A Honeywell Company
(Honeywell Nr. S4865)
Gas Burner Safety Control
For 1- or 2-stage forced draught and
atmospheric gas burners, with DC valves
Possible flame detectors:
- Ionisation probe
- Infrared flicker detector 1020.1
- UV flame sensor UVD 971
INTRODUCTION
The burner control boxes DVI980/982 controls and
supervises forced draught and atmospheric gasburners.
They are approved and certified according to the applicable
European standards and regulations. The use on direct air
heaters according DIN 4794 is also possible.
The microprocessor-based programming sequence ensures
extremely stable timings independent of voltage variations,
ambient temperature and/or switch-on cycles. The built-in
DVI 980/982
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.
CONSTRUCTION FEATURES
Microprocessor, electronic components, output relais,
ignition spark generator and flame amplifier are placed on
the printed circuit board.
These plus the optional lockout- and reset circuit are well
protected inside a flame resistant plastic housing.
The LED for displaying the information system are placed
on top of the housing.
TYPES AVAILABLE
DVI 980 1-stage
DVI 982 2-stage
MODELS
The following functions can be configured by factory:
• with or without air proving switch
• IR-data transmission over Palm Pilot, PC or hand-held
• volatile or non volatile lock out
• recycling (numbers eligible) or lock out / blocked after
loss-of-flame during operation
• recycling (numbers eligible) or lock out / blocked without
flame establishment after safety time
• with or without internal reset button
• potential free output for flame signal
• with or without lock out lamp (LED)
Table of timings (sec.)
Model max. reaction time or supervised pre-ignition ignition time stray light safety time delay 2nd stage
01 60 24 0 4 5 5 10
02 60 10 0 4 5 5 –
05 60 30 0 4 5 5 –
EN1C-0121SZ20 R0305
air proving switch pre-purge time time total monitoring (DVI 982)
tlw tv1 tvz tz tf ts tv2
TECHNICAL DATA
Operating voltage 220 / 240 V (-15... +10%)
50/60 Hz (±5%)
Fuse rating 10 A fast, 6 A slow
Power consumption ca. 12 VA
Max. load per output
- term. X2/6 motor 2.0 A, cos ϕ 0.4
Variation A
- term. X3 ,X5, X6 solenoid valves 90mA, DC
Variation B
- term. X3, X9, X5, X6 solenoid valves 90mA, DC
only DC-valves can be connected!
- term. X2/8 lock out 1.0 A, cos ϕ 0.4
total load max. 6 A during 0,5 sec
Air proving switch 1 working contact
STB Safety temperature delimiter 1 working contact
Ignition spark generator
Ignition frequency up to 40 Hz
Energy ignition spark 10 µAs
Ignition voltage 20 kV
Sensitivity (operation) 1 µA
Min. required ion. current 1.5 µA
Sensitivity for stray light 0.4µA
Flame signal output Optocoupler
max 70V DC/100mA
Ionisation probe insulation Probe - earth
greater than 50 MΩ
Stray capacity Probe - earth
less than 1000 pF
Cable length < 3 m
Flame detectors
IRD 1020.1 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 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 standard
EN 298, as well as all other
relevant Directives and
standards
1
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
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 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 Flash-Code
waiting for ❘ ❘ .
air proving switch
pre-purge ❘ ❘ ❘ .
tv1
pre-ignition ❘ ❘ ❘ ❘ .
tvz
safety time ❚ ❘ .
ts
delay 2nd stage ❚ ❘ ❘ .
tv2
running ❘ _
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 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 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 signal during
operation
Flash-Code for manual lock out
manual/external ❘ ❘ ❚ ❚ ❚ ❚ ❚ ❚ ❚ ❚
lock out
(see also 3. lock out and reset)
Error RV1 ❚ ❚ ❚ ❚ ❘ ❘ ❚ ❚ ❚ ❚
or STB opens
Safety temperature delimiter STB opens. For reset, the supply
line must, for a short time, be interrupted after pushing the reset
button.
low mains voltage ❘ ❚ ❚ _
Internal fuse defect ❘ ❚ _
> control box defect
Description
❘ = short pulse
❚ = long pulse
. = short pause
_ = long pause
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
The stray light check is performed at the end of the prepurge time for the duration as mentioned in the table of
timings.
