guide

1. Safety Information
2. Product and Delivery Information
3. System Overview
4. Mechanical Installation
5. Electrical Installation
6. Commissioning

• Quick Setup
• Full Setup

7. Communication
8. Maintenance
9. Fault Diagnosis
10. Technical Information

• Default Settings

11. Appendix

• Data Registers

12. Menu Diagram

1. Safety Information

Compliance with the operating instructions and correct installation, commissioning, use, and maintenance by professionally qualified personnel is the sole guarantee of safe operation of this product (see Section 1.11). Installation must comply with general installation and safety guidelines for piping and equipment, as well as correct use of tools and safety equipment.

In the United Kingdom, the IEE Wiring Regulations (BS 7671) must be followed; in other regions, the corresponding regulations must be followed.

All wiring materials and procedures must comply with the corresponding EN and IEC standards.

Warning

This product is designed and manufactured to withstand external forces during normal use. If this product is not used as a boiler controller or the installation process does not follow the instructions in this manual, during product modification or repair it may:

• Cause personal injury or death;

• Cause product/property damage;

• Invalidate the CE mark;

These guidelines should always be kept in a safe place near the boiler controller installation location.

Warning

This product complies with the Electromagnetic Compatibility Directive 2004/108/EC and meets all its requirements.

The product is suitable for Class A environments (e.g., industrial). Comprehensive and detailed EMC testing has been performed, with UK reference number UK Supply BHLC2250 2008.

Under the following conditions, this product may be exposed to interference exceeding heavy industry immunity limits:

• The product or its connecting cables are near wireless transmitters;
• The main power supply has interference. If the power supply may have interference, a line protector should be installed. The protector functions include filtering, rectification, surge, and peak protection.
• Using mobile radios and mobile phones within approximately 1 meter of the product or its connecting cables may cause interference. However, the actual safe distance varies depending on the site environment.

The product complies with the Low Voltage Directive (2006/95/EC) and meets the following standards:

• EN61010-1:2001 Safety requirements for electrical equipment for measurement, control, and laboratory use;

The product, when type-tested as a level controller, complies with the following standards:

• VdTÜV Water Control Equipment 100 (07: 2006).

Electrostatic Discharge (ESD) Prevention

Care must be taken to prevent electrostatic discharge to avoid product damage.

For Steam Boiler Level Control and Level Limiting

The product must be selected, installed, operated, and tested according to the following:

• Local or national standards and regulations

• Guidance manuals (UK Health and Safety Executive guidance PM5)

• Requirements of the approving authority

• Boiler inspection authority

• Boiler manufacturer’s instructions

Steam boilers must be installed with two independent low water level limiting/alarm systems. Level sensors must be installed in separate protection tubes/chambers, with adequate space between the sensor end and the ground terminal.

Each sensor must be connected to an independent controller. During a low alarm, the alarm relay must cut off the boiler heating system.

The high water level alarm must be part of the water level control, or a separate system. If safety requirements are considered, a separate high water level alarm system must be installed.

In this case, during a high water level alarm, the relay must simultaneously cut off the boiler feedwater and heating system. All boiler water level limiting/alarms require periodic functional testing.

Level sensing probes and controllers are only part of the safety system. A complete system also requires other circuits (wiring, relays, alarm bells/lights).

Continuous safe and correct operation of water level control and limiting systems requires the use of appropriate water treatment. Please consult an authoritative water treatment company.

Symbols

The device uses double or reinforced insulation protection;

Functional ground terminal, ensures normal product operation; Not used to guarantee electrical safety;

Safety ground

Safety ground

Caution, risk of electric shock;

Caution, danger, please refer to relevant documentation;

Opto-isolated current source signal;

Caution, the circuit board is susceptible to electrostatic discharge. Do not touch the circuit board without anti-static equipment.

AC, alternating current

1.1 Preparation for Use

i) Check that the product is suitable for the fluid being controlled. ii) Check the suitability of materials, and the maximum and minimum values of pressure and temperature; if the maximum operating range of the product is lower than that of the system where it is to be installed, or if product failure may lead to dangerous over-temperature or over-pressure conditions, safety devices must be installed in the system to protect against such exceedances. iii) Determine the correct product installation location and fluid flow direction; iv) Spirax Sarco products cannot withstand additional stress; the installer should consider system stress and take appropriate preventive measures to reduce stress. v) Before installing the product in steam or high-temperature media, remove all connection port protection caps and the nameplate protective film.

