Dungs VPM-VC Manuel utilisateur

1 … 10

Control unit for system

leakage tests

Type VPM-VC

(Valve Check)

8.22

Description

The VPM-VC valve test module

checks the tightness of burner gas

shut-o valves in combination with

one or two pressure switches. The

test is performed in accordance with

EN 1643.

The program sequence, lling and

venting parameters as well as pro-

gram times can be adjusted by the

user according to the system require-

ments.

Application

The VPM-VC has been designed for

automatic leak testing between two

solenoid valves in gas-consuming

devices, either prior to start-up or

after switching o the system. The

test system can be used as a single

leakage tester or in combination with

automatic burners. It is used in gas

burner systems for heating, process

heating,

process industry and gas engines.

Approvals

EU type testing certicate as per:

• EU-Gas Appliances Regulation

• EU-Pressure Equipment Directive

The VPM meets the requirements of:

- Machinery Directive 2006/42/EC

- Low Voltage Directive 2014/35/EU

- EMV 2014/30/EU

Approvals in other important gas-

consuming countries.

FM Approvals Class 7610

VPM VC

V1 V2

LGV

(NO)

GW 1

VPM VC

V3 V2

GW 1

Printed in Germany • Edition 03.21 • Nr. 260 257

3 … 10

2 … 10

VPM-VC

Control unit for system leakage tests according to En 1643.

Checks tightness of the gas burner shut-o valves either before burner start or after shutdown.

Equipment: one or two gas pressure switches.

Additional pilot valves are required depending on the system

Pressure switches/valves/pilot valves are not part of the scope of delivery!

Technical data

Rated voltage

(depending on the model)

~ (AC) 230 V +10 % / -15 % 50-60 Hz ±5 %

~ (AC) 115 V +10 % / -15 % 50-60 Hz ±5 %

Power consumption max. 10 W

Power consumption

Typical

115 V: standby 2.6 W

operation 4.6 W

230 V: standby 3.1 W

operation 5.4 W

Backup fuse L1 6.3 A T (10 A F), integrated, replaceable

Humidity DIN 60730-1, no dewing admissible

Type of protection IP 42

Ambient temperature -20 °C to +60 °C

Storage temperature -40 °C to +80 °C

Switch-on duration 100 %

Operational altitude Suitable for use up to 2000 metres above sea level

Test volume Unlimited

Medium Any; gas type depending on pressure switch and valve

Inlet pressure Any; depending on pressure switch and valve

Multifunction output (MFA) Number of operating cycles V1 > 100.000

(terminal 19 + 20, potential-free).

Further settings possible via VisionBox + parameter change:

1. Freely selectable number of operating cycles up to 6.5 million (standard

100,000)

2. Signal output with freely selectable number of operating cycles of V2,

LGV or release

3. Signal output while the test is running or while voltage is applied

4. Signal after successful switch-o

Program sequence can be selected Three dierent program sequences can be selected via DIP switches:

1. Valve test before burner start

2. Valve test after burner switch-o

3. Test sequence with optimised valve operating cycles after burner switch-

o without additional switching cycles. In this case, only one valve will be

tested at a time after successful switch-o, --> lower power consumption

and increased valve life.

Test times can be set DIP switches can be used to select predened test times of V1 and V2,

enabling optimal setting in case of dierent test volumes, inlet pressures

and leakage rates.

Alternatively, individual test times, even dierent times for V1 and V2,

can be set via VisionBox.

Filling and venting attempts Depending on the test volume, dierent combinations can be selected

using DIP switches.

Signalling for V1 and V2 Red/green LEDs signal various information on the program and release

states or error codes.

TWI interface Plug-in connection for DUNGS VisionBox. The VisionBox can be used

to access the VPM via a PC. The VisionBox is hardware and software

for VPM parameter setting. Status information and error error memory

data can be read out.

Mounting position As desired

3 … 10

2 … 10

Application information

EN 676: 2008-11 ... requests tightness checks at burner capacities above 1,200 kW

or already at capacities from 70 kW for burners without pre-purging.

