Honeywell Combustion Controls S.r.l.
Technical Specification
Title: DKG-N
Doc.: 50036723

Summary description

The burner control boxes DKG972-N control and supervise 2 stage atmospheric burners. They are tested and approved according to EN298:2012. They can also be used with direct air heaters (DIN 4794).

Important Notes

Safety instructions

1. Comply with the operating instructions.
2. Use the device as
   ● intended
   ● in flawless condition,
   ● aware of safety and hazards.
3. Note that all assembly, startup, maintenance and adjustment activities may only be performed by authorized skilled technicians.
4. Malfunctions that may compromise safety must be remedied immediately.
5. We do not assume liability for damages and operating malfunctions resulting from disregard of these instructions or improper handling of the digital burner control boxes!

In regard to construction and program sequence, the burner controllers DKG97x-N correspond to the applicable European directives, standards and regulations (see PRODUCT INFORMATION).

Intended use

The digital burner control boxes DKG 972-N are solely intended for OEMs using the controller in or on their products. The control box DKG972-N will functionally replace the control box DKG972.
The intended use also includes observing the operating instructions.
Any other or additional use is considered not in compliance with the intended use. The manufacturer is not liable for resulting damages.

Note for the equipment operator

The equipment operator shall exclusively follow the instructions and safety notes of the corresponding operating and maintenance instructions of the burner or heater manufacturer.

Meaning of symbols and signal terms used

Symbol	Danger term and structure	Meaning
	DANGER!	Safety note – High danger potential High risk, disregard leads to irreversible personal injury and even death or significant property damage. Prohibiting symbol (complemented by specific pictograph) in conjunction with the term ‘DANGER’
	Description of danger location and danger • Measures for danger prevention
	DANGER!	Safety note – High danger potential High risk, disregard leads to irreversible personal injury and even death or significant property damage. Attention symbol (complemented by specific pictograph) in conjunction with the term ‘DANGER’
	Description of danger location and danger • Measures for danger prevention
	WARNING!	Safety note – Medium danger potential Medium risk, disregard may lead to irreversible personal injury and even death or significant property damage. Attention symbol (complemented by specific pictograph) in conjunction with the term ‘WARNING’
	Description of danger location and danger • Measures for danger prevention
	CAUTION!	Safety note – Low danger potential Low risk, disregard may lead to light personal injuries or light property damage. Attention symbol (complemented by specific pictograph) in conjunction with the term ‘CAUTION’
	Description of danger location and danger • Measures for danger prevention
	Description of instruction	Instruction, e.g. required protective measures No danger term, round symbol (complemented by instructionrelated pictograph)
	Text	Note, tip or important information

Product Information

Application
The burner controllers DKG 972-N control and supervise 2 stage atmospheric burners. They are tested and approved according to EN298:2012. They can also be used with direct air heaters (DIN 4794).

Possible flame sensors:

• Ionization probe
• Infrared flame detector IRD 1020.1

Design and Function
The enclosure consists of a flame-resistant plug-in type plastic housing.
Microprocessor, electronic components, output relay, automatic flame guard are arranged on a printed circuit board. wellprotected in the housing.

The LEDs for the information system are located on the top of the housing.
Stable timings are achieved with the microprocessor-controlled program sequence, independent of:

• fluctuations of the line voltage
• ambient temperature
• starting cycles

The built-in visual information system not only permits continuous monitoring of the current events (useful especially to monitoring the starting process) but also provides information on causes of a possible lockout.
In each instance, the last error causes are stored in the device and can even be reconstructed after a voltage drop when the unit is switched on again.
The design of the burner controllers provides safety against low voltage conditions; thus the system is not endangered even in case of extreme voltage drops.

Model functions
Listed are the features of the family:

• 2-stage featured
• restart / repetitive or fault lockout / blocking in case of flame failure after safety time or in case of flame failure during operation
• IR data transfer to PC
• with fault indicator (LED)
• only non-volatile lockout possible

pin to pin compatibility with previous product family DKG 972

Type overview
Product Family DKG 972-N consists on one standard product with different software customizations (Model) – see below.

Order information
DMG 972-N Burner control boxes

Accessories

The above ordering information refers to standard design. The sales program also includes special designs.

Technical data

Dimensional drawing
The maximum mechanical outline dimensions of the plastic box hosting the control box DMG97x-N are reported:

Block Diagram – see Connection diagram and process diagram section for legend.

CE Statement of conformity
The products DxG97x-N meet the basic requirements of the following directives:

• Low Voltage Directive: 2014/35/EU
• EMC Directive: 2014/30/EU
• Gas devices Directive in conjunction with EN 298:2012

Timings
DKG 972-N Burner control boxes

Special Features:
All models (except Mod. 28 & Mod. 31) perform re-start 4 times after flame loss.
Mod. 28 & Mod. 31 re-start = 0

Mod. 21 no blinking until running
Mod. 27 re-starts after flame loss and when no flame after safety time
Mod. 28, 31 and 33 no re-start (lock-out after flame-loss or fault occurs).
There is no re-start after flame loss in stabilization (only in running mode).
Mod. 30 no blinking during start-up and operation
Mod. 32 unlimited re-start after flame-loss
Connection diagram and process diagram

CAUTION!
Use only the connection schema for the wiring noted for the respective model variant (see type overview).