1.2 Access

Before performing any operation, ensure safe access; if necessary, a safe working platform (with appropriate protection) is required. If necessary, arrange suitable lifting equipment.

1.3 Lighting

Ensure adequate lighting, especially where detailed or complex operations are performed.

1.4 Hazardous Liquids or Gases in Piping

Consider in advance the fluids that may exist or already exist in the piping; factors to consider include: flammability, health hazards, and temperature limits.

1.5 Hazardous Environment Around the Product

Consider: explosive environments, oxygen deficiency (e.g., in vessels or pits), hazardous gases, extreme temperatures, hot surfaces, fire hazards (during welding), excessive noise, and moving mechanical equipment.

1.6 System

Consider the impact of the planned operation on the entire system. Will the planned operation (e.g., closing shut-off valves, cutting power) cause danger to other parts of the system or any personnel?

Danger may arise from the shutdown of discharge or protection devices, or the cancellation of controls or alarms. Shut-off valves should be opened and closed slowly to avoid system oscillation.

1.7 Pressure Systems

Ensure that all pressure has been isolated and safely vented to atmospheric pressure. Consider double isolation and locking and tagging of closed valves. Even when the pressure gauge reads zero, the system cannot be considered pressure-free.

1.8 Temperature

After isolation, allow time for cooling to ambient temperature to avoid burns.

1.9 Tools and Spare Parts

Before starting use, ensure that suitable tools and consumable spare parts are available. Use only original spare parts provided by Spirax Sarco.

1.10 Protective Clothing

Consider whether you or nearby personnel need to wear protective clothing to prevent hazards such as: chemicals, high/low temperatures, radiation, noise, falling objects, and eye and face injuries.

1.11 Work Permit

All operations must be performed or supervised by suitable personnel qualified for the work. Installation and maintenance personnel must be trained on how to correctly operate this product according to the installation and maintenance guide.

Comply with formal “work permit” systems; operations must be strictly performed as described above. If no such system exists, it is recommended that the responsible person understand the operation being performed and, if necessary, arrange an assistant responsible for safety.

If necessary, post “caution” notices.

1.12 Manual Handling

Manual handling of large or heavy objects can cause danger or personal injury. Directly lifting, pulling, pushing, raising, or supporting loads by human force can cause personal injury, especially to the back. It is recommended that customers conduct a risk assessment considering the task, personnel, workload, and working environment, and adopt appropriate handling methods according to the working environment.

1.13 Residual Hazards

Under normal conditions, the outer surface of the product may be hot.

Many products do not have self-draining functions. Extreme care should be taken when disassembling products.

1.14 Freezing

When the product is exposed to sub-zero environments, valves without self-draining functions are at risk of freezing and must be protected.

1.15 Disposal

When disposing of this product, appropriate preventive measures should be taken according to local regulations.

Unless otherwise noted in the installation and maintenance guide, this product is recyclable and, if properly disposed of, has no harmful effect on the ecological environment.

1.16 Returns

Customers and stockists are reminded that, in accordance with EC Health, Safety and Environmental legislation, when returning products to Spirax Sarco, customers must provide information on hazards and the precautions taken when handling contaminated residues or mechanical damage that may pose risks to health, safety, or the environment. Safety data sheets for any hazardous or potentially hazardous substances must be provided in writing.

2. Product and Delivery Information

2.1 Introduction

The LC2250 is used for level control of conductive fluids. It has one alarm channel for high/low alarms.

Warning: The minimum conductivity when using LP20/PA20 is 5 μS/cm or 5 ppm at 25 °C.

The product can be panel, rail, or baseplate mounted, with 99-264 Vac power supply.

2.2 Front Panel

The front panel has a 3-digit LCD display and a 5-button keypad:

Figure 1, Front panel and definitions LC2250 LCD display % Manual valve close (commissioning mode only) Manual valve open (commissioning mode only) Test alarm spirax sarco Scroll menu, increase value OK When parameter or number flashes, enter parameter. Press and hold for 5 seconds to enter commissioning mode.