EN 746-2: 2011-02 …requests the use of a VPM for some applications. Pre-venting

of the burner chamber can be omitted when using a VPM.

Venting of the furnace is done to the atmosphere.

EN 1643: 2001-02 …in combination with a VPM, venting may be done into the

furnace for max. 3 s.

Wiring scheme Outputs Electrical data

The sum of the currents of all safety-related

consumers must not exceed 5 A!

The sum of the currents of all consumers

must not exceed 6.3 A (10 A).

Release 115/230 VAC / 5 A cos ϕ = 1

Minimum load 0.5 W

6V1 115/230 VAC / 2 A cos ϕ = 1

Minimum load 0.5 W

8V2 115/230 VAC / 2 A cos ϕ = 1

Minimum load 0.5 W

10 LGV 115/230 VAC / 2 A cos ϕ = 1

Minimum load 0.5 W

External

fault

115/230 VAC / 1 A cos ϕ = 1

MFA 115/230 VAC / 1 A cos ϕ = 1

Inputs Electrical data

4 TR Test

request

115/230 VAC

13 Pp1 115/230 VAC (NO)

14 Pp2 115/230 VAC (NC)

12 Remote

unlocking

115/230 VAC

7V1_In 115/230 VAC

9V2_In 115/230 VAC

5 … 10

4 … 10

Signalling unit Error information

V2 V1

Detailed error information

via ash codes

All LEDs are ashing:

• when a key press is

requested during a

level change

• when the VPM is ready

for extended unlocking

MFT (RESET)

= multifunction

switch:

Unlocking switch for

error status

…max. 5x/15 min.

Changeover switch

to switch to the

password-protected

function level for

service and OEM

parameter setting

via TWI interface

by means of

the VisionBox.

two LEDs

green / red

two LEDs

green / red

O Constantly red V1 leaking

Constantly red O V2 leaking

Red ashing 1x Red ashing 1x Venting error

Red ashing 2x Red ashing 2x Filling error

Switch-on (mains): All

LEDs light up as a functional

test for approx. 1.5 s.

Waiting for test request:

Green LED's ashing slowly

(4 s o, 0,125 s on).

Depending on the states, the

LED-V1 and LED-V2 indicators

are ashing or lit constantly

Red ashing 3x Red ashing 3x Wrong position

of DIP switch

Red ashing 4x Red ashing 4x Unlock

failed

Red ashing 5x Red ashing 5x Power at V1.In or V2.In

before test sequence

completed

Constantly red Constantly red ...all other errors

Constantly

green

Constantly

green

Release signal

RESET V1V2

5 … 10

4 … 10

ATest sequence Bttest V1, V2 test time CNumber of venting or

lling attempts

1100

Test during the start

phase before burner

ignition

1100 10 s 1100 Venting 10 ()

Filling 1

0110 22 s 0110 Venting 1

Filling 1

1001 30 s 1001 Venting 1

Filling 10

1001 Test after regular

shutdown

0011 55 s

The following can

be changed via the

software:

P22 for test time V1

P23 for test time V2

If this switch position is

used, parameter set-

ting should be checked

via the VisionBox.

0011 Venting 3 ()

Filling 3 ()

The following can

be changed via the

software:

P32: Number of vent-

ing operations

P31: Number of lling

operations

If this switch position is

used, parameter set-

ting should be checked

via the VisionBox.

0011 Test after regular shut-

down in reduced mode

without additional

operating cycles

Operating mode

"T- Down optimised“:

after regular switch-o,

one valve is tested at a

time alternatively,

the other valve is kept

open. The alternation

takes place during

release, when remov-

ing the test request

next time.

- burner with

frequent starts

- longer valve life

- reduced power con-

sumption

ttest For the calculation of

the test times, see p. 7

Setting must be higher

than the calculated

time.

t DIP > ttest V1 , ttest V2

For more detailed ex-

planations, see instal-

lation examples in the

VPM-VC operating and

mounting instructions.

