Dungs VPM-VC User manual

1 … 10
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)
Pp
GW 1
VPM VC
V1
Pp
V3 V2
GW 1
V4
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).
11 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
16
17
External
fault
115/230 VAC / 1 A cos ϕ = 1
19
20
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.
V2
two LEDs
green / red
V1
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)
Pp
GW 1
NO
NC
Pp1 Pp2
TR
L1
V1
V2
V1 in
LGV
OK
FAULT
REMOTE RESET
VPM-VC
1 a + 1b
Direkte Ventilkontrolle
mit LGV
FA
FAULT COM
MULTI
MULTI COM
NO
NC
N
Pp1
GW1
N
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
Pp
GW 1
LGV
(NO)
NO
NC
Pp1 Pp2
TR
L1
V1
V2
V1 in
LGV
OK
FAULT
REMOTE RESET
VPM-VC
1 a + 1b
Direkte Ventilkontrolle
mit LGV
FA
FAULT COM
MULTI
MULTI COM
NO
NC
N
Pp1
GW1
N
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
V1
Pp
V3
GW 1 V2
LGV
(NO)
NO
NC
Pp1 Pp2
TR
L1
V3 LGV
OK
FAULT
REMOTE RESET
VPM-VC
2 Ventilkontrolle
mit Hilfsventilen
V3,LGV
FA
FAULT COM
MULTI
MULTI COM
NO
NC
N
Pp1
GW1
V1
N
V2
N
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
Pp
GW 1
NO
NC
Pp1 Pp2
TR
L1
V1 V2
OK
FAULT
REMOTE RESET
VPM-VC
3
Direkte
Ventilkontrolle
FA
FAULT COM
MULTI
MULTI COM
NO
NC
N
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
V1
Pp
V3 V2
GW 1
V4
NO
NC
Pp1 Pp2
TR
L1
v3 V2
OK
FAULT
REMOTE RESET
VPM-VC
4
Ventilkontrolle
FA
FAULT COM
MULTI
MULTI COM
NO
NC
N
Pp1
GW1
V1
N
V4
N
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
Pp
GW 1
LGVTyp 2
(NC)
NO
NC
Pp1 Pp2
TR
L1
v1
OK
FAULT
REMOTE RESET
VPM-VC
5a + 5b
Ventilkontrolle mit Hilfsventilen,
Entlüftung nach V2
über LGVTyp2 (Normaly close)
FA
FAULT COM
MULTI
MULTI COM
NO
NC
N
Pp1
GW1
V1 in
V2 in
LGV
Typ2
v2
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
Pp
GW 1
LGVTyp 2
(NC)
NO
NC
Pp1 Pp2
TR
L1
v1
OK
FAULT
REMOTE RESET
VPM-VC
5a + 5b
Ventilkontrolle mit Hilfsventilen,
Entlüftung nach V2
über LGVTyp2 (Normaly close)
FA
FAULT COM
MULTI
MULTI COM
NO
NC
N
Pp1
GW1
V1 in
V2 in
LGV
Typ2
v2
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
Pp
GW 1
LGVTyp 2
(NC)
LGV
(NO)
NO
NC
Pp1 Pp2
TR
L1
v1 LGV
Typ2
OK
FAULT
REMOTE RESET
VPM-VC
6a + 6b
Ventilkontrolle mit Hilfsventilen
und LGV, Entlüftung nach V2
über LGVTyp2 (Normaly close)
FA
FAULT COM
MULTI
MULTI COM
NO
NC
N
Pp1
GW1
V2
N
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
Pp
GW 1
LGVTyp 2
(NC)
LGV
(NO)
NO
NC
Pp1 Pp2
TR
L1
v1 LGV
Typ2
OK
FAULT
REMOTE RESET
VPM-VC
6a + 6b
Ventilkontrolle mit Hilfsventilen
und LGV, Entlüftung nach V2
über LGVTyp2 (Normaly close)
FA
FAULT COM
MULTI
MULTI COM
NO
NC
N
Pp1
GW1
V2
N
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
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 [phone]
Fax [phone]
Postal address
Karl Dungs GmbH & Co. KG
Postfach 12 29
D-73602 Schorndorf, Germany
e-mail: [e-mail]
Internet: www.dungs.com
Dimensions Installation
150
77
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