Dungs CM 100, CM 101 Installation Instructions Manual

CM 100 & CM 101 Relay Module

Power Equipment Company

2011 Williamsburg Road Richmond, VA 23231 USA

Phone: [phone] Fax: [phone] E-Mail: [e-mail]

Installation Instructions

DESCRIPTION

The CM100/101 control module contains the relay logic necessary to operate the DUNGS VPS 504 or VDK 200A valve prov­ing systems on a system start-up and during a system shutdown. On startup the valve proving system will interrupt the start­up sequence if it detects an open shutoff valve, thus preventing ignition under potentially dangerous conditions. On shutdown,
an open valve detection causes a manual lock-out requiring reset, and an alarm contact will energize; an optional blower
terminal can also be energized.

CM 100: Contains enclosure and relay board CM101: Relay board only for panel mounting

NEMA Type 1 Enclosure (IEC 529, IP 30) No Enclosure

SPECIFICATIONS

Electrical Rating

110-120 Vac / 60 Hz
When operated at 50Hz, the CM will run a hotter.
Therefore, the contact ratings are reduced. In addition, the
internal timers will be slower by a factor of 1.2.

Ambient Temperature

+5° F to 140° F

Power Consumption

1 Amp

ATTENTION

• Read these instructions carefully.

• Failure to follow them and/or improper installation may

cause explosion, property damage and injuries.

• Installation must be done with the supervision of a

licensed burner technician.

• Check the ratings in the specications to make sure that

they are suitable for your application.

• Never perform work if gas pressure or power is applied,

or in the presence of an open flame.

• Ensure that the switch is not subject to vibration during

operation.

Approvals

UL Recognized Component: File MH 17004
FM Approved: File J.I. 3004006

Contact Ratings

Input @120 Vac/60 Hz Output @120 Vac/60 Hz
J2,J3: 13 A res J1: 13 A res
J4: 12 A res J5: 12 A res
J6,J7: 1 A res J8: 6 A res
J9,J10: 1 A res

• Once installed, perform a complete checkout.

• Label all wires prior to disconnection when servicing.

Wiring errors can cause improper and dangerous
operation

• Verify proper operation after servicing.

• The system must be installed, used, and maintaned to

meet all applicable national and local code requirements
such as but not limited to NFPA 70, NFPA 86, CSD-1,
ANSI Z21.13, UL 795, NFPA 85, or CSA B149.3.

Karl Dungs, Inc.

CM 100 & 101 Installation Manual - P/N 80117 - Ed. 01/09

1 … 4

Phone: [phone] Fax: [phone] E-mail: [e-mail]

524 Apollo Drive,Suite 10 Lino Lakes, MN 55014 U.S.A.

WIRING

Preparation

•Reference the General Wiring Schematic on page 3.

•Disconnect all power to the valve proving system and the

flame safeguard before wiring to prevent electrical shock
and equipment damage.

• All wiring must comply with local electrical codes,

ordinances, and regulations.

• Do not exceed the terminal ratings given in the
specications.

• Loosen the screw which secures the cover. (CM 100 only)

• Open the cover.

• Route the wires through the conduit connectors.

• Provide adequate strain relief.

OPERATION

1 Initial Power:

When the main system is rst powered (L1) and there is no

call for heat, J2 gets powered, which allows power to J8.
When J8 gets energized. This applies 120Vac to the valve
proving system, which will cycle, verifying the automatic
shutoff valves position.

2 Valve Proving - Pass on initial system start.

If the valve proving system conrms that both automatic

shutoff valves are closed, it energizes terminal J9, which
closes normally open contact C2. If J7 from the flame
safeguarge is energzied, then energizing J9 does not close
C2.

3 Valve Proving - Pass on call for heat.

When there is a call for heat, terminal J4 is energized, which
then breaks relay S1 and then makes relay S2, even if J7
is energized. This restarts the valve proving system. If the
valve proven system energizes J9, C2 makesm, and power
is then applied to J5. The flame safeguard’s safety interlock
terminal is then energized, and the burner continues its igni­tion sequence.

