Dungs VPS 508 User Manual

Valve testing system VPS 508 for multiple actuators

8.13

1 … 12

Printed in Germany • Edition 02.10 • Nr. 255 265

Technical description

The VPS 508 is the valve proving system for DUNGS multiple actuators. The valve proving system complies with EN 1643:

- Equipment operates independent of residual pressure in the range of the permissible operating range.

- Test volume ≤ 8 l

- Setting work not necessary on site

- Short test period: min. 10 s, max. 34 s

- Tightness or leaks are displayed by an LED

- External fault display possible for series 04 and S05

- Suitable for TRD systems

-

Electrical connection possible by plug connection S03. No rewiring is required for contact allocation as per DIN 4791.

- S04 and S05: electrical connection at screw terminals via PG 13.5 cable entry

Application

Valve proving system for DUNGS single valves, DMV double solenoid valve and GasMultiBloc MB. The VPS 508 can also be used for monitoring the DUNGS solenoid valves up to DN 100, with and without bypass connection. 24 VDC design for gas motors. Suitable for gases of gas families 1, 2, 3 and other neutral gaseous media.

Approvals

EC type test approval as per EC Gas Appliance Directive: VPS 508… CE-0085 AP 0168 EC type test approval as per EC Pressure Equipment Directive: VPS 508… CE0036 Approvals in other important gas consuming countries.

2 … 12

VPS 508 Valve proving system for automatic shuto valves as per EN 161, Class A and Class B

The VPS 508 may be used with any other valve whose tightness in counter-ow direction

excludes by construction a leakage in ow direction.

The VPS 508 is suitable for all DUNGS valves according to EN 161 Classes A and B.

Specications

Operating pressure

Test volume

Pressure increase by motor pump

Nominal voltage, Frequency

Rating requirement

Prefuse (provided by customer)

Fuse installed in housing cover, replaceable

Switching current

Degree of protection

Ambient temperature

max. 500 mbar (50 kPa)

≥ 1.5 l ≤ 8.0 l

≈ 20 mbar

refer to type overview page 11

During pumping time approx. 60 VA, in operation 17 VA

10 A quick-acting or 6.3 A slow-acting fuse

Microfuse 6.3 slow-blow L 250 V; IEC-127-2/III (DIN 41 662)

Operating output VPS 508 S03, S04, S05: max. 4 A Refer to motor startup current! Interference output VPS 508 S04, S05: max.1A

VPS 508 S03: IP 40 VPS 508 S04, S05: IP 54

50 Hz 230 VAC -15 °C to +70 °C others: -15 °C to +60 °C

Release time

Sensitivity limit

Switch-on duration of control

Max. number of test cycles

Installation position

Media

Approx. 10 - 34 s, depending on test volume and input pressure

max. 50 l/h At inlet pressures of < 50 mbar, limit pressure rates well below 50 l of air per hour occur due to the mode of operation. This allows for applications involving low inlet pressures.

100 % ED

10/h. Wait for at least 2 minutes after carrying out more than 3 consecutive test cycles.

vertical, horizontal, not upside down

Gas families 1, 2, 3, sewage gas, landll gas and biogas (dry, H2S < 0.1 % by

volume) and other gaseous media Not for gases having a butane content of > 60 %

3 … 12

VPS 508 sectional diagram

V1 V2

1

7

8

VPS 508

DMV… Series

p

1

p

1

+

20 mbar

V2

4 3 2 1 2 1

p

2

p

1

16

15

14

13

12

6

5

4

3

2

1

7

10

11

8

9

17

5

18

19

1 Hall switch 2 Solenoid 3 Pressure switch diaphragms 4 Compression spring 5 Filter 6 Solenoid valve anchor

7 Solenoid valve coil 8 Pressure pump 9 Unlock switch 10 Fault lamp 11 Operating lamp 12 Test nipple

13 Volume restrictor 14 Pump diaphragm 15 Pump linkage 16 PCB 17 Plug connection 18 Equipment fuse 19 Spare fuse

4 … 12

Functional description

V1

p = 500 mbar

max.

