Honeywell Kromschroder TC 1 Bedienungsanleitung

DK S N P GR

➔www.docuthek.com

D GB F NL I E

TR CZ PL RUS H

Safety

Please read and keep in a safe place

Please read through these instructions

carefully before installing or operating. Following the

installation, pass the instructions on to the opera-

tor. This unit must be installed and commissioned

in accordance with the regulations and standards

in force. These instructions can also be found at

www.docuthek.com.

Explanation of symbols

• ,  ,  ,  ... = Action

▷= Instruction

Liability

We will not be held liable for damage resulting from

non-observance of the instructions and non-com-

pliant use.

Safety instructions

Information that is relevant for safety is indicated in

the instructions as follows:

DANGER

Indicates potentially fatal situations.

WARNING

Indicates possible danger to life and limb.

CAUTION

Indicates possible material damage.

All interventions may only be carried out by qualiﬁed

gas technicians. Electrical interventions may only be

carried out by qualiﬁed electricians.

Conversion, spare parts

All technical changes are prohibited. Only use OEM

spare parts.

Changes to edition 08.7

The following chapters have been changed:

– Installation

– Wiring

– Certiﬁcation

Contents

Operating instructions

GB-1

05469

Tightness control TC , TC , TC 

Tightness control TC , TC , TC .........

Contents ..............................

Safety.................................

Checking the usage .....................

Installation ............................

Mounting TC1V to valVario controls .........3

VAS 6 – 9, VCS 6 – 9 ......................3

Mounting TC1C to combination controlCG ...4

Mounting TC2..........................4

Mounting TC3..........................4

Wiring ................................5

Preparing the wiring ......................5

Connection diagram for TC1, TC2 ..........5

Connection diagram for TC3...............6

Finishing the wiring.......................6

Tightness test ..........................6

Setting the test instant ..................6

Setting measurement time tM.................7

Commissioning.........................8

Indicators and operating controls............8

Power failure ...........................8

Assistance in the event of malfunction .....8

Replacing the fuse .......................9

Maintenance ...........................9

Technical data ........................0

Safety information in accordance with

EN6508- ...........................0

Logistics .............................

Certification ..........................

Contact ..............................

Safety

Contents

GB-2

Checking the usage

Tightness control for checking two safety valves be-

fore and after burner run, with adjustable measure-

ment time for adjustment to different test volumes,

leakage rates and inlet pressures. The TC is used in

industrial thermoprocessing equipment, on boilers

and on forced draught burners.

TC 1, TC 2

For gas solenoid valves, quick opening or slow open-

ing with start gas rate.

TC 3

With ﬁtted auxiliary valves for quick or slow opening

gas solenoid valves as well as for motorized valves.

This function is only guaranteed when used within the

speciﬁed limits– see page10 (Technical data). Any

other use is considered as non-compliant.

Type code

Code Description

TC Tightness control

V

C





For attachment to valVario

For attachment to CG

For quick opening individual valves

For quick or slow opening valves

With Rp internal thread

With NPT internal thread

05 pu max. 500 mbar

Mains voltage:

230VAC, 50/60 Hz

120VAC, 50/60 Hz

24VDC

Control voltage:

230VAC, 50/60 Hz

120VAC, 50/60 Hz

24VDC

Part designations

TC 1C

TC 1V

TC 2

TC 3

TC 1V

Connectors

5 x M16 cable glands

42 x O-rings

TC 1C

TC 1V

TC 2

TC 3

TC 1C for combination controlsCG

1 x adapter

2 x O-rings

2 x retaining screws

Connectors

45 x M16 cable glands

52 x O-rings

TC 1C

TC 1V

TC 2

TC 3

TC 2 for solenoid valves

1 x adapter

2 x O-rings

2 x retaining screws

Connectors

45 x M16 cable glands

52 x O-rings

TC 1C

TC 1V

TC 2

TC 3

TC 3

Auxiliary valves

Valve block

45 x M16 cable glands

51 x screw plug

GB-3

Type label

▷

Gas type, measurement time, installation po-

sition, mains voltage, mains frequency, power

consumption, ambient temperature, enclosure,

max. switch-on current and max. inlet pressure–

see type label.