2.3 Using the Buttons

Buttons:

• Scroll main menu

• Increase value in menu

OK button:

• Enter or move right to next parameter, value, or menu

• Enter commissioning mode (press and hold for 5 seconds)

2.4 Manual Test Buttons (Priority)

Note: These buttons do not function when editing parameters in commissioning mode. When these buttons are released, return to the end of the commissioning menu.

AL alarm button - In run and commissioning modes, tests the alarm relay and external circuit. (+) Valve open or pump start button - Used to open the valve (proportional control) or start the pump (pump control).

• Valve close button - Used to close the valve (proportional control).

2.5 Run Mode

Run mode is the normal operating mode, displaying what the system is doing.

Displays whether:

• An alarm condition exists

• Pump operation (on-off control)

• Valve is operating (proportional control)

Block movement shows whether the water level is rising or falling during pump operation. A stationary block indicates that water inflow/steam output has reached balance.

The AL button can test the alarm and external circuit.

Alarm

Alarm (optional Hi or Lo)

Level exceeds alarm value

Note: When an alarm exists, pump or valve status is not displayed

On-Off Control

Water level rising - pump in

Pump-in mode, pump on - vessel filling

Display animation: PP- → PP= → PP= (moving blocks show level rising)

Water level falling - pump out

Pump-out mode, pump on - vessel draining

Display animation: PP= → PP= → PP- (moving blocks show level falling)

Pump off

Water level between pump on and off

Block does not move, pump not operating (off)

Proportional Control

Valve open

Display animation: Pr- → Pr= → Pr= (moving blocks show valve opening; water enters boiler/tank and level rises)

Valve close

Display animation: Pr= → Pr= → Pr- (moving blocks show valve closing; water inflow reduces and level falls)

Valve stationary - water inflow/steam output has reached balance.

Display: Pr- (blocks not moving)

2.6 Parameter View Mode

In run mode, press the ⚠ button to view the current level, displayed as a percentage of the gauge glass. Parameters can be retained for 2 minutes for recording. Press the ⚠ button to view parameters. Each parameter can be retained for 2 minutes until the button is pressed again.

2.7 Alarm/Error Display Information

If an error occurs, the error menu ‘ErX’ is displayed at the end of the parameter screen. Press and hold the OK button for 3 seconds to clear the error message and re-energize the alarm relay. If the cause of the error is not corrected, the same error will reappear. For latched errors and alarms, only the message disappears; the alarm relay remains de-energized until the correct password is entered in commissioning mode. If more than one error or fault exists, the next will be displayed after the previous one is cleared. See Section 9 - Fault Diagnosis.

2.8 Equipment Delivery, Transport, and Storage

Factory Shipment

Before shipment from the factory, the product has been tested, calibrated, and inspected to ensure normal operation.

Receipt

Upon delivery, each carton should be inspected to avoid external damage. Any visible damage should be immediately recorded on the delivery note.

Carefully open the carton and inspect the product for damage. If there is damage or loss, immediately notify Spirax Sarco and provide details. Additionally, notify the transport personnel of the damage and ask them to inspect the damaged product and packaging carton on site.

Storage

If storage is required before installation, ambient temperature 0-65 °C, 10%-90% relative humidity (non-condensing)

Before installation and power connection, ensure there is no condensation inside the product.

3. System Overview

3.1 Function

The LC2250 controls the water level of boilers, tanks/vessels by operating pumps, valves, or solenoid valves. Typical applications:

On/Off Operation

• Pump on-off control

• One alarm output

• 4-20 mA level output

Note: A solenoid valve can be used instead of a pump.

Regulation Control

The regulating valve control method is valve motor drive or 4-20 mA control signal.

• One alarm output

• 4-20 mA level output

Note:

The 4-20 mA output is only available with valve motor drive.

3.2 Inputs

The product accepts the following input signals:

• Level sensor or transmitter 1-6 V or 4-20 mA.

Note: The level probe must be long enough to sense the entire measurement range.

• 1 K potentiometer input - valve motor drive (VMD)

3.3 Outputs

Output signals can be connected to pumps or regulating control valves. One relay is provided for high/low alarms and one isolated 4-20 mA retransmission output signal.