V2

VPS 508

p

2

p

a

p

1

p

e

p

2

p

a

p

1

p

e

DMV-D(LE)

A

A Program module

Instrument gland

Connection

V1

V2

VPS 508

p2 pa

p1 pe

p2 pa

p1 pe

Program

modul

p

e

p + 20 mbar

e

V1

V2

VPS 508

p

2

p

a

p

1

p

e

p

2

p

a

p

1

p

e

Program

modul

p

e

V1

V2

VPS 508

p

2

p

a

p

1

p

e

p

2

p

a

p

1

p

e

Program

modul

p

e

p + 20 mbar

e

V1

V2

VPS 508

p

2

p

a

p

1

p

e

p

2

p

a

p

1

p

e

Program

modul

p

e

V1

V2

VPS 508

p

2

p

a

p

1

p

e

p

2

p

a

p

1

p

e

Program

modul

p

e

V1

V2

VPS 508

p

2

p

a

p

1

p

e

p

2

p

a

p

1

p

e

Program

modul

p

e

p

e

p

e

2 3456 7 81

4 2

6

8

10

12

14

16

18

20

22

24

26

28

30

32

34

p

1

/p

e

= 100 mbar

p

1

/p

e

=

20 mbar

p

1

/p

e

= 200 mbar

p

1

/p

e

= 300 mbar

p

1

/p

e

= 500 mbar

tF [s]

The VPS 508 operates depending on pressure build-up. The program module starts to function when heat is requested. Test is performed depending on the burner functional procedure:

Check prior to burner start or Check during pre-purge period or Check after burner shut-down

Function principle

Release period t

F

Period which a VPS requires to perform a complete operation procedure. The release period of the VPS 508 depends on test volume and input

pressure:

tF max. ≈ 34 s

Test period t

test

Pumping time of motor pump.

Test volume V

Test

Volume between V1 output-side and V2 input-side and the intermediate tube pieces.

V

test min. / VPS 508

V

test max. / VPS 508

= 1,5 l

= 8 l

Program sequence

Release period

Field of application

Test volume V

[l]

prüf

Idle state: Valves 1 and 2 are closed. Pressure build-up: The internal mo-

tor pump increases the gas pressure in the test section by approx. 20 mbar compared to the input-side pressure applied to valve V1. During the test period, the installed

dierential pressure switch monitors

the test section for leakage. If the test pressure is attained, the motor pump

is switched o (end of test period). The

release time (10-34 s) depends on the

Idle state

test volume (max. 8.0 l) and input pressure (max. 500 mbar). If the test section is tight, the contact is released to the automatic burner control after max. 34 s - the yellow signal lamp lights up. If the test section is leaky or if the pressure increase by + 20 mbar is not attained during the test period (max. 34 s), the VPS 508 switches to fault. The red signal lamp lights as long as the contact release by the regulator or thermostat is present (heat requirement).

Pressure build-up

Operation

If there is a short power failure during the test or burner operation, the test is started again automatically. If the pumping time < approx. 10s,

the pressure dierence between the

testing system and the inlet pressure is

balanced after pumping is nished.

Operation: The internal valve of the VPS 508 is closed.

5 … 12

Program owchart

Regulator

Pump motor

Solenoid valve

Differential pressure switch

Release signal

Regulator

Pump motor

Solenoid valve

Differential pressure switch

Release signal

0 5 10 15 20 25 [s]30

VPS 508 "TIGHT" V

Prüf

= 2,0 l

VPS 508 "TIGHT" V

Prüf

= 8,0 l

VPS 508 "LEAKY"

35

40

Regulator

Pump motor

Solenoid valve

Differential pressure switch

Release signal

Fault signal

t

test

6 … 12

Electrical connection

N

Pe

L

6 5 4 2 1

3

B4 S3 T2 T1

N L

B4 S3 T2 T1 N L

6 5 4 3

2 1

B4 S3 T2 T1 N L

6

5

4

3

2 1

6

5

4

3

2 1

h

P1 H2 H1

F3 F2

S1

F1

S P S P

VPS 508 S03

The VPS 508 S03 is connected in series between the temperature regulator and the control box via a 7-pin plug connector. The pin assignment of the connector

between burner and boiler is specied

in DIN 4791. For contact assignment, refer to wiring diagram.If the heat generator is wired to DIN 4791,no boiler or burner rewiring is required for electrical connection. Connect the burner connector to the

oating connector of the VPS 508

S03. Connect the VPS 508 S03 connector

to the oating connector on the heat

generator.

If there is a fault signal at S3 (burner fault), the regulator chain is bridged via an additional relay in VPS 508 S03 on the burner side. At the same time, the operating voltage of VPS 508 S03 is interrupted. After eliminating the burner fault, the valve testing system can be started again.

Only connect the incoming

fault signal from the igniter of the burner control to port S3. If this is not observed, damage or injury may result. Therefore, please keep to the instructions.

Solenoid valve

Burner operation

Fault

Regulator

F1 Fuse F2 Sensor or limiter F3 Regulator H1 Fault signal H2 Operation signal

P1 Operating hours meter stage 1 S1 Switch X1B Connector, female X1S Connector, male

Operation

exchangeable fuse: T 6,3 L 250 V IEC 127-2/III (DIN 41662) D5 x 20

Burner female connector (X 1B)

Male connector (cable to cable) VPS 508 (X 1S)

Control line 7 x 1

VPS 508 S03 internal

Female connector

(xed)

VPS 508 (X 1B)

Male connector of heat generator (X 1S)

7 … 12

Electrical connection

VPS 508 series 05 internal

B +–

Operating voltage = (DC) 24 V

Release

signal

tight

leaky

V3

P

S

Falut

signal

I

max./maxi.

