A Honeywell Company

DKG 972

Gas Burner Safety Control

For 2-stage atmospheric gas burners Flame detection: - Ionisation probe - Infrared-flicker detector IRD 1020.1 - UV flame sensor UVD 971
INTRODUCTION The burner control box DKG 972 controls and supervises atmospheric burners for gas. They are approved and certified according to the applicable European standards and regulations. The microprocessor-based programming sequence ensures extremely stable timings independent of voltage variations, ambient temperature and/or switch-on cycles. The built-in information system not only provides a continuous monitoring of the actual state of the box (very helpful especially for monitoring the start-up phase) but also informs about the cause of a possible lock out. The lock out cause is stored in such a way that it can be retrieved even after a power failure. The control box is designed for maximum safety in case of fluctuations in the voltage supply. If the mains voltage drops below the permitted level, operation is interrupted and the control box automatically prevents the start sequence from being repeated. In this way, the safety of the system is not put at risk by a drop in the mains voltage. This low-voltage protection works not only during start-up but also permanently during operation. CONSTRUCTIONAL FEATURES The control box circuitry is protected by a flame resistant, transparent plug-in type plastic housing. A central fixing screw locks the control box to the wiring base. The plug-in control box incorporates the microprocessor based timer, flame check and reset circuits. Manual reset from lock out and set to lock out is provided by a push button with an integrated LED information system. A variety of cable entry points provides complete flexibility for electrical wiring. The wiring base S98 is equipped with spare- and extraterminals and allows together with a variety of cable entry points utmost flexibility of electrical wiring. The DKG 972 are compatible with the TFI 812. Different are only the pre- and post-ignition times. Max. heating power according the limits in the Gas Appliance Directive.

TECHNICAL DATA
Operating voltage or Fuse rating Power consumption Max. load per output - term. 3 ignition trafo - term. 5 + 6 solenoid valves - term. 7 alarm indicator - term. 4 auxiliary blower total load Reset time from lock out 220 / 240 V (-15... +10%) 50 Hz ( 5%) 110 / 120 V (-15... +10%) 60 Hz ( 5%) 10 A fast, 6 A slow ca. 12 VA 1.0 A, cos 0.2 0.5 A, cos 0.4 0.5 A, cos 0.4 2.0 A, cos 0.4 4.0 A, cos 0.4 max. 16 A during 0,5 sec none

Re-cycling / repetition (max. 4x) after a loss-of-flame during operation Sensitivity min. ionisation current required Sensitivity for stray light Ionisation probe insulation Stray capacitance max. cable length Flame detectors IRD 1020.1 UVD 971 Weight incl. Wiring base Mounting position Protection class Approved ambient parameter for control and flame detector - for operation - for storage Build-up of ice, penetration of water and condensing water are Approvals according to European standards 1 A 1.5 A 0.4 A probe - earth greater than 50 M probe- earth less then 1000 pF <3m side-on or end-on viewing end-on viewing 190 g any IP 40 max. 95% at 30 C -20 C... +60 C -20 C... +80 C inadmissible EN 298 and EN 230, as well as all other relevant Directives and standards ATLLXN

EN1C-0127SZ20 R0305

Classified acc. to EN 298

Table of timings (sec.)

Model 05 10 waiting time start tw 12 12 pre-ignition time tvz 3 3 Stray light monitoring tf 5 5 1 safety time ts 5 10 post-ignition time tn 4 9 delay 2nd-stage tv2 25 25

APPLICATION FEATURES 1. Information system The information system is microprocessor based and reports on all aspects of burner control box operation and flame supervision. It informs continuously about the actual programming sequence the unit is just performing. Besides monitoring of the programming sequence it also allows to identify errors during start-up of operation without any additional testing devices. The automatically performed diagnosis is a valuable tool which facilitates service/ maintenance work and therefore saves costs. The analyses of the error cause can be done directly on stage or if not possible afterwards as the lock out reason is stored in a nonvolatile lock out mode memory. The information system communicates with the outside world using a LED (the used Flash-Code is similar to the Morse-Code). The messages are optically transmitted by a appropriately flashing LED. Using an additional terminal (optional), the messages can be recorded and displayed in easy readable form.