DVI 980/982
2
3. Lock out and reset
6. Mounting and electrical wiring
The unit can be reset or brought into lock out mode in two
different ways:
Internal (optional)
In the lock out case the unit can be reset by pushing the
reset button meaning a new start-up cycle is performed.
External
Instead of using the reset lock out button the same
function can be achieved by using an external button which
connects terminal X2/12 with X2/9 (see also circuit and
block diagram).
Models with volatile lock out also can be reset by a shorttime interrupt of the supply line.
If the pushbutton (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.
Don't apply to units with volatile lock out.
4. Low-voltage protection
The mains voltage has to be more than 193 V
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 < 175 V
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 > 193 V
5. Safety
The design and control sequence of the DVI980/982 controls
will comply with the currently applicable standards and
regulations (see also TECHNICAL DATA).
during start-up or run time
eff
.
eff
in order to
eff
The DVI 980/982 is put directly on the solenoid valve.
Molex plug connector 3003 for:
– Power supply line
– Control thermostat RT
– Air proving switch LW
– Motor M
– External lock out signal
– Safety temperature delimiter STB
– External reset and lock out button
Counterpart:
– Molex plug connector 3001
General
The control box and the sensor shall not be exposed to
excessive vibrations.
7. Model functions
The following functions are configured by factory
Model 01:
• with air proving switch
• IR-data transmission over Palm Pilot, PC or hand-held
• non volatile lock out, no reset with interrupt of the supply
line
• direct lockout after loss of flame during operation
• direct lockout if no flame established after safety time
• with internal reset button
• without potential free output for flame signal
• Circuit diagram: "valve supply over air proving switch
contact", variation A, see page 5)
Model 02:
• with air proving switch
• IR-data transmission over Palm Pilot, PC or hand-held
• non volatile lock out, no reset with interrupt of the supply
line
• altogether 2 times recycling if no flame established after
safety time or loss of flame during operation
• without internal reset button
• potential free output for flame signal
• Circuit diagram: "valve supply not over air proving
switch contact", variation A, see page 5)
• with internal lock out lamp (LED)
DVI 980/982
Model 05:
• with air proving switch
• IR-data transmission over Palm Pilot, PC or hand-held
• volatile lock out, reset with interrupt of the supply line
• altogether 2 times recycling if no flame established after
safety time or loss of flame during operation
• without internal reset button
• potential free output for flame signal
• Circuit diagram: "valve supply over air proving switch
contact", variation A, see page 5)
• with internal lock out lamp (LED)
3
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
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
– for direct lockout operation, after safety time is over
the unit has to go into lock out mode!
– for recycling operation (max. recycling limited) carry
out a re start-up.
b) Normal start-up, when burner is running, close gas valve
– for direct lockout operation, after loss of flame the
control box has to go into lockout mode!
– for recycling operation (max. recycling limited) carry
out a re start-up.
c) Normal start-up, during pre-purge or operation, interrupt
the air proving switch
– for direct lockout operation, the control box has to go
into lockout mode immediately!
– for recycling operation (max. recycling limited) carry
out a re start-up.
3. Fault finding
The built-in information system facilitates 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 reason 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“).
Interrupting the supply line (by models with non volatile lock
out) may not reset a lock out. Therefore, by applying power,
the fan motor switches on for 2-3 secs. before the control
box goes to lock out again in cause of the last lock out.
Error Possible fault
Burner not working - Thermostat circuit open
- Faulty electrical wiring
- Mains voltage < 193 V
Fan motor starts for a short -Control box has not been reset
period of time, control box - Air proving switch not in open
goes to lock out position
Control box locks out or - Air proving switch has not closed
recycled during pre-purge within 60 sec.