3.4 Other Functions

On fluctuating boilers, additional delays can be selected to increase damping.

All commissioning parameters are password-protected to prevent unintended changes.

Can communicate with adjacent controllers via infrared (only with Spirax Sarco products). Set as slave only - see Section 7 - Communication.

4. Mechanical Installation

Note: Before installing this product, please read the safety information in Section 1.

The product must be installed in a suitable industrial control panel or fireproof enclosure, providing impact and environmental protection. Minimum IP54 (EN60529) or Type 3, 3S, 4, 4X, 6P, and 13 (UL50/NEMA250) is required.

Note: Do not obstruct or cover infrared communication between controllers.

4.1 Environmental Conditions

The product installation environment should reduce the effects of heat, vibration, and electrical interference (see Section 1 - ‘Safety Information’).

Do not install the product outdoors without additional weather protection.

4.2 Installation on DIN Rail

Clips and a set of self-locking screws are provided with the product for installation on a 35 mm DIN rail. On the rear of the housing, there are two sets of holes to determine the height position. The clip head can be adjusted to change position. Install the clip head in one set of holes and secure with the two provided screws. Ensure the clip and rail are clamped.

Note: Use only the screws provided with the product

4.3 Installation on Baseplate

• On the baseplate, drill holes as shown in Figure 2.

• Install the product on the baseplate, securing with two screws, nuts, and washers through the upper and lower slots.

Note: Do not drill holes in the product housing or use self-locking screws.

4.4 Installation on Cut Panel

(If using an instrument frame, minimum panel thickness is 1 mm)

• The product has integral threaded sockets (M4 x 0.7) at the top and bottom

• Two M4 x 25 mm screws, washers, and instrument frames are provided

Note: Do not use screws longer than 25 mm to avoid electric shock.

Cut the panel according to the dimensions in Figure 2, and drill screw holes as indicated.

• After removing the backing from the washers, place them on the front of the product.

• Instrument frames can be used to improve appearance. If required, install them on the outside of the panel.

• Install the product from the rear of the panel, securing with screws, washers (and instrument frames).

• Tighten M4 screws to 1.0 - 1.2 Nm

Note: Do not drill holes in the product or use self-locking screws

Figure 2 Baseplate/panel - cutout drawing

Fixing Plate Cutout Notes:

• Solid lines indicate the cutout required for the installation panel.
• Dashed lines indicate the product outline
• The minimum clearance required between products is 15 mm for heat dissipation and cooling.
• For panel and wall mounting, the mounting hole dimensions are the same.

5. Electrical Installation

Note: Before installing this product, please read the safety information in Section 1.

Warning: Before touching the wiring terminals, disconnect the power supply as there may be contact with hazardous voltage.

Use only the connectors provided with the product, or spare parts. Using other different connectors must comply with product safety and authorization.

5.1 General Wiring Instructions

The product has been designed with user safety in mind, but the following points must be noted:

1. Maintenance personnel must be qualified to operate under hazardous voltage.
2. Ensure correct installation. Failure to follow these rules may reduce the safety level of the product.
3. The product design relies on building installation overcurrent protection and main isolation
4. All phase conductors must be fitted with 3-amp current-limiting protection devices. If current-limiting protection devices are installed on both power lines, the operation of one device must trigger the other. Please refer to IEC60364 (Building electrical installations), or follow local regulations for overcurrent protection requirements
5. Relay circuits must be fitted with 3 A fast-blow fuses
6. Relay contacts must use the same phase as the main power supply
7. Designed according to installation category II
8. Wiring standards:

• IEC60364 - Low-voltage electrical installations

• EN50156 - Electrical equipment for furnaces and ancillary equipment

• BS6739 - Instruments for process control: installation design, practice, or corresponding local standards.

• National and local electrical codes (NEC) or Canadian Electrical Code (CEC) for the United States and Canada Note: Use NEC Class 1, with temperature rating greater than 75 °C. If cables are exposed to higher temperatures, select a higher temperature rating.

9. The shield of signal cables must be connected to ensure electromagnetic compatibility.

10. All external circuits must meet and maintain IEC 60364 or equivalent double protection requirements

11. Additional measures must be taken to prevent accessible components (such as signal terminals) from coming into contact with power lines if power terminals suddenly become loose. Additional devices should be as close to the circuit board as possible, but no additional force should act on the wiring terminals. For example, use cable ties to bundle live and neutral wires together. If one becomes loose, the other will prevent it from contacting other components.

