Honeywell Satronic DMG 971 Instructions for use

A Honeywell Company

certified Qualitysystem

ISO 9001 / EN 29001

Reg. Nr. 10529

INTRODUCTION

The burner control box DMG 971 controls and supervises

power burner for gas and dual fuel. The control box is

approved and certified according the relevant European

standards. The use on direct air heaters according DIN 4794

is also possible.

The microprocessor- based programming sequence ensu-

res extremely stable timings independent of voltage varia-

tions, 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 es-

pecially 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 perma-

nently during operation.

CONSTRUCTIONAL FEATURES

Microprocessor, electronic components, output relais and

flame amplifier are placed on two printed circuit boards.

These plus the lockout- and reset circuit are well protected

inside a flame resistant, plug-in type plastic housing.

The reset switch for reset / remote lockout with its built-in

LED for displaying the information system plus the central

fixing screw are placed on top of the housing.

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 DMG 971 is funstionally compatible to MMI 811 and

MMI 811.1

Please note: Is the DMG 971 to be used to

replace the MMI 811 or 811.1, care has to be

taken to make sure the air proving switch (LW) is

wired between terminals 4 and 7 and not like on

the MMI between 5 and 7.

DMG 971

Gas Burner Safety Control

For 2-stage forced draught and combi

oil/gas burners

Possible flame detectors:

- Ionisation probe

- Infrared flicker detector 1020

- UV flame sensor UVD 971

TECHNICAL DATA

Operating voltage 220 / 240 V (-15... +10%)

50 Hz ( ±5%)

Fuse rating 10 A fast, 6 A slow

Power consumption ca. 15 VA

Max. load per output

- term. 3 ignition trafo 1.5 A, cos ϕ0.2

- term. 4 motor 2.0 A, cos ϕ0.4

- term. 5 + 6 solenoid valves 1.0 A, cos ϕ0.4

- term. B alarm indicator 1.0 A, cos ϕ0.4

total load 5.0 A, cos ϕ0.4

max. 10 A during 0.5 sec

Air proving switch 1 working contact 4 A, 230V

Stray light monitoring 5 sec

Sensitivity (operation) 1 µA

Min. required ion. current 1.5 µA

Sensitivity for stray light 0.4µA

Ionisation probe insulation Probe - earth

greater than 50 MΩ

stray capacity Probe - earth

less than 1000 pF

cable lenght < 3 m

Flame detectors

IRD 1020 side-on or end-on viewing

UVD 971 end-on viewing

Weight incl. Wiring base 190 g

Mounting position any

Protection class IP 40

Approved ambient parameter

for control and flame detector max. 95% at 30°C

- for operation -20°C... +60°C

- for storage -20°C... +80°C

Build-up of ice, penetration of water and condensing

water are inadmissible

Approvals according

to European standards EN 298 and EN 230, as

well as all other relevant

Directives and standards

Classified acc. to EN 298 FTLLXN

Timings (sec.)

0737.11-00-e/01/99

Model waiting time max. reaction time for supervised pre-ignition ignition time Stray light safety time delay

start air proving switch pre-purge time time total monitoring 2nd-stage

tlw tv1 tvz tz tf ts tv2

01 0 60 24 3 5 5 3 12.5

APPLICATION FEATURES

1. Information system

The information system is microprocessor based and re-

ports 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 non-

volatile 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.

1.1 Programming sequence display

The built-in microprocessor controls not only the pro-

gramming 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 Flash-Code

waiting for ❘ ❘ .

air proving switch

pre-purge ❘ ❘ ❘ .

tv1

pre-ignition ❘ ❘ ❘ ❘ .

tvz

safety time ❚ ❘ .

delay 2nd stage ❚ ❘ ❘ .

tv2

running ❘_

low mains voltage ❘ ❚ ❚ _

Description

❘= short pulse

❚= long pulse

. = short pause

_ = long pause

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,

whichindicatesthecauseoftheerror.Thereforethefollowing

sequence is performed which is repeated as long as the unit

is not reset.

Sequence:

illuminated phase dark phase Flash-Code dark phase

❘ ❚ ❚ ❚ ❚

for 10 sec for 0.6 sec for 1.2 sec

Error diagnosis

Error message Flash-Code Possible fault

lock out ❘ ❚ ❚ ❚ ❚ within lock out safety time

safety time no flame establishment

stray light ❘ ❘ ❚ ❚ ❚ stray light

during monitored phase,

detector may be faulty

air proving switch ❚ ❚ ❘ ❘ ❘ air proving switch

in closed position contact welded

air proving switch ❘ ❘ ❘ ❚ ❚ air proving switch does not

time-out close within specified time

air proving switch ❘ ❘ ❘ ❘ ❚ air proving switch opens

opened during start or operation

loss of flame ❚ ❚ ❚ ❚ ❘ loss of flame during

operation

Flash-Code for manual lock out

anual/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 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 neu-

tral earth connection.

Connecting the IRD 1020 or UVD 971 the correct wiring

has to be observed.

2.1 Stray light monitoring

The stray light check is performed at the end of the pre-

purge time for thr duration as mentioned in the technical

datas.

DMG 971

3. Lock out and reset

The unit can be reset or brought into lock out mode in two

different ways:

Internal

Inthe lock out casethe unit can bereset by pushing thebuilt-

in 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 1 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.