Wiring

• A typical wiring diagram for operating a valve proving

system on burner start-up and after shutdown is shown in
the wiring diagram on page 2.

• If the blower is to be operated every time the valve

proving system detects an open valve, connect the blower
to J1, and the blower terminal of the flame safeguard to J6.
(The connection from the flame safeguard blower terminal
to J6 is required to provide proper operation of the blower
during a normal start-up procedure.) If the above is not
required, connect the blower directly to the flame safeguard
terminal and do not make the connection from the flame
safeguard blower terminal to J6. Terminal J1 can be used to
energize an alarm.

• NOTE: Frequency converters with insufcient

shielding can cause faults in the VPS 504/VDK 200A
as the result of transients. Verify that the equipment

is provided with sufcient shielding.

5 Safety Shutdown:

During a safety shutdown, the flame safeguard control en­ergizes J7, which closes (if open) normally closed relay C2,
overrides the input to J4, and forces relay S2 to break and
then relay S1 to make. This resets the valve proving system.
If the valves are proved closed, J9 is energized and closes
C2 (or remains closed. If the valve proving fails, J10 will be
energized and C2 opens (or remains open).

6 Normal Shutdown:

On normal shutdown, J4 and subsequently J5 are deener­gized when the “burner start” switch is opened. When J4
is de-energized, relay S2 breaks and then relay S1 makes,
which causes the valve proving system to reset and veri-

es the position of the two automatic shutoff valves. If the

valves are proved closed, J9 is energized and closes C2. If
the valve proving fails, J10 will be energized and C2 remains
open.

4 Valve Proving - Failure

If at anytime the valve proving system fails to prove the
automatic shutoff valve are closed, it energizes terminal J10,
which closes normally open relay C1. The blower turns on if
it is wired to J1 as shown in the wiring diagram. The internal
contact C2 remains opened, and J5 cannot be energized
even if J4 is energized; this prevents the burner system from
continuing with the ignition sequence.

2 … 4

CM 100 or CM 101

(Shown in the de-energized state)

VDK or VPS
Valve Proving system

N

L1

J4:
When energized, S1

brakes, and then S2
makes, which will start
a valve proving
sequence. If J7 is
energized, it will
override J4 and force
S2 to brake and then
S1 to make, which will
start a valve proving
sequence.

When de-energized,
S2 brakes, and then
S1 makes, which will
start a valve proving
sequence.

S1

J7:
When energized, C2 will close

(or remains closed), and J7 will
override J4, force S2 to brake,
and then force S1 to make,
which will start a valve proving
sequence.

When de-energized and if
J4 is powered (i.e. resetting
of FSG and Burner Start is
still on), C2 will open, S1 will

brake, and then S2 will make,
which will start a valve proving
sequence.

When de-energized and if
only J2 is powered (i.e.
resetting of FSG and Burner
Start is off), S1 remains in the

closed position and S2 remains
in the opened position. C2 will
open. If J9 is powered, then C2
will immediately close, but there
is no valve proving sequence.

Neutral

Normally
opened relay

Normally
opened relay

J9: When energized,

closes C2. If J7 is

already energized,

having J9 powered

does nothing.

J10: When
energized,

closes C1

S2

C2

J6: When

energized,

closes C1

Interlock
Limits

Blower

Blower

Alarm

Flame
Safeguard
Control
(FSG)

Alarm

High
Gas

Burner
Start

Low
Gas

Run

L1

N

Valves are Proved Closed

To PLC, additional alarm, light, or horn, if desired.

Do not connect to J7!

GENERAL WIRING SCHEMATIC AND INTERNAL LOGIC

3 … 4

A manual reset on the valve proving system can
be performed at anytime by pressing the red reset

button on the valve proving system. Resetting the
valve proving system will initiate a new test run. Refer to
the valve proving system installation manual for specica­tions and for operational details.

DIMENSIONS

CM 100 CM 101

PART NUMBERS

Type

CM 100

CM101

Description

Contains enclosure and relay board
NEMA Type 1 Enclosure (IEC 529, IP 30)

Relay board only for panel mounting
No Enclosure

Part Number

46022

46023

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