- Air proving switch has re-opened
Control box locks out or - Air proving switch open
recycled at the end - Flame signal (stray light)
of pre-purge
Burner starts, - No ignition or no gas
flame not established,
after safety time
lock out or recycling
Burner starts, - No or to low flame signal (flame
flame established, does not stick, bad insulation of
after safety time the ionisation probe, bad conneclock out or recycling tion to frame ground)
- Insufficient light on IRD or UVD
- Sensitivity adjustment
to low on IRD
d) Bridged air proving switch before start
– the fan motor switches on for approx. 2 - 3 sec.,
followed by a lockout. After 10 sec., this quick lockout
is resetted by the control box and a second start
attempt follows (fan motor switches on for approx.
2 - 3 sec.). 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.
DVI 982/982
4
CIRCUIT AND TIMING DIAGRAM DVI 980/982
Using only the connection diagram for the wiring which is noted down for the respective model variation (see "7. model
functions", page 3).
A wrong wiring leads to malfunctions!
Valve supply not over air proving switch contact
tlw
Ph
X2
N
tv1
1
tvz
max. 10A fast
6A slow
2
ts
tz
tv2
HS
3
4
P
LW
5
T
STB
6
Without air proving switch
Ph
N
X2
max. 10A fast
6A slow
1
2
HS
3
4
5
STB
T
EV
X8
8
10
9
RT
11
T
EV
10
11
9
T
7
RT
M
6
SA
8
7
M
SA
X7
12
IS
Z
X8
X7
12
IS
Z
X9
X3
V1
V1
V1
V1 V2
X3
V1
V1
V1
V1 V2
X5
X9
X5
X6
V2
variation A
variation B
X6
variation A
V2
variation B
ts
tv2
tz
tv1
tvz
Valve supply over air proving switch contact
Ph
X2
N
tlw
tv1
1
tvz
max. 10A fast
6A slow
2
ts
tz
IRD- OR UVD CONNECTION
IRD 1020.1
UVD 971
DVI 980/982
tv2
HS
3
4
P
STB
6
5
LW
T
8
7
RT
M
SA
blue
black
brown
EV
X8
10
11
9
T
X7
12
IS
Z
HS Mains switch
EV External reset and lock out button
RT Control thermostat
X9
X3
V1
V1
V1
V1 V2
X5
X6
V2
variation A
variation B
Z Ignition probe
V1 Solenoid valve 1st-stage
V2 Solenoid valve 2nd-stage
LW Air proving switch
Kl. X2/11
Kl. X8
Kl. X2/12
STB Safety temperature delimiter
Using wire link for application
without STB.
M Motor
SA External lock out signal
IS Ionisation probe (IRD 1020.1, UVD 971
see separate diagram)
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
5
BLOCK DIAGRAM DVI 980/982
DIMENSION DVI 980/982
lock out lamp
Oscillator
EEPROM
µC
Watchdog
Reset
Flame
X8
amplifier
Flame
signal
output
Ignition
spark
X7
generator
+
-
1 2 74 56108 11 12 9
rv1
–
+
RV1
µC
RV2 RS
X3
X9
X5
valve supply
X6
(LED)
Information
system
rs
Variante A
230V DC
Reset and
lock out
Mains
monitoring
Power
supply
monitoring
Power
supply
Variante B
V1
V1
V1
230V DC
230V DC
V2
230V DC230V DC
Note:
Equipment for connection version A is fitted differently to version B.
–> no exchange possible!
60
113
106.5
X2
V1
V2
31.5
UVD 971 IRD 1020.1
HOLDER M 93 FOR IRD
UVD = 29
29
21,8
29
21,8
ø13,5
50
IRD = 44
35
14
UVD = 89
IRD = 104
15.1
48
4
17
ø20.5
ORDERING INFORMATION
ITEM DESIGNATION ITME NO.
Control box DVI 980 Mod. 02 0390602
Control box DVI 980 Mod. 05 0390605
Flame detector IRD 1020.1 D end-on 16552
or UVD 971 16722
Holder IRD Holder M 93 for IRD 1020.1 59093
Holder UVD Holder M 74 for UVD 971 59074
Connection cable Plug-type, 3-core cable, 0.6 m with tag wire end 7236001
3
26
4.5
The above ordering information refers to the standard version.
Special versions are also included in our product range. Specifications subject to change without notice
DVI 980/982
A Honeywell Company
6
Satronic AG
Honeywell-Platz 1
Postfach 324
CH-8157 Dielsdorf
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