12. A disconnecting device (switch or circuit breaker) must be provided in the building system, and this product must:

• Have sufficient breaking capacity;
• Be as close to the equipment as possible for easy operator access;
• Not be installed in a difficult-to-operate location;
• Be able to disconnect all phase conductor terminals;
• Be labeled as the product’s disconnecting device;
• Not affect protective grounding;
• Not be used as the main power supply;
• Comply with IEC60947-1 and IEC60947-3 disconnecting device requirements;

13. See Section 10 ‘Technical Information’ for terminal and cable specifications

5.2 Main Wiring

1. Please read Section 5.1 before connecting the main power supply;
2. The terminal plug has wiring markings
3. All live conductor terminals must be fitted with fuses;

Disconnecting devices comply with IEC 60947-1 and IEC 60947-3

Figure 3

Disconnecting devices comply with IEC 60947-1 and IEC60947-3

Figure 4

4 Double or reinforced isolation must be used between the following devices;

• Live conductor terminals (main power and relay outputs)
• Other low-voltage devices (other components/terminals/wires)

5. The relay and switching devices shown on the wiring diagram are in the closed position;

5.3 Signal Wiring Instructions

If signal cables or shields are grounded at both ends, loop currents will be generated due to unequal ground potentials (voltages) at both ends. If the wiring diagram is correctly followed, the sensor should be grounded at one end.

Product grounding is functional grounding, not protective grounding.

Protective grounding prevents electric shock in the event of a single fault. Functional grounding ensures normal operation of the product. In this product’s application, functional grounding serves as a source or discharge pool for electromagnetic interference. The ground terminal must follow EMC directive grounding.

5.4 Sensor Wiring

The maximum cable length for all transmitters is 100 meters.

Warning:

It is important to determine the sensitivity of the PA20 preamplifier (see PA20 installation and maintenance guide for details).

Note:

Do not connect terminal 54 to other grounds

Ensure the resistance from the sensor to the pipe/boiler shell is less than 1 ohm

E = functional ground.

Figure 6 Signal circuit

5.5 Level Sensors

The output signals from PA20 and LP20 capacitive level sensors can be connected to multiple controllers.

Figure 7 Multiple controllers connected to one PA20

Each instrument must be able to accept 1-6 Vdc signals. Only one of the instruments needs to provide 24 V power. In Figure 7, the LC2250 supplies power to the capacitive sensor.

Loop-powered 4 - 20 mA

Externally powered 4 - 20 mA Level transmitter Figure 8 4 - 20 mA Level Transmitter

UL Specification PA20 Wiring Diagram

PA20 preamplifier and LP20 capacitive sensor (see PA20 and LP20 installation and maintenance guides for details)

Figure 9 Capacitive level sensor

6. Commissioning

6.1 Overview

All commissioning is performed on the product’s front panel.

Warning: When entering commissioning mode, the product will stop some control functions. The control relay disconnects valve power. For safety reasons, the alarm relay continues to function. To restore normal control function, press ‘end’ to return to the run menu.

Warning: If no button is pressed for more than 5 minutes, it will return to run mode and display an error. If commissioning is incomplete, control function will not operate.

Figure 10 Panel display and keypad

6.2 Entering Commissioning

In run mode, press and hold the OK button for 5 seconds to enter commissioning mode.

The bar graph disappears, displaying ‘PASS CODE’ and ‘888’ in the bottom right corner of the screen. Enter the password ‘745’; the password cannot be modified.

If an incorrect password is entered, the display automatically returns to showing the current pump status - run mode.

If the correct password is entered, the main menu structure is displayed. Select END to exit the menu.

In commissioning mode, press the ⚠ button:

• Scroll up the main menu

• Increase value

Press the OK button to confirm selection (parameter or value) and move to the next digit.

6.2.1 Quick Setup - Introduction

This section allows the user to perform the minimum settings to operate the system.

Accept factory default settings; when the original defaults have not been changed, the system can operate. Refer to the default settings in Section 10 for confirmation.