1.2 Lock-out diagnoses In case of a failure the LED is permanently illuminated. Every 10 seconds the illumination is interrupted by a flash code, which indicates the cause of the error. Therefore the following sequence is performed which is repeated as long as the unit is not reset. Sequence:
illuminated phase for 10 sec dark phase for 0.6 sec Flash-Code dark phase for 1.2 sec

Error diagnosis Error message lockout stray light

Flash-Code

Possible fault within lock out safety time no flame establishment stray light during monitored phase, detector may be faulty

1.1 Programming sequence display The built-in microprocessor controls not only the programming sequence but the information system too. The individual phases of the programming sequence are displayed as Flash-Code. The following messages can be distinguished:
Message waiting time tw pre-ignition tvz safety time ts post ignition tn delay time to valve V2 tv2 running low mains voltage Internal fuse defect > control box defect Flash-Code . . . . _ _ _

Flash-Code for manual lock out manual/external lock out (see also 3. lock out and reset)

2. Flame detection The following types of flame detectors are suitable: Ionisation probe, temperature resistant material, well insulated (material and insulation same as for ignition electrode). Infrared-flicker detector type IRD 1020.1 with mounting flange M 93 or the UV solid state flame sensor UVD 971. Flame detection using an ionisation probe is only possible in conjunction with mains supplies which provides a neutral earth connection. Connecting the IRD 1020.1 or UVD 971 the correct wiring has to be observed.

2.1 Stray light monitoring Description = short pulse = long pulse . = short pause _ = long pause The stray light check is performed at the end of the prepurge time for thr duration as mentioned in the table of timings.

DKG 972

3. Lock out and reset The unit can be reset or brought into lock out mode in two different ways: Internal In the lock out case the unit can be reset by pushing the builtin button meaning a new start-up cycle is performed. External Instead of using the built-in lock out button the same function can be achieved by using an external button which connects terminal 9 with A (see also circuit and block diagram). If the pushputton (internal or external) is pressed during normal operation or during the start sequence for more then 3 sec. and afterwards released, the control box will perform a shutdown. Please note The unit can only be brought to lockout mode or be reseted if power is applied to the unit.

6. Mounting and electrical wiring Wiring base: 3 earth terminals with additional terminal for burner earthing 3 neutral terminals with internal permanent connection to neutral terminal 8 2 independant spare terminals (S1 and S2) extra terminals A, B and C are standard (wiring base S98 12-pin) 2 slide-in plates and 2 easy knock out holes plus 2 knock out holes in the base bottom faciliate the base wiring

Please note To assist trouble-free operation the main neutral connection terminal 8 in the wiring base must be fully tightened. The terminal screws are already in the undone position. To connect a wire to the terminal, the screw only needs to be fastened. General: The control box and detector probes should not be subjected to excessive vibration.

4. Low-voltage protection at 220 / 240V (110 / 120V) nominal voltage The mains voltage has to be more than 187 Veff (94 Veff ) in order to allow the unit to perform a start-up. The mains voltage is not only monitored in the start-up phase but also permanently during operation. If the voltage drops below < 160 Veff (80 Veff ) during start-up or run time the control box proceed to safety shut-down and goes into a waiting status. If the voltage rises again, the control box performs automatically a start-up as soon as the mains voltage is > 187 Veff (94 Veff ) . 5. Safety The design and control sequence of the DKG 972 controls will comply with the currently applicable standards and regulations (see also TECHNICAL DATA).

DKG 972

INSTALLATION INSTRUCTIONS AND MAINTENANCE 1. Important notes The controls must be installed by qualified personnel only. The relevant national regulations have to be observed. On commissioning the wiring has to be carefully checked according the appropriate diagram, Incorrect wiring can damage the unit and endanger the installation. The fuse rating has to ensure that the limits specified in TECHNICAL DATA will not be exceeded. If these precautions are not observed, the effect of a short circuit can cause severe damage to the control and installation. For safety reasons a minimum of one control shutdown every 24 hours has to be observed. Disconnect the mains before the control box is plugged in or out. The control box is a safety device and must not be opened!