4. Low-voltage protection

The mains voltage has to be more than 187 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 during start-up or run time the control

box goes into lock out mode. If the voltage rises again, the

control box performs automatically a start-up as soon as the

mains voltage is > 187 Veff.

5. Safety

The design and control sequence of the DMG 971 controls

will comply with the currently applicable standards and

regulations (see also TECHNICAL DATA).

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

– 2 slide-in plates and 2 easy knock out holes (PG11

thread) plus 2 knock out holes in the base bottom faciliate

the base wiring

The digital controls are ideally wiried on the new wiring

bases S98, which are equipped with (terminals B and C are

only for some special types of DMO or DMG) terminal A,.

whichisusedfor the remote reset / remotelockoutfunctions.

Please note

To assist trouble-free operation the main neutral

connection terminal 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.

DMG 971

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 check-

ed 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 precau-

tions 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

per 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!

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) Start-up with closed gas valve

– After lock out safety time is over the unit has to go into

lock out mode!

b) Normal start-up, when burner is running, close gas valve

– After loss of flame, the control box has to go into

lockout mode

c) Normal start-up, during pre-purge or operation, interrupt

the air proving switch

– The control box has to perform a lockout immediatly

d) Bridged air proving switch before start

– the fan motor switches on for approx. 2 - 3 secs,

followed by a lockout. After 10 secs., this quick

lockout is resetted by the control box and a second

startattemptfollows(fanmotorswitchesonforapprox.

2 - 3 secs.). A standard lockout appears if the air

proving switch (LW) contact is still in it’s closed

position (e.g. welded contacts). Has the air proving

switch (LW) changed to it’s open position in the

meantime (e.g. by a run down motor), a normal start

sequence follows.

3. Fault finding

The built-in information system facilitates the trouble shoot-

ing 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:

Thecontrol box islocked in lock out modeand

the reasen for the lock out is displayed until

thecontrol boxis reset,either byan internalor

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. There-

fore, by applying power, the fan motor switches on for 2-3

secs. before the control box goes to lock out again and the

cause of the last lock out.

Error Possible fault

Burner not working - Thermostat circuit open

- Faulty electrical wiring

- mains voltage < 187 V

Fan motor/nozzle preheater - Control box has not been reset

starts for a short period of - Air proving switch not in open

time, control box goes to position

lock out

Control box locks out - Air proving switch has not during

pre-purge closed within 60 secs.

- Air proving switch has re-opened

Control box locks out - Air proving switch open

at the end of pre-purge - Flame signal

Burner starts, - Stray light on flame detector

flame not established, (IRD only)

lock out - No ignition or no fuel

Burner starts, - No or too low flame signal (flame

flame established, does not stick, bad insulation of

after safety time, the ionisation probe, bad connec-

lock out tion to frame ground)

- Insufficient light on IRD

- Sensitivity adjustment

too low on IRD

CIRCUIT AND TIMING DIAGRAM DMG 971

BLOCK DIAGRAM DMG 971

term. 8

term. 2

term. 9

blue

black

brown

IRD 1020

UVD 971

IRD- OR UVD CONNECTION

DMG 971

HS Mains switch

GW Gas proving switch

ST Limit thermostat

RT Control thermostat

EV External reset and lock out button

IS Ionisation probe

(IRD 1010, UVD 971 see separate

diagram)

Z Ignition

M Burner motor

V1 Solenoid valve, 1st-stage

V2 Solenoid valve, 2nd-stage

LW Air proving switch

SA External lock out signal

tlw max. reaction time for air proving switch

tv1 Supervised pre-purge time

tvz Pre-ignition time

tz Ignition time total

ts Safety time

tv2 Delay 2nd-stage

HS ST GW

IS ZV1 V2 SA

123456789C

tvz tz ts tv2

tw tv1

tlw

rv1

2 6 57 43C 9B 8 1 A

rv2

Flame

amplifier

Reset µC

Reset and

lock out

Power

supply

monitoring

RZ RV1 RV2 RS

Fault display

Information

system

EEPROM

Oscillator

µC

Watchdog

Mains

monitoring

Power

supply

max. 10A fast

6A low

RLK

A Honeywell Company

Satronic AG

Brüelstrasse 7

Postfach 324

CH-8157 Dielsdorf

DMG 971 AND SOCKET

DMG 971

ORDERING INFORMATION

ITEM DESIGNATION ITEM NO.

Control box DMG 971 Mod. 01 0351001

Socket Wiring base S98 75310

Insert plate PG-Plate 70502

optional Cable entry plate 70501

Flame detector IRD 1020 end-on 16522

Flame detector IRD 1020 left 16523

Flame detector IRD 1020 right 16521

optional UVD 971 16722

Support for IRD Holder M93 for IRD 1020 59093

Support for UVD Holder M74 for UVD 59074

Connection cable Plug type, 3 core cable, 0.6 m with tag wire ends 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

VARIATION IRD

right

HOLDER M 93 FOR IRD

left

axial

35 3

4.5

15.1

ø20.5

62,5

4,5

38,5

PG 11

Earth

Reset button

57-60

25 35

30 Underside cable

entry ø16 mm

Slide-in plate

UVD 971 IRD 1020

29 50 UVD = 29

IRD = 44

21,8

ø13,5

UVD = 89

IRD = 104

21,8

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