If required, settings can be made according to individual customer/application needs.

Warning: - It is important that you comply with national/local regulations and guidance instructions, and the boiler manufacturer’s recommendations. The set parameters will enable safe boiler operation.

Quick Setup

Commissioning examples for two typical boiler applications

- On/Off Control (Pump In), Using LP20/PA20

High level alarm

| CtL | Select ON/OFF, press OK to confirm |

- On/Off Control (Pump In), Using LP20/PA20 and VMD Actuator

High level alarm

| CtL | Select PrO, press OK to confirm | | Phl | Potentiometer high - calibrate valve open position. Press OK button when valve is fully open to 100% flow position | | PLo | Potentiometer low - calibrate valve closed position. Press OK button when valve is fully closed. |

Test whether the system is working

6.3 Commissioning - Full

Follow the instructions in Section 6.2 to enter commissioning, and change settings as needed according to the “Main Menu Structure” in Section 6.3.1.

6.3.1 Main Menu Structure

Input selection - select level transmitter input type. 1-6 V or 4-20 mA.

Input filter - 3-level water level signal damping for fluctuating conditions.

Note: Excessive delay can cause system instability. 2 seconds, 8 seconds, or 16 seconds.

Input alarm - alarm when input signal is outside 1-6 V or 4-20 mA range. Off or on.

Alarm selection - set as low alarm or high alarm. Hi or Lo.

Alarm level percentage - set alarm level as a percentage of the gauge glass. Hysteresis is fixed at 5%.

Alarm filter - select “on” to generate an 8-second delay to avoid excessive alarms caused by fluctuations.

Alarm latch -

Latch off - alarm disappears after water level returns to normal

Latch on - alarm persists until password reset.

Off or on

Retransmission - select 4-20 mA or 0-20 mA retransmission output signal.

Drive type - valve motor drive or 4-20 mA retransmission. rel or rEt (only available in proportional control).

| ACT | Drive action - output to actuator, potentiometer, or pump fill control, select IN, e.g., boiler feed tank. Drain control, select Out, e.g., condensate tank. In proportional control mode, if VMD or 4-20 mA, a signal for increasing water level: if IN is selected - output decreases; if OUT is selected - output increases. | | Lhi | High level - calibrate 100% level of gauge glass, set boiler or tank level to top of gauge glass, press OK to confirm. See Figure 11, (enter level transmitter submenu to display current/voltage signal. If exiting level calibration without saving, press AL button. | | Llo | Low level - calibrate 0% level of gauge glass, set boiler or tank level to bottom of gauge glass, press OK to confirm. See Figure 11, (enter level transmitter submenu to display current/voltage signal. If exiting level calibration without saving, press AL button. | | SP | Setpoint - the base point for generating the proportional band, usually set midway between maximum and minimum levels. | | Cb | Proportional band - set the width of the proportional band as a percentage of the gauge glass, e.g., control 20%, as shown in Figure 11. | | CtL | Control - Pro or ON/OFF, on-off or proportional control | | Phl | Potentiometer high - calibrate valve open position. Press + button to open valve to 100% flow position, press OK button to select submenu, press OK button again to confirm input setting value*. | | PLo | Potentiometer low - calibrate valve closed position. Press - button to close valve to closed position. Press OK button to select submenu, press OK button again to confirm input setting value*. | | End | End - press OK button to end commissioning. |

*Note: Only available in proportional control; the valve potentiometer feeds back valve position signals to the controller. Phl and PLo set the minimum and maximum potentiometer positions to match the valve flow. The submenu can display potentiometer readings.

Note: In run mode, the end menu is not displayed; an alarm menu is displayed. See Run Mode - Section 2.5.

Figure 11 Typical gauge glass water level percentage setting Refer to the boiler manufacturer’s recommendations.

6.4 Main Menu Commissioning Instructions

6.4.1 Lhi - High Level

Calibrate 100% of gauge glass water level

Set the boiler or tank to the top of the gauge glass.

Press the ⚠ button to select Lhi

Press the OK button to select the submenu

Press the OK button for 3 seconds to confirm value input

6.4.2 Llo - Low Level

Calibrate 0% of gauge glass water level

Set the boiler or tank to the bottom of the gauge glass.

