Satronic DKO 974 Instruction manual

1
A Honeywell Company
certified Qualitysystem
ISO 9001 / EN 29001
Reg. Nr. 10529
Oil Burner Safety Control
For 1- or 2-stage oil burners up to 30 kg/h
throughput and intermittent operations
with or without oil preheating
Flame detection:
- Photoresistor MZ 770 S
- Infrared-flicker detector IRD 1010
- UV flame sensor sensor UVD 970
INTRODUCTION
The DKO 974/976 oil burner safety control boxes are suitable
for oil burners with or without preheater with throughputs up
to 30 kg/h. They will be approved and certified according to
the applicable European standards and regulations.
The microprocessor- based programming sequence ensu-
res extremely stable timings independent of voltage varia-
tions, ambient temperature and/or switch-on cycles. The
built-in information system not only provides a continuous
monitoring of the actual state of the box (very helpful es-
pecially 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 perma-
nently during operation.
TYPES AVAILABLE
DKO 974 1-stage operation with release thermostat
DKO 976 2-stage operation with release thermostat
DKO 974N 1-stage operation without release thermostat
DKO 976N 2-stage operation without release thermostat
CONSTRUCTIONAL FEATURES
The control box circuitry is protected by a flame resistant,
transparent plug-in type plastic housing. A central fixing
screw locks the control box to the wiring base. The plug-in
control box incorporates the microprocessor based timer,
flame check and reset circuits. Manual reset from lock out
and set to lock out is provided by a push button with an
integrated lock out signal lamp. The wiring base S98 is
equipped with spare- and extraterminals and allows together
with a variety of cable entry points utmost flexibility of
electrical wiring.
The DKO 974 is compatible with the TF 834, TF 834.2. The
DKO 976 is in addition compatible with the TF 804, TF 804.2,
TF 836, TF 836.2.
Using the DKO 976 as a replacement for the TF
804 or TF 804.2, the flame sensor FZ 711 S must
be replaced by its compatible type MZ 770 S.
DKO 974/976
DKO 974 N/976 N
TECHNICAL DATA
Operating voltage 220 / 240 V (-15... +10%)
50 Hz ( ±5%)
Fuse rating 10 A fast, 6 A slow
Power consumption ca. 15 VA
Max. load per output
- term. 3 ignition trafo 1.0 A, cos ϕ 0.2
- term. 4 motor 2.0 A, cos ϕ 0.4
- term. 5 + B solenoid valves 0.5 A, cos ϕ 0.4
- term. 6 oil preheater 2.0 A, cos ϕ 1.0
- term. 7 alarm indicator 0.5 A, cos ϕ 0.4
total load 4.0 A, cos ϕ 0.4
max. 6 A during 0.5 sec
Reset time from lock out none
Flame detectors < 3 m length of cable
MZ 770 S side-on and
end-on viewing
Light sensitivity better 6 Lux
IRD 1010 side-on or end-on viewing
UVD 970 end-on viewing
Weight incl. Wiring base 190 g
Mounting position any
Protection class IP 40
Approved ambient parameter
for control and flame detector max. 95% bei 30°C
- for operation 0°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 standards EN 230, aswell as all other
relevant Directives and
standards
Model waiting time max. warm-up Pre-purge and Stray light safety Post-ignition delay time to V2
start time oil preheater pre-ignition time monitoring time time after V1 DKO 976 only
ta tv1 tf ts tn tv2
05 0 400 15 5 5 7 20
Timings (sec.)
0650.11-01-e/01/99

2
APPLICATION FEATURES
1. Information system
The information system is microprocessor based and re-
ports 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
diagnoses 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
flashing appropriately a LED. Using an (optional) additional
terminal the messages can be recorded and displayed in
easy readable form.
1.1 Programming sequence display
The built-in microprocessor controls not only the pro-
gramming 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 control ❘ ❘ .
thermostat
pre-ignition ❘ ❘ ❘ ❘ .
tv1
safety time ts ❚ ❘ .
post ignition tn
delay 2nd stage ❚ ❘ ❘ .
tv2
running ❘_
low mains voltage ❘ ❚ ❚ _
Description
❘= short pulse
❚= long pulse
. = short pause
_ = long pause
DKO 974/976 DKO 974 N/976N
1.2 Lock-out diagnoses
In case of a failure the LED is permanently illuminated. Every
10 seconds the illumination is interrup-ted 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 lock out safety time
no flame establishment
stray light ❘ ❘ ❚ ❚ ❚ stray light
during monitored phase,
detector may be faulty
limit thermostat ❘ ❘ ❘ ❚ ❚ contact of limit thermostat
time-out does not close within 400 sec.
Flash-Code for manual lock out
manual/external ❘ ❘ ❚ ❚ ❚ _ ❚ ❚ ❚ ❚ ❚
lock out
(see also 4. lock out and reset)
2. Flame control
The following detectors can be used for flame supervision:
– for yellow oil flame: photoresistor MZ 770 S
– for blue or yellow flame: infrared-flicker detector type IRD
1010 or as an alternative the UV solide state flame sensor
UVD 970
Generally, the no flame signal is generated at light levels
below 3 Lux with respect to the operating cycle of the
control. According to EN 230 stray light safety level has to
be established in conjunction with the accompanying burner.
Connecting the IRD 1010 or UVD 970, the correct wiring has
to be observed.
2.1 Stray light monitoring
The stray light check is performed at the end of the pre-
purge time for thr duration as mentioned in the technical
datas.