: B : 4A S : 1A

exchangeable fuse:

6.3 slow-blow L 250 V as per IEC 127-2/III (DIN 41662) D5 x 20

NC COM NO B L1 N

Floating fault signal

(control room signal)

Operating voltage 230 V AC 50 Hz

}

Release

signal

Operating

voltage

Zero

conductor

Groung

tight

leaky

V3

P

exchangeable fuse:

6.3 slow-blow L 250 V as per IEC 127-2/III (DIN 41662) D5 x 20

VPS 508 S04 internal

VPS 508 S04

PG 13.5 cable duct and connection to screw terminals below cover in housing (see Dimensions VPS 508 S04, S05).

Floating control room signal may only be used for signal-

ling, never for burner release.

Electrical connection VPS 508 S05

PG 13.5 cable duct and connection to screw terminals below cover in housing (see Dimensions VPS 508 S04, S06).

Operating voltage range 20 V - 30 V DC. Refer to mo-

tor startup current!

Test volume of DUNGS multiple actuators DMV-..., MBC-...

Type

DMV-D(LE) 5080/11 DMV-D(LE) 5100/11 DMV-D(LE) 5125/11 DMV-D(LE) 5065/12 DMV-D(LE) 5080/12 DMV-D(LE) 5100/12 DMV-D(LE) 5125/12

Rp/DN

DN 80 DN 100 DN 125 DN 65 DN 80 DN 100 DN 125

Test volume [l]

1,47 l 2,28 l 3,56 l 1,47 l 2,28 l 3,55 l 6,00 l

Type

MBC 1900 MBC 3100 MBC 5000 MBC 7000

Rp/DN

DN 65 DN 80 DN 100 DN 125

Test volume [l]

1,47 l 2,28 l 3,55 l 6,00 l

8 … 12

Use of VPS 508 at DUNGS single

V1 V2

L [m]

1 2

3

VPS 508

p

2

p

a

p

1

p

e

Adapter Nr. 222 740

Instrument gland

Connection

Volume V1

Volume V2

Volume

Intermediate pipe part V1 <−> V2

3

p

2

p

a

p

1

p

e

1

2

valves. Determining the test volume.

When mounting the VPS 508 on single valves DN 40-DN 100, the adapter set is required, Ordering No. 222 740.

Determining the test volume V

test

1. Determine the output volume of V1 (refer to table).

2. Determine the input volume of V2 (refer to table).

3. Determine the volume of the intermediate pipe part 3 (refer to table).

4. V

=

test

Volumen Volumen Volumen

+

valve 1

intermediate pipe part

valve 2

The max. test volume of 8 l must not be exceeded.

V

Test

=

+

Valve volume

V1 outlet+ V2 inlet

+

Volume of pipeline

Demetering test volume V

Rp / DN

Valve - Volume [l]

V1

+

outlet

V2

inlet

Rp DN Rp DN

Test

Test volume [l] = Volume V1

Pipeline lengths between individual valves L [m]

0,5 m

outlet

1,0 m

+ V2

inlet

+ Pipeline length

Rp DN

1,5 m

Rp DN

2,0 m

Rp DN

Rp 3/8

Rp 1/2

Rp 3/4 (DN 20)

Rp 1 (DN 25)

Rp 1 1/2 / DN 40

Rp 2 / DN 50

0,01 l

0,07 l

0,12 l

0,20 l

0,50 l

0,90 l

DN 65

DN 80

DN 100

DN 125

DN 150

DN 200

VPS 504 0,1 l ≤ V

------- VPS 508 0,4 l ≤ V VDK 1,5 l ≤ V

········· DSLC 1,5 l ≤ V

0,06 l

0,17 l

0,27 l

0,45 l

0,70 l

1,20 l

1,10 l

1,90 l

2,0 l

3,8 l

6,5 l

12,0 l

17,5 l

46,0 l

≤ 4,0 l 1 l = 1 dm3 = 10-3 m

prüf

≤ 20,0 l

prüf

≤ 8,0 l

prüf

1,35 l

2,20 l

3,7 l

6,3 l

10,5 l

18,2 l

26,5 l

61,7 l

0,11 l

0,27 l

0,42 l

0,70 l

1,70 l

2,90 l

2,00 l

3,20 l

5,30 l

8,80 l

14,40 l

24,3 l

35,2 l

77,4 l

0,16 l

0,37 l

0,57 l

0,95 l

2,20 l

3,90 l

2,65 l

4,20 l

7,00 l

11,30 l

18,40 l

30,50 l

44,10 l

93,10 l

0,21 l

0,47 l

0,72 l

1,20 l

2,80 l

4,90 l

3,30 l

5,50 l

8,60 l

13,80 l

22,3 l

36,6 l

52,9 l

108,9 l

3

9 … 12

Startup

1. Check test section for leaks after assembly.

2. Start test by using temperature regulator and/or restart or by pressing the reset button of VPS 508.

3. If the test section is tight

Depending on the length of the test

section and the residual pressure applied, the pumping time is between 3 s and 34 s.