Warning: The water level must be visible in the gauge glass

Press the ⚠ button to select Llo

Press the OK button to select the submenu

Press the OK button for 3 seconds to confirm value input

7. Communication

Infrared (IR)

Adjacent products within a certain range can communicate via infrared bus.

It enables the parameters of this product (OEM) to be transferred to equipment equipped with RS485 (user).

User products are equipped with graphic displays and OEM products have LEDs, or 3-digit numeric displays.

This product is always an infrared slave - no setup or adjustment required.

For further information on infrared and RS485 communication, see the user installation and maintenance instructions.

Important: Do not cover or obstruct the infrared light of infrared products.

Data register details are in the appendix.

8. Maintenance

Note: Before performing any maintenance, please read Section 1 Safety Information.

The product requires no special servicing, preventive maintenance, or inspection.

Level Control

However, boiler water level control and level alarms require testing and inspection. The Health and Safety Executive guidance PM5 provides general guidance.

For specific guidance on Spirax Sarco systems, please refer to separate literature.

Cleaning Instructions:

Use a cloth dampened with water or isopropyl alcohol. Using other cleaning materials may damage the product and void the warranty.

9. Fault Diagnosis

Warning:

Before starting fault diagnosis, please read Section 1 Safety Information and Section 5.1 Wiring Instructions.

Please note that there is hazardous voltage; only qualified personnel may perform fault diagnosis.

Before opening the enclosure cover, the product must be disconnected from the power supply and must be properly installed before powering up.

Failure to follow the procedures in this manual for fault diagnosis will result in a reduced safety level.

9.1 Introduction

If the product develops a fault, this section’s guidance allows the fault to be isolated and corrected. Faults are most likely to occur during installation and commissioning. The most common fault is incorrect wiring.

9.2 System Faults

9.3 Operating Error Messages

In run mode, any operating errors are displayed on the alarm and error screen.

10. Technical Information

10.1 Technical Assistance

Contact your local Spirax Sarco representative.

10.2 Returning Faulty Equipment

Please return all parts of the product to your local Spirax Sarco representative. Please ensure all parts are well packaged for transport (preferably using the original carton).

Please provide the following information when returning equipment:

1. Your name, company name, address and telephone number, order number and invoice, and return delivery address.
2. Equipment description and serial number.
3. Detailed description of the fault or repair required.
4. If the equipment is returned within the warranty period, please indicate:

• Date of purchase.

• Original order number.

10.3 Power Supply

| Supply voltage range | 99 to 264 V AC at 50/60 Hz | | Power consumption | 7.5 W |

10.4 Environment

| General | Indoor use | | Maximum altitude | 2000 m above sea level | | Ambient temperature range | 0 - 55 °C (32 - 131 °F) | | Maximum relative humidity | 80% at 31 °C (88 °F) linearly decreasing to 50% at 40 °C (104 °F) | | Overvoltage | III | | Pollution degree | 2 (as supplied) 3 (when installed in an enclosure) - minimum IP54 or UL50 / NEMA Type 3, 3S, 4, 4S, 6, 6P or 13. See Section 4, Mechanical Installation | | Sealing rating (front panel only) | NEMA Type 4 hose down only (UL certified) approved and compliant with IP65 (TRAC GLOBAL certified) | | LVD (Safety) | Electrical safety EN 61010-1 UL61010-1 CAN/CSA C22.2 No. 61010-1 | | EMC Immunity/Emission | Suitable for heavy industrial locations | | Housing Material | Polycarbonate | | Front Panel Material | Silicone rubber, 60 shore. | | Solder | Tin/lead (60/40%) |

10.5 Cables/Data Lines and Connectors

Power and Signal Connectors

| Terminal | Plug-in terminal block with screw connector | | Cable size | 0.2 mm² (24 AWG) to 2.5 mm² (14 AWG). | | Stripping length | 5 - 6 mm |

Note: Use only connectors provided by Spirax Sarco; otherwise the safety level will be reduced.