D-49018 Osnabrück, Germany

tM(s) 5 10 15 20 25 30

Installation

CAUTION

Please observe the following to ensure that the unit

is not damaged during installation and operation:

– Dropping the device can cause permanent dam-

age. In this event, replace the entire device and

associated modules before use.

– Avoid formation of condensation in the device.

– Do not store or install the unit in the open air.

– Check max. inlet pressure.

– Use a suitable spanner. Do not use the device

as a lever. Risk of external leakage.

▷Installation in the vertical or horizontal position,

housing cover/indicators must not point upwards

or downwards. The electrical connection should

preferably be pointing downwards or towards

the outlet.

▷

The device must not be in contact with masonry.

Minimum clearance 20mm (0.78").

▷Use the O-rings supplied.

▷

In the case of very large test volumes VP, an

installed relief line should be of nominal size40

to allow for the discharge of the test volumeVP.

 Disconnect the system from the electrical power

supply.

 Shut off the gas supply.

43 5

▷The O-rings must be inserted in the connectors

of theTC.

Mounting TCV to valVario controls

▷The solenoid actuator cannot be rotated on so-

lenoid valves with proof of closure switch VCx..S

or VCx..G.

▷

Connect the TC to the inlet pressure connec-

tionpuand the interspace pressure connection

pzof the inlet valve. Ensure that connections pu

and pzon the TC and the gas solenoid valve

are not reversed.

▷TC and bypass/pilot gas valve cannot be ﬁtted

together on the same side of the double block

valve.

▷

When using a valve/pressure regulator combi-

nation VCG/VCV/VCH, the pressure regulator

must be activated with air during the entire test

periodtP.

▷

The TC is secured using two captive combination

Torx screws T20(M4) inside the housing. Do not

undo any other screws!

Torx T20

VAS  – , VCx  – 

max. 250 Ncm

6 7

VAS 6 – 9, VCS 6 – 9

max. 250 Ncm

GB-4

Mounting TCC to combination controlCG

▷

Use the adapter plate supplied to mount the

TC1C to combination controlCG.

▷

Connect the TC to the inlet pressure connec-

tionpuand the interspace pressure connection

pz of the inlet valve. Ensure that connections pu

and pzon the CG are not reversed.

87 9

max. 250 Ncm

Mounting TC

▷

Connect the TC to the inlet pressure connection

and the interspace pressure connection p

the inlet valve.

▷Use the adapter plate supplied for installation.

TC 2..R: Rp ¼

TC 2..N: ¼ NPT

Rp ¼ (¼ NPT)

▷We recommend using Ermeto screw couplings

to attach the adapter plate to the gas solenoid

valve. It may be necessary to compensate the

distance to the valve housing.

▷Only use approved sealing material to seal the

pipe connections.

250 Ncm

6 7 8

10 11

9 Connect the interspace pressure connectionpz

on the adapter plate to the space between the

valves using a 12x1.5 or 8x1 pipe.

▷

Ensure that connections puand pzon the TC

and adapter plate are not reversed.

250 Ncm

6 7 8

10 11

Mounting TC

▷

Connect the TC to the inlet pressure connection

pu, the interspace pressure connection pzand

the outlet pressure connection pdof the inlet

valve. Ensure that connections pu, pzand pdon

the TC are not reversed.

▷TC 3..R: Rp 1/4, TC 3..N: 1/4 NPT

pzpd

▷Use a 12x1.5 or 8x1 pipe for the pipe con-

nections.

pzpd

6 Mount TC3.

▷Only use approved sealing material to seal the

pipe connections.

7 Seal the unused connection pzon the TC using

the sealing plug supplied.

GB-5

Wiring

WARNING

Electric shocks can be fatal!

– Before working on possible live components,

ensure the unit is disconnected from the power

supply.

– Incorrect wiring may result in unsafe states and

the destruction of the tightness control, the au-

tomatic burner control unit or the valves.

– Do not reverse L1 (+) and N (–).

– Cable cross-sections must be designed for the

current rating of the selected external fuse.