3. Fault finding The built-in information system facilitate the trouble shooting in the case of problems occurring during start-up or during operation. A list of possible lock out messages can be found in APPLICATION FEATURES chapter 1.2. Please note: The control box is locked in lock out mode and the reasen for the lock out is displayed until the control box is reset, either by an internal or external reset (see also subject 3. Lock out and reset"). Removing the control box from its wiring base or by interrupting the supply line may not reset a lock out. Therefore, by applying power, it needs 2-3 secs. before the control box goes to lock out again and the cause of the last lock out.
Error Burner not working Possible fault - Thermostat circuit open - Faulty electrical wiring - Mains voltage < 187 V (< 80 V) - Terminal A continuously on power (e.g. terminal A is used as a support terminal) After 2-3 secs. after applying - Control box has not been reseted power. the unit goes to lock out Burner starts, - stray light signal during waiting flame not established, time lock out - no ignition or no fuel Burner starts, - no or too low flame signal (min. flame established, valves see TECHNICAL DATA) after safety time, - wrongly wired, phase and neutral lock out reversed - Ionisation probe dirty, broken or has contact to frame ground - too little light on flame sensIor (IRD)

2. Function control For safety reasons the flame detection system should be tested on commissioning the installation as well as after a service or longer shut-down. a) Attempt to start with gas valve closed: At the end of the safety interval -> Lockout b) After a normal start, with the burner in operation, close the gas valve: After restart at the end of the safety interval -> Lockout

DKG 972

CIRCUIT AND TIMING DIAGRAM DKG 972

Ph

max. 10 A fast 6 A slow 1 2 3 4

HS

ST

GW

RT

EV

A
HS GW ST RT EV IS Mains switch Gas proving switch Limit thermostat Control thermostat External reset and lock out button Ionisation probe (IRD 1020.1, UVD 971see separate diagram) Ignition Solenoid valve, 1st-stage Solenoid valve, 2nd-stage External lock out signal Auxiliary blower Waiting time Stray light monitoring Pre-ignition time Post-ignition Safety time 2nd-stage delay

IS Z N

V1 V2 SA

Z V1 V2 SA M tw tf tvz tn ts tv2

tw

tf tvz tn ts tv2

IRD- OR UVD CONNECTION

IRD 1020.1 UVD 971 blue black brown term. 8 term. 1 term. 9

BLOCK DIAGRAM DKG 972

Fault display Information system Reset and lock out

Oscillator

EEPROM

C Watchdog

Reset

Mains monitoring

Flame amplifier

Power supply monitoring

RZ

RV1

RV2

RS

Power supply

rz

rv1 rv2

rs

DKG 972

DKG 972 AND SOCKET

4,5

HOLDER M 93 FOR IRD

35 3

62,5

24

38,5

15.1

86

60

48

Slide-in plate 24 Reset button

17

20.5

HOLDER M 74 FOR UVD

30 44
Earth

35

35

30 16

25

30 57-60

Underside cable entry 16 mm

20 48

4 7

UVD 971
29

IRD 1020.1
29 50 UVD = 29 IRD = 44

13,5

21,8

21,8

UVD = 89 IRD = 104

VARIATION IRD
right

axial left

ORDERING INFORMATION ITEM Control box Control box Control box Control box Socket Insert plate optional Flame detector Flame detector Flame detector optional Support for IRD Support for UVD Connection cable DESIGNATION DKG 972 Mod. 5 DKG 972 Mod. 10 DKG 972 Mod. 10 110 / 120V 50Hz DKG 972 Mod. 10 110 / 120V 60Hz Wiring base S98 12-pin PG-Plate Cable entry plate IRD 1020.1 end-on IRD 1020.1 left IRD 1020.1 right UVD 971 Holder M93 for IRD 1020 Holder M74 for UVD Plug type, 3 core cable, 0.6 m with tag wire ends ITEM NO. 0332005 0332010 0332310 0332410 75310 70502 70503 16532 16533 16531 16722 59093 59074 7236001

The above ordering information refers to the standard version. Special versions are also included in our product range.

Specifications subject to change without notice

DKG 972
6

A Honeywell Company

26
Satronic AG Honeywell-Platz 1 Postfach 324 CH-8157 Dielsdorf

M4

4,5

4.5 26

14