Sensor and Feedback Circuit Cables/Wires

| Type | High temperature | | Shield type | Shielded | | Number of cores | 3 | | Cable size | 1 - 1.5 mm² (18 - 16 AWG) | | Maximum length | 100 m (328 ft) |

4 - 20 mA Output Cables/Wires

| Type | Twisted pair | | Shield type | Shielded | | Number of cores | 1 core | | Cable size | 0.23 - 1 mm² (24 - 18 AWG) | | Maximum length | 100 m (328 ft) | | Recommended type | Various |

10.6 Input Technical Data

Level Probe Voltage

| Minimum voltage | 0 Vdc or 1 V (overrange selection) | | Maximum voltage | 6 Vdc (absolute maximum = 7 Vdc) | | Input impedance | 28 kΩ | | Accuracy | 5% FSD operating range | | Repeatability | 2.5% FSD operating range | | Resolution | 14 bit (approximately 0.15 mV) | | Sampling time | 260 Hz |

4-20 mA(s)

| Minimum current | 0 mA | | Maximum current | 22 mA | | Input impedance | 110 Ω | | Accuracy | 5% FSD operating range | | Repeatability | 2.5% FSD operating range | | Resolution | 14 bit (approximately 1 μA) | | Sampling time | 260 Hz |

Level ‘Overrange’ Alarm - Voltage

| Minimum alarm level | < 0.2 Vdc | | Minimum recovery level | > 1 Vdc | | Maximum alarm level | > 6.5 Vdc | | Maximum recovery level | < 6 Vdc |

Level ‘Overrange’ Alarm - Current

| Minimum alarm level | < 2.5 mA | | Minimum recovery level | > 4 mA | | Maximum alarm level | > 21 mA | | Maximum recovery level | < 20 mA |

10.7 Output Technical Data

24 Vdc Power Supply

| Maximum voltage | 32 Vdc (no load, open circuit) | | Maximum current | 25 mA | | Ripple voltage | 10 mV at 264 V, full load |

4 - 20 mA

| Minimum current | 0 mA | | Maximum current | 20 mA | | Open circuit voltage (maximum) | 19 Vdc | | Resolution | 0.1% FSD | | Maximum output load | 500 ohms | | Isolation | 100 V | | Output rate | 10 / second |

Relay(s)

| Contacts | 2 × single-pole changeover relays (SPCO) | | Rated voltage (maximum) | 250 Vac | | Resistive load | 3 amp at 250 Vac | | Inductive load | 1 amp at 250 Vac | | AC motor load | 1/4 HP (2.9 amp) at 250 Vac 1/10 HP (3 amp) at 120 Vac | | Pilot duty | C300 (2.5 amp) - control circuit/coil | | Electrical life (operations) | 3 × 10⁵ or greater, depending on load | | Mechanical life (operations) | 30 × 10⁶ |

Infrared Communication

| Physical layer | IrDA | | Baud rate | 38400 | | Range | 10 cm | | Operating angle | 15° | | Eye safety information | Summary: EN 60825-12: 2007 Safety of laser products - does not exceed Class 1 emission limit (AEL) |

10.8 Parameter Settings/Default Settings

The default settings in the table below are used in the ‘Quick Setup’ guide - see Section 6.2.1

InS - Input Selection

| Range | 1-6 or 4.20 | | Default | 1-6 | | Unit | Vdc or mA |

InF - Input Filter

| Range | 2, 8 or 16 | | Default | 2 | | Unit | seconds |

inA - Input Alarm (Overrange)

| Range | OFF or ON | | Default | OFF |

ALS - Alarm Selection

| Range | Hi or Lo | | Default | Hi |

ALP - Alarm Percentage (Water Level Gauge)

| Range | 5-100 (high alarm) or 0-95 (low alarm) | | Default | 85 (high alarm) or 20 (low alarm) | | Resolution | 1 | | Unit | % |

ALF - Alarm Filter

| Range | OFF or ON | | Default | OFF |

ALL - Alarm Latch

| Range | OFF or ON | | Default | OFF |

rEt - Retransmission

| Range | 4 - 20 mA or 0 - 20 mA | | Default | 4 - 20 mA |

dr - Drive

| Range | rel (relay) or ret (retransmission) | | Default | rel (relay) |

Act - Action

| Range | rel (decrease) and inc (increase) | | Default | rel (decrease) with rising level |

11. Appendix

Parameter and Register Data

Register format is 16-bit integer, high 8 bits transmitted first.

12. Menu Diagram