The release for the automatic burner

control is then given after approx. 10 s at the earliest (at small test volumes and small input pressures) and after approx. 34 s at the latest (at large test volumes and large input pressures)

- the yellow signal lamp lights up.

If the test section is leaky

The test pressure is not attained.

The motor pump switches o, the red

fault lamp lights up. Switch-through to the automatic burner control does not take place.

Functional check

By opening a screw plug in test nipple p2 (pa) during test period (pumping time), leakage can be simulated and a function check can take place.

Setting

The VPS 508 must not be adjusted on site.

Assembly

Directly ange the VPS 508 laterally to

the DUNGS multiple actuators (mounting is possible on left-hand or right-hand side) using two 10.5 x 2.25 O rings and four M4 x 16 self-tapping screws.

If an exhaust gas valve is

installed in the boiler, it must be open at the beginning of the test.

In order to prevent functional

and leakage problems, we recommend the use of solenoid valves as per EN 161 Class A and Class B.

Insufficiently shielded fre-

quency converters could cause faults in the VPS due to network disturbances.

Make provisions for sucient

electrical shielding.

10 … 12

Dimensions [mm]

p

1

p

2

Ø 9

Betrieb

Fonctionamento

Funziamento

Run

Störung

Dérangement

Blocco

Lockout

126,5

Achtung, Warning, Attention, Attentione

Vor dem Öffnen ist das Gerät stromlos zu schalten

Before opening switch off power supply

Ouverture uniquement hors tension

Prima di apire l'aparecchio togliere la corrente

Typ: VPS 508

S04

pa

pe

100

22

4,3

72

53,7

5

13

147

150

5 6 7 8

p

1

p

2

Ø 9

Betrieb

Fonctionamento

Funziamento

Run

Störung

Dérangement

Blocco

Lockout

Typ: VPS 508

Serie 03

126,5

pa

pe

100

22

4,3

72

53,7

5

13

147

150

Sicherung eingebaut, auswechselbar Fuse built into housing, exchangeable Fusibile integré dans la couvercle du boîtier interchangeable

Typ/Type/Type/Tipo T 6,3 L 250 V

Betriebsanleitung beachten! Please comply with the operating instructions! Suivre les instructions de la notice d'utilisation! Seguire le istruzioni!

VPS 508 S03

Female connection X1B as per DIN 4791

pe test nipple

pa test nipple

Dimensions [mm] VPS 508 S04, S05

Additionally, PG 11 cable duct possibile

Standard: cable duct PG 13,5

Fuse

Spare fuses

Connector X1S as per DIN 4791

Cover, electrical connection

Spar fuse

Suction connection (gas input)

Pressure connection (to test section)

pe test nipple

pa test nipple

Suction connection (gas input)

Pressure connection (to test section)

11 … 12

VPS 508 type overview / accessories / order data

Version VPS 508 Series …

Nominal voltage, Frequency

VPS 508 S03

7-pole plug connection Cable length: 1.50 m Wiring as per DIN 4791 IP 40 degree of protection

VPS 508 S04

Connection to screw terminals PG 13.5 cable duct Additionally, PG 11 possible Floating fault signal (control room signal) IP 54 degree of protection

VPS 508 S05 (Gasmotors)

Accessories/spare parts

Adapter kit VPS 504 for solenoid valves Adapter kit VPS / VDK for solenoid valves

Mounting kit (4 x M4 x 16,2, 2 x O-Ring, 2 x lter insert)

Appliance fuse link (5 pieces)

Spare parts set VPS lter

20-30 VDC

251 008

222 740 223 470 221 503 231 780 243 801

230 V

-15 % 240 V +6 % 50 Hz

251 011

251 004

110 V

-15 % +10 % 50 Hz

251 012

251 005

Valve testing system VPS 508 for multiple actuators

We reserve the right to make any changes in the interest of technical progress.

Head Oces and Factory

Karl Dungs GmbH & Co. KG Siemensstraße 6-10 D-73660 Urbach, Germany Telephone +49 (0)7181-804-0 Fax +49 (0)7181-804-166

Postal address Karl Dungs GmbH & Co. KG Postfach 12 29 D-73602 Schorndorf, Germany e-mail [email protected] Internet www.dungs.com

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