– The valve outputs on the automatic burner con-

trol unit connected to the TC must be safe-

guarded by an external slow-acting fuse of max.

5 A (e.g. in the automatic burner control unit).

▷Wiring to EN60204-1.

▷

Use connection terminals with a cable cross-

section of max. 2.5mm2.

▷

Conductors which have not been connected

(spare conductors) must be insulated at their

ends.

▷Do not set the remote reset so that it operates

(automatically) in cycles.

▷

The data on the type label must comply with the

mains voltage.

▷

Length of the connection cable, see page 10

(Technical data).

CAUTION

Please observe the following to ensure that the unit

is not damaged during operation:

– Avoid voltage and current peaks! It is recommen-

ded to equip connected valves with a protective

circuit in accordance with the manufacturer’s

instructions.

 Disconnect the system from the electrical power

supply.

 Shut off the gas supply.

▷

Before opening the unit, the ﬁtter should ground

himself.

 Open the housing cover of the TC.

Preparing the wiring

max. 3,5 Nm

7 Secure used cable glands. Tightening torque:

max. 3.5 Nm.

▷Unused cable glands are to remain closed with

a plug. Otherwise, dirt or moisture can penetrate

the housing.

8 Wire as shown on the connection diagram.

▷

For PE wire connection, 5 PE terminals are avail-

able for forwarding. They are designed as dis-

tributor terminals, e.g. to connect the PE wires

of the valves to the system PE (connection to the

system PE must be carried out/wired by the user).

Connection diagram for TC, TC

Mains voltage and control voltage:

24VDC/120VAC/230VAC

Mains voltage: 120VAC/230VAC,

control voltage: 24VDC

GB-6

Connection diagram for TC

▷

The tightness test is carried out with the auxiliary

valves installed on TC 3 (pre-wired). The terminals

for the valve inputs remain vacant.

Mains voltage and control voltage:

24VDC/120VAC/230VAC

Mains voltage: 120VAC/230VAC,

control voltage: 24VDC

Finishing the wiring

Tightness test

▷All new connections between the valve and the

TC must be checked for tightness.

 Pressurize the system. Do not exceed the maxi-

mum inlet pressure.

 Soap off pipe connections.

Setting the test instant

▷

The test instant (MODE) can be set using two

DIP switches.

 Disconnect the unit from the electrical power

supply.

▷

Before opening the unit, the ﬁtter should ground

himself.

 Unscrew the housing cover.

 Set the test instant to Mode 1, 2 or 3.

Mode 1

10s

15s

20s

25s

30s

▷Mode 1: test before burner start-up with incom-

ing thermostat/start-up signalϑ(factory setting).

Mode 1

10s

15s

20s

25s

30s

▷Mode 2: test after burner run when the thermo-

stat/start-up signal ϑ drops and after switching

on the mains voltage.

▷The tightness test also starts after a reset.

Mode 2

▷

Mode 3: test with incoming thermostat/start-up

signal ϑbefore burner start-up and when the

thermostat/start-up signal ϑdrops after burner

run.

Mode 3

▷Invalid switch setting: no function. The

Power

LED

is permanently red, see page8 (Assistance

in the event of malfunction).

▷

Continue on page 7 (Setting measurement

time tM).

GB-7

Setting measurement time tM

▷

The measurement time tMcan be set with a

jumper in increments of 5s to max. 30s.

▷tMis set to 30s at the factory.

10s

15s

20s

25s

30s

▷

No jumper: no function. The

Power

LED is perma-

nently red, see page 8 (Assistance in the

event of malfunction).

▷

The longer the measurement timet

, the greater

the sensitivity of the tightness control. The longer

the measurement time, the smaller the leakage

rate at which a safety shut-down/fault lock-out

is triggered.

▷

For all CG versions, the measurement

timetMmust be set to 5s on TC1C.

▷If no leakage rate is speciﬁed, we recommend

the max. measurement time is set.

▷

Within the scope of the European Union, the

maximum leakage rate QLis 0.1% of the maxi-

mum ﬂow rate Qmax. [m3/h (n)].