• Wrong wiring will cause faulty functions!

DKG 972-N, connection diagram:

Legend:

Application-specific features

Information system
The information system indicates the processes in the burner control. It provides constant information on the program phase the digital burner control box is currently in.
The information system allows to immediately reveal burner faults during start or operation.
If the cause of the fault cannot be analyzed immediately on site, this can be done later thanks to the non-volatile memory.

Once the digital burner control boxes has been reset, the cause of the fault can visually no longer be detected.

The messages of the information system are visualized via a LED using a blinking code (like a Morse code). With the help of an (optional) accessory device, these messages can also be recorded and displayed in plain text.

Program sequence display
The built-in microprocessor controls both the information system and the program sequence. The individual phases of the program sequence are indicated as blinking code as follows:

Legend:
I = short pulse
= long pulse

Locking and unlocking
The device can be locked (fault occurred) or unlocked (fault remedied) in the following way:
– External
Fault elimination is done via an external button connecting Terminal 9 with Terminal A.
If the button is pushed longer than 3 seconds and released again during normal operation, the device switches to fault mode.

Locking or unlocking of the device is only possible when line voltage has been applied to it!

Flame monitoring
Flame monitoring can be conducted with the following flame sensors:

• Ionization probe, temperature-resistant material. Material and isolation like ignition electrode
• Infrared flicker detector IRD 1020.1 with bracket M93.

Flame monitoring with ionization probe is only possible in networks with grounded neutral. When connecting the IRD 1020.1, correct wiring must be ensured.

Stray light monitoring
Stray light monitoring takes place during the period specified in the technical data at the end of pre-purge.

Assembly and installation

Safety instructions

WARNING!

• Assembly may only be performed by trained personnel. The relevant national installation regulations must be observed.
• The series fuses are to be chosen so that the limit values specified under TECHNICAL DATA are positively not exceeded! Disregarding this stipulation may have serious implications for burner control box or system in case of a shortcircuit!
• The burner control box may only be plugged in and unplugged without voltage!
• Burner controllers are safety devices and may not be opened!

Assembly and electrical installation

CAUTION!

• The controller and the sensor shall not be subject to excessive vibration!

Flame monitoring
The following flame sensors are available for flame monitoring:
Ionization probe, temperature-resistant material. Material like ignition electrode.
Infrared flame detectors IRD 1020.1 with bracket M93

Dimensional drawing IRD 1020.1

Dimensional drawing bracket M93 to IRD 1020.1

IRD 1020.1 connection

Startup and inspection

Safety note

WARNING!

• The wiring shall be closely inspected prior to startup. Wrong wiring may damage the device and endanger the safety of the system!

Function check
A safety check of the flame monitoring must be performed both at initial startup and during revisions or prolonged shut-down periods of the system.

1. Starting test with closed gas valve
   • During blocking operation, the burner control box must switch to lockout after the end of the safety time.
2. Normal start; close gas valve when burner is in operation
   • During blocking operation, the burner control box must switch to lockout after a flame failure.
   • During repetitive operation, the burner control box must repeat a restart.

Lockout conditions

Potential faults
Thanks to the built-in information system, faults can be detected during the start or in operation without a major effort.

The device remains in the lockout and the cause of the fault is indicated until the burner control box is unlocked (fault remedied) again (see also “Locking and unlocking”).
Because the lockout is not remedied by pulling the plug from the device (for models with unalterable fault lockout) or by interrupting the line supply, the device switches once more to the lockout position approx. 5 sec. after applying the line voltage and the last lockout is indicated.

Lockout diagnostics
During the start or operation, faults are detected with the built-in information system.
The LED is permanently lit in case of a fault.
Lighting is interrupted approx. every 10 sec. and a blinking code, providing information on the cause of the fault, is emitted.
The following sequence is repeated until the fault has been acknowledged, i.e. the digital gas burner control boxes has been reset.

1. Light on (10 sec)
2. No light
3. Blinking-code
4. No light

Legend:
I = short pulse
= long pulse

Repair and disposal

Digital gas burner control boxes may only be repaired by the product manufacturer.

Your warranty becomes void if you open the digital gas burner control boxes.
When taking back the digital gas burner control boxes , the supplier of the heating system guarantees professional disposal or forwarding for inspection to the product manufacturer.

CAUTION!

• Handling the control box during maintenance and service could potentially generate Electrical Discharges dangerous for the electronic device.
• The effects of the operator discharge may be a simple malfunction of the equipment or damage of electronic components.
• The generation of electrostatic charges is especially favoured by the combination of synthetic fabrics and dry atmosphere.
• Suggested to touch the control box only using insulating shields (e.g. antistatic gloves).

Documents / Resources

Honeywell Mod.10 Gas Burner Control Unit [pdf] Instruction Manual Mod.10 Gas Burner Control Unit, Mod.10, Gas Burner Control Unit, Burner Control Unit, Control Unit

References

• User Manual