According to EN1643,

1 lling or 1 empty-

ing attempt for max.

3 s into the burner

chamber is admissible

(DUNGS as-delivered

conguration). At lling

and emptying times

of 1 s of the gas main

valves, max. 3 attempts

are admissible.

If the number of vent-

ing attempts is higher,

venting must be into

a safe area (LGV vent

valve).

Modication of the program sequence by an application-specic setting of the B/C DIP switches

A B C

0000 0000 0000

AAAA BBBB CCCC

7 … 10

6 … 10

Please note: Switch positions 



According to

EN1643, 1 lling or

1 emptying attempt

for max. 3 s into the

burner chamber is

admissible (DUNGS

as-delivered con-

guration). At lling

and emptying times

of 1 s of the gas

main valves, max. 3

attempts are admis-

sible.



When lling or

emptying attempts

are carried out via

pilot valves, the

situation described

in , shows that

the specications

of EN1643 are

also met with 10

lling or emptying

attempts if pilot

valves are used

that can reach at

most only 1/10 of

the maximum gas

ow of the main

valves.



If the valve check is

carried after a regu-

lar shutdown, the

system setup must

ensure that locking

the system prevents

a valve check during

a fault situation. This

can only be achieved

by safe interruption

of the power supply

to the VPM when a

fault occurs.



If this switch position

is used, parameter

setting should be

checked via the

VisionBox.

1a Direct valve check via LGV, venting through roof

Valve check system component: VPM-VC, Pp, LGV

- - -

VPM VC

V1 V2

LGV

(NO)

GW 1

Pp1 Pp2

V1 in

LGV

FAULT

REMOTE RESET

VPM-VC

1 a + 1b

Direkte Ventilkontrolle

mit LGV

FAULT COM

MULTI

MULTI COM

Pp1

GW1

DIP-mode:

A: 1100

1001 

0011 

B: xxxx

C: 1100

0110

0011 

Parameter:

---

1b Direct valve check via LGV, venting into the burner chamber

Valve check system component: VPM-VC, Pp, LGV

- - -

VPM VC

V1 V2

GW 1

LGV

(NO)

Pp1 Pp2

V1 in

LGV

FAULT

REMOTE RESET

VPM-VC

1 a + 1b

Direkte Ventilkontrolle

mit LGV

FAULT COM

MULTI

MULTI COM

Pp1

GW1

DIP-mode:

A: 1100

1001 

0011 

B: xxxx

C: 1100 

0110

0011 

Parameter:

---

Installation examples

The functional principle must be selected in accordance with the local regulations

Prevent soiling by using appropriate gas lters

Use of pilot valves recommended

Notes regarding 1a, 1b, 2:

If a valve closed when not powered is replaced instead of a LGV (open when not powered), it must be connected

to output V2 (terminal 8).

7 … 10

6 … 10

2 Valve check via pilot valves V3, LGV venting through the roof

Valve check system component: VPM-VC, Pp, V3, LGV

- - -

VPM VC

GW 1 V2

LGV

(NO)

Pp1 Pp2

V3 LGV

FAULT

REMOTE RESET

VPM-VC

2 Ventilkontrolle

mit Hilfsventilen

V3,LGV

FAULT COM

MULTI

MULTI COM

Pp1

GW1

DIP mode:

A: 1100

1001 

0011 

B: xxxx

C: 1100

0110

1001 

0011 

Parameter:

---

3 Direct valve check

Valve check system component: VPM-VC, Pp

- - -

VPM VC

V1 V2

GW 1

Pp1 Pp2

V1 V2

FAULT

REMOTE RESET

VPM-VC

Direkte

Ventilkontrolle

FAULT COM

MULTI

MULTI COM

Pp1

GW1

V1 in

V2 in

DIP mode:

A: 1100

1001 

0011 

B: xxxx

C: 0110

0011 ,

Parameter:

---

4 Direct valve check via pilot valves, venting into the burner chamber

- - - Valve check system component: VPM-VC, Pp, V3, V2

VPM VC

V3 V2

GW 1

Pp1 Pp2

v3 V2

FAULT

REMOTE RESET

VPM-VC

Ventilkontrolle

FAULT COM

MULTI

MULTI COM

Pp1

GW1

DIP mode:

A: 1100

1001 

0011 

B: xxxx

C: 1100 

0110

1001

0011 ,

Parameter:

---

9 … 10

8 … 10

5a Valve check via pilot valves, venting to V2 via LGVtype2 (normally closed)

Valve check system component: VPM-VC, Pp, LGVType2 (NC)

- - -

The LGV type 2 is required for opening the gas ow behind V2 (to the burner chamber or atmosphere), al-

lowing it to be emptied when V2 is deliberately (during the test) open. The pressure behind V2 must be able

to escape, since otherwise V2, as response to "No gas pressure", allows gas to pass in the reverse direction

during the test time, if there is still pressure behind V2. This allows the pressure to drop in the monitored inter-

space if V2 is leaking. During release (automatic burner control is working), the LGV type 2 is closed.

VPM VC

V1 V2

GW 1

LGVTyp 2

(NC)

Pp1 Pp2

FAULT

REMOTE RESET

VPM-VC

5a + 5b

Ventilkontrolle mit Hilfsventilen,

Entlüftung nach V2

über LGVTyp2 (Normaly close)

FAULT COM

MULTI

MULTI COM

Pp1

GW1

V1 in

V2 in

LGV

Typ2

Das LGV-Typ2 wird benötigt um den Gasweg hinter V2 zu öffnen (zum

Brennraum oder Atmosphäre), damit kann einerseits entleert werden

wenn V2 bewusst (während der Prüfung) offen ist. Der Druck

hinter V2 muss entweichen können da sonst V2 während der Prüfzeit auf

„kein Gasdruck“ Gas in Rückrichtung durchlässt falls hinter V2 noch Druck

besteht.

Andererseits kann der Druck im überwachten Zwischenraum bei

undichtem V2 abfallen. Während der Freigabe (Feuerungsautomat

arbeitet) ist das LGV-Typ2 geschlossen.

DIP mode:

A: 1100

1001 

0011 

B: xxxx

C: 1100

0110

0011 

Parameter:

P12 = 1

5b Valve check via pilot valves, venting to V2 via LGVtype2 (normally closed)into the burner chamber

Valve check system component: VPM-VC, Pp, LGVType 2 (NC)

- - -

The LGV type2 is required for opening the gas ow behind V2 (to the burner chamber or atmosphere).

This allows the pressure to drop in the monitored interspace if V2 is leaking. Emptying takes place via LGV.

During release (automatic burner control is working), the LGV and the LGV-type 2 are closed.

VPM VC

V1 V2

GW 1

LGVTyp 2

(NC)

Pp1 Pp2

FAULT

REMOTE RESET

VPM-VC

5a + 5b

Ventilkontrolle mit Hilfsventilen,

Entlüftung nach V2

über LGVTyp2 (Normaly close)

FAULT COM

MULTI

MULTI COM

Pp1

GW1

V1 in

V2 in

LGV

Typ2

Das LGV-Typ2 wird benötigt um den Gasweg hinter V2 zu öffnen (zum

Brennraum oder Atmosphäre), damit kann einerseits entleert werden

wenn V2 bewusst (während der Prüfung) offen ist. Der Druck

hinter V2 muss entweichen können da sonst V2 während der Prüfzeit auf

„kein Gasdruck“ Gas in Rückrichtung durchlässt falls hinter V2 noch Druck

besteht.

Andererseits kann der Druck im überwachten Zwischenraum bei

undichtem V2 abfallen. Während der Freigabe (Feuerungsautomat

arbeitet) ist das LGV-Typ2 geschlossen.