▷If a leakage rate is speciﬁed, ﬁnd the measure-

ment timetMfrom the following:

Qmax. = max. ﬂow rate [m3/h]

QL= Qmax. [m3/h] x 0.1% = leakage rate [l/h]

pu= inlet pressure [mbar]

VP= test volume [l], see page7 (Values for

valve and pipe volume)

▷

The tightness control TC requires a minimum

start rate in order to carry out tightness tests

on slow opening valves:

up to 5l (1.3gal) test volume VP= 5% of maxi-

mum ﬂow rateQmax., up to 12l (3.12gal) test

volume VP= 10% of maximum ﬂow rateQmax..

 Determine measurement time tM.

▷Measurement times tMfor V1 and V2:

tM[s] =

2.5 x pu[mbar] x VP[l]

QL[l/h]

▷

The entire test period is made up of the meas-

urement timestMof both valves and the ﬁxed

opening timetLof both valves together:

tP[s] = 2 x tL+ 2 x tM

Values for valve and pipe volume

LVP= VV+ L xV

Valves

Valve

volume

VV[l]

Nomi-

nal size

Pipe

volume VR

[l/m]

VG 10 0.01 10 0.1

VG 15 0.07 15 0.2

VG 20 0.12 20 0.3

VG 25 0.2 25 0.5

VG 40/VK 40 0.7 40 1.3

VG 50/VK 50 1.2 50 2

VG 65/VK 65 265 3.3

VG 80/VK 80 480 5

VG 100/VK 100 8.3 100 7.9

VK 125 13.6 125 12.3

VK 150 20 150 17.7

VK 200 42 200 31.4

VK 250 66 250 49

VAS 1 0.08

VAS 2 0.32

VAS 3 0.68

VAS 6 1.37

VAS 7 2.04

VAS 8 3.34

VAS 9 5.41

VCS 1 0.05

VCS 2 0.18

VCS 3 0.39

VCS 6 1.11

VCS 7 1.40

VCS 8 2.82

VCS 9 4.34

Calculation example:

Qmax. = 100 m3/h

pu= 100 mbar

VP= VV+ L x VR= 7 l

QL= 100 m3/h x 0.1% = 100 l/h

2.5 x 100 x 7 = 17.5 s

100

Set the next highest value (in this example 20s)

with the jumper.

 Disconnect the unit from the electrical power

supply.

 Unscrew the housing cover.

4 Set the jumper to the position for the required

measurement time.

5 Position the housing cover and screw tight.

6 Mark the set measurement timetMon the type

label with a waterproof pen.

D-49018 Osnabrück, Germany

tM(s) 5 10 15 20 25 30

▷The entire test period for this example is as fol-

lows: 2 x 3 s + 2 x 20 s = 46 s.

GB-8

7 Switch on the power supply.

▷

The

Power

LED ﬂashes yellow (0.2 s on/off). After

10s, the TC accepts the new setting and

Power

yellow or green, see table on page 8 (Com-

missioning).

Commissioning

Indicators and operating controls

Power

= power supply

Power

= operating signal

Power

= valve 1

Power

= valve 2

= reset button

The LEDs can display messages using three colours

(green, yellow, red) and permanent

Power

or ﬂashing

light

Power

LED Messages/Operating status

Power

green Power supply OK

Power

yellow TC is ready for operation; no safety

interlock* input signal

Power

green

TC is ready for operation; active

safety interlock* input signal

Power

green V1 is tight

Power

yellow V1 is untested

Power

yellow Tightness test is running on V1

Power

red V1 is leaking

Power

green V2 is tight

Power

yellow V2 is untested

Power

yellow Tightness test is running on V2

Power

red V2 is leaking

All yellow Initialization

* Linking of all the relevant safety control and switching

equipment for the use of the application. The burner

start enable signal is issued via the safety interlock

output (terminal 6).

▷

For further messages, see page 8 (Assis-

tance in the event of malfunction).

 Switch on the mains voltage.

▷

All LEDs are yellow for 1s. The TC is in the

initialization phase.

▷

The test starts according to the test instant

(Mode) which has been set.

Mode 1 or Mode 3, test before burner start-up:

voltage is applied to terminal 10 (thermostat/

start-up signalϑ).

Mode 2, test after burner run: the TC shows the

last operating status. In the case of untested

valves, the LEDs

Power

and

Power

are yellow.

There is mains voltage at terminal1 and renewed

test after switching off the voltage to terminal10

(thermostat/start-up signalϑ).

▷During the test, the 1

Power

LED ﬂashes

yellow.

The

Power

and

Power

LEDs are green:

▷Both valves are tight.

Mode 1 or Mode 3: the enable signal is issued via

terminal6 when voltage is applied to terminal5.

Mode 2: the enable signal is issued via terminal6

when voltage is applied to terminals 10 and5.

The

Power

LED is red:

▷A valve is leaking.

▷Voltage at terminal 12. A fault signal is output.

Power failure

▷If the power fails brieﬂy during the test or during

operation, the tightness test will restart in accord-

ance with the test procedure described above.

▷If there is a fault message, the fault is displayed

again after a power failure.

Assistance in the event of

malfunction

CAUTION

Electric shocks can be fatal!

– Before working on possible live components,

ensure the unit is disconnected from the power

supply.

– Fault-clearance must only be undertaken by

authorized trained personnel!

– (Remote) resets may only be conducted by au-

thorized trained personnel.

• Faults may be cleared only using the measures

described below.

• Press the reset button to test whether the TC

restarts.

▷

If the tightness control will not start even though

all faults have been remedied, remove the entire

TC (in the case of TC 3, including auxiliary valves

and corresponding valve block) and send it to

the manufacturer for inspection.

? Fault

! Cause

• Remedy

Power

red and permanently lit?

! There is over-/undervoltage. The TC performs a

safety shut-down.

• Check the mains voltage. As soon as there is

no longer over-/undervoltage, the TC returns to

normal operating mode and the

Power

LED is

green. It is not necessary to reset the device.

GB-9

Power

yellow and permanently lit?

! Safety interlock input signal is interrupted, no

voltage at terminal 5. The tightness test is still

being carried out. No enable signal is issued to

the automatic burner control unit.

• Check safety interlocks.

! Fuse F2 defective.

• Replace fuse F2, see page9 (Replacing the

fuse).

Power

yellow and ﬂashing?

! Permanent remote reset. The remote reset signal

has been active for more than 10s.

• The warning signal is cancelled once the remote

reset signal to terminal11 has been removed.

Power

red and permanently lit?

! Incorrect jumper/DIP switch setting.

• Correct jumper and DIP switch setting, see

pages 7 (Setting measurement time tM)

and6 (Setting the test instant). Then press

the reset button.

! Internal error.

• Remove the unit and return it to the manufacturer

for inspection.

Power

red and ﬂashing?

! Too frequent burner start commands. The TC

performs a fault lock-out. The start commands

are limited to 5x in 15minutes.

▷

As long as this limit is not exceeded, another

start-up attempt is possible after three further

minutes. If a tightness test is completed, the

counter which limits the number of start com-

mands is reset.

• Then press the reset button.

! Too many remote resets. More than 5resets

have been conducted within the last 15minutes,

either automatically or manually.

! Consecutive fault caused by a previous fault

whose actual cause has not been remedied.

• Pay attention to previous fault messages.

• Remedy cause. Then press the reset button.

Power

red and permanently lit?

! The valve is leaking. The TC performs a fault

lock-out.

• Replace the valve.

! Wiring of the TC to the valves is faulty.

• Start the program and observe the interspace

pressurepz. The pressure must change during

the TEST phase. Check the wiring.

! Inlet pressurepu<10mbar.

• Provide the min. inlet pressure of 10mbar.

! Interspace pressurepzcannot be reduced.

• The volume downstream of the valve on the

burner side must be 5times higher than the

volume between the valves and atmospheric

pressure must prevail.

! The measurement time tMis too long.

• Readjust tM, see page 7 (Setting measure-

ment time tM).

Power

and

Power

red and permanently lit?

! During the tightness test, the TC has determined

that inlet valve1 and outlet valve2 have been

reversed (fault lock-out).