DIP mode:

A: 1100

1001 

0011 

B: xxxx

C: 1100

0110

0011 

Parameter:

P12 = 1

9 … 10

8 … 10

6a Valve check via pilot valves and LGV, venting to V2 via LGVtype2 (normally closed)Venting through roof

Valve check system component: VPM-VC, Pp, LGV, LGVtype2 (NC)

- - -

VPM VC

V1 V2

GW 1

LGVTyp 2

(NC)

LGV

(NO)

Pp1 Pp2

v1 LGV

Typ2

FAULT

REMOTE RESET

VPM-VC

6a + 6b

Ventilkontrolle mit Hilfsventilen

und LGV, Entlüftung nach V2

über LGVTyp2 (Normaly close)

FAULT COM

MULTI

MULTI COM

Pp1

GW1

V1 in

LGV

Das LGV Typ2 wird benötigt um den Gasweg hinter V2 zu öffnen

(zum Brennraum oder Atmosphäre). Dadurch kann der Druck im

überwachten Zwischenraum bei undichtem V2 abfallen. Entleert wird

über LGV.

Während der Freigabe (Feuerungsautomat arbeitet) ist das LGV und

das LGV-Typ2 geschlossen.

DIP mode:

A: 1100

1001 

0011 

B: xxxx

C: 1100

0110

0011 

Parameter:

P11 = 1

6b Valve check via pilot valves and LGV, venting to V2 via LGVtype2 (normally closed)

Valve check system component: VPM-VC, Pp, LGV, LGVtype2 (NC)

- - -

VPM VC

V1 V2

GW 1

LGVTyp 2

(NC)

LGV

(NO)

Pp1 Pp2

v1 LGV

Typ2

FAULT

REMOTE RESET

VPM-VC

6a + 6b

Ventilkontrolle mit Hilfsventilen

und LGV, Entlüftung nach V2

über LGVTyp2 (Normaly close)

FAULT COM

MULTI

MULTI COM

Pp1

GW1

V1 in

LGV

Das LGV Typ2 wird benötigt um den Gasweg hinter V2 zu öffnen

(zum Brennraum oder Atmosphäre). Dadurch kann der Druck im

überwachten Zwischenraum bei undichtem V2 abfallen. Entleert wird

über LGV.

Während der Freigabe (Feuerungsautomat arbeitet) ist das LGV und

das LGV-Typ2 geschlossen.

DIP mode:

A: 1100

1001 

0011 

B: xxxx

C: 1100 

0110

0011 

Parameter:

P11 = 1

10 … 10

Subject to technical modication in the interest of technical progress.

Control unit for system leakage

tests

Type VPM-VC

(Valve Check)

Company address

Karl Dungs GmbH & Co. KG

Karl-Dungs-Platz 1

D-73660 Urbach, Germany

Phone +49 7181-804-0

Fax +49 7181-804-166

Postal address

Karl Dungs GmbH & Co. KG

Postfach 12 29

D-73602 Schorndorf, Germany

e-mail: info@dungs.com

Internet: www.dungs.com

Dimensions Installation

150

2 x ø for PG 9

6 x ø for M16 x 1.5

Accessories

Gas pressure switch

Depending on the operating pressure, see data sheets

LGW...A4 (5.08)

GW...A6 (5.01)

GW...A4 HP (5.04)

Pilot solenoid valves

see data sheets DMV... (7.30, 7.37, 7.38), MV 502 (6.21)

MVD ... (6.20)

MPA VisionBox

As addition to MPA parameterisation and service box for setting VPM

parameters via a PC/laptop.

Hat rail mounting

Mounting rail 35 mm

Mounting bores ø 4.5

Screw ø 4

100

38,5

ø 4,5

Version Description Order No.

Complete device VPM-VC cpl. 230 VAC 259 696

VPM-VC cpl. 115 VAC 259 697

Top part VPM-VC 230 VAC 258 625

VPM-VC 115 VAC 258 890

Base 1 piece 259 694

48 piece 259 695

152.5

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