• Check the wiring. Then press the reset button.

? No LED lit even though mains voltage ap-

plied?

! Fuse F1 defective.

• Replace fuse F1, see page9 (Replacing the

fuse).

Replacing the fuse

▷

The fuses F1 and F2 can be removed for in-

spection.

▷Insert a screwdriver into the opening in the con-

tact guard to prise out the fuse.

 Disconnect the TC from the electrical power

supply.

▷

Before opening the unit, the ﬁtter should ground

himself.

 Unscrew the housing cover.

 Remove fuse F1 or F2.

4 Check function of fuse.

5 Replace the defective fuse.

▷

When replacing the fuse, use only the approved

fuse type, see page10 (Technical data).

▷Restart the TC, see page8 (Commissioning).

Maintenance

Tightness controls TC require little servicing. We rec-

ommend carrying out a function check once a year

or twice a year in the case of biogas.

GB-10

Technical data

Electrical data

Mains voltage and control voltage:

120 VAC, -15/+10%, 50/60 Hz,

230 VAC, -15/+10%, 50/60 Hz,

24 VDC, ±20%.

Power consumption (all LEDs green):

5.5 W at 120 VAC and 230 VAC,

2 W at 24 VDC,

TC 3: plus 8VA for an auxiliary valve.

Fine-wire fuse:

5 A, slow-acting, H, 250V, pursuant to

IEC60127-2/5,

F1: protection of valve outputs (terminals 15

and16), fault signal (terminal12) and supply of the

control inputs (terminals 2, 7 and8).

F2: protection of the safety interlock/controller en-

able signal (terminal6).

The input current at terminal1 must not exceed

5A.

Max. load current for safety interlock/controller

enable and valve outputs:

at 230/120 VAC mains voltage, max. 3A resistive

load,

at 24 VDC mains voltage, max. 5A resistive load.

External fault signal (terminal 12):

fault output at 120 V AC/230 V AC/24 V DC mains

and control voltage: max. 5 A,

fault output at 120 V AC/230 V AC mains voltage,

24 V DC control voltage: max. 100 mA.

TC switching cycles:

250,000 pursuant to EN13611.

Reset: using a button on the device or by remote

reset.

Environment

Gas type: natural gas, town gas, LPG (gaseous),

biogas (max. 0.1%-by-vol. H2S) and air.

The gas must be clean and dry in all temperature

conditions and must not contain condensate.

Inlet pressure pu: 10 to 500 mbar (3.9 to 195"WC).

Measurement time tM: 5 to 30 s, adjustable.

Set at the factory to 30s.

Medium and ambient temperatures:

-20 to +60°C (-4 to +140°F).

No condensation permitted.

Long-term use in the upper ambient temperature

range accelerates the ageing of the elastomer

materials and reduces the service life.

Storage temperature: -20 to +40°C (-4 to +104°F).

Max. installation altitude: 2000 m AMSL.

Mechanical data

Length of connection cable:

at 230 V AC/120 V AC: any,

at 24 V DC (supply connected to PE):

max. 10 m permitted,

at 24 V DC (supply not connected to PE): any.

5 cable glands: M16 x 1.5.

Electrical connection:

Cable cross-section: min.0.75mm2 (AWG19),

max.2.5mm2(AWG14).

Valve opening time: 3 s.

Housing made of impact-resistant plastic.

Connectors: aluminium.

Enclosure: IP65.

Weight:

TC 1V: 215 g

TC 1C: 260 g (including adapter)

TC 2: 260 g (including adapter)

TC 3: 420 g

Designed lifetime

This information on the designed lifetime is based on

using the product in accordance with these operating

instructions. Once the designed lifetime has been

reached, safety-relevant products must be replaced.

Designed lifetime (based on date of manufacture) in

accordance with EN13611 for TC1–3: 250,000

switching cycles.

You can ﬁnd further explanations in the applicable

rules and regulations and on the afecor website

(www.afecor.org).

This procedure applies to heating systems. For

thermoprocessing equipment, observe local regu-

lations.

Safety information in accordance

with EN6508-

See Technical Information TC (D, GB, F) –

www.docuthek.com

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