3
3. Burner control
With oil preheater
The fuel heater of the burner has to have a temperature
control switch. The closing contact-switch of the heater has
to be connected between terminals 4 and 6. A special
contact in the control unit connects the thermo-switch of the
heater as soon as the burner is operating and a photocurrent
is generated. Therefore an interruption of the burner operation
due to a decrease in oil temperature is prevented (e.g. in
case of high oil flow).
According to EN 230 A 2.1, the short circuiting of the ther-
moswitch is allowed only for an oil flow of max. 10 kg/h oil.
Burners with a higher throughput have to shut down if the oil
temperature gets below the allowed minimum. In such a
case the thermo-switch has to be put in the phase-circuit
and terminals 4 and 6 have to be connected with a link.
The contact of the release thermostat of the oil preheater is
monitored. If the contact does not close within the pre-
defined time (400 sec), the programmer goes into lock out
mode.
Therefore excessive oil temperatures in the preheater over
long periods can be prevented avoiding cracking of the oil
and oulsequent blocking of the preheater or nozzle.
Without oil preheater
In such a case the terminals 4 and 6 have to be connected
with a link.
Attention
The switch of the release thermostat for the oil
preheater must never be linked between 4 and 6
or 6 and 9!
During lockout, the preheater will not be separe-
ted from power. This could lead to a defective
pre-heater due to burn out its heating winding.
4. Lock out and reset
The unit can be reset or brought into lock out mode in two
different ways:
Internal
In the lock out case the unit can be reset by pushing the built-
in button meaning a new start-up cycle is performed.
External
Instead of using the built-in lock out button the same
function can be achieved by using an external button which
connects terminal 9 with A (see also circuit and block
diagram).
If the pushputton (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.
5. Low-voltage protection
The mains voltage has to be more than 187 Veff in order to
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 < 160 Veff during start-up or run time the control
box goes into lock out mode. If the voltage rises again, the
control box performs automatically a start-up as soon as the
mains voltage is > 187 Veff.
6. Safety
The design and control sequence of the DKO 974/976
controls will comply with the currently applicable standards
and regulations (see also TECHNICAL DATA).
7. Mounting and electrical wiring
Wiring base:
– 3 earth terminals with additional terminal for burner
earthing
– 3 neutral terminals with internal permanent connection to
neutral terminal 8
– 2 independant spare terminals (S1 and S2)
– extra terminals A, B and C are standard
– 2 slide-in plates and 2 easy knock out holes (PG11
thread) plus 2 knock out holes in the base bottom faciliate
the base wiring
The digital controls are ideally wiried on the new wiring
bases S98, which are equipped with (terminals B and C are
only for some special types of DMO or DMG) terminal A,.
which is used for the remote reset / remote lockout functions.
Please note
To assist trouble-free operation the main neutral
connection terminal in the wiring base must be
fully tightened. The terminal screws are already in
the undone position. To connect a wire to the
terminal, the screw only needs to be fastened.
General: The control box and detector probes should not be
subjected to excessive vibration.
DKO 974/976 DKO 974 N/976N

4
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 check-ed
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 precau-
tions 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 covered flame detector
– After lock out safety time is over the unit has to go into
lock out mode!
b) Start-up with exposed flame detector
– After 12 sec prepurge time the unit has to go into lock
out mode!
c) Normal start-up with burner in the normal position, cover
up the flame detector
– After start-up, and end of lock out safety time the unit
has to go into lock out mode!
3. Fault finding
The built-in information system facilitates the trouble shoot-
ing 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 reasen for the lock out is displayed
until the control box is reset, either by en
internal or external reset (see also subject “3.
Lock out and reset").
Removing the control box from its wiring base or by
interrupting the supply line may not reset a lock out (according
to EN 230). There fore, by applying power, the fan motor/
nozzle preheater switches on for 2-3 secs. before the
control box goes to lock out again and the cause of the last
lock out.
Error Possible fault
Burner not working - Thermostat circuit open
- Faulty electrical wiring
- Oil preheater defective
- mains voltage < 187 V
Fan motor/nozzle preheater - Control box has not been reset
starts for a short period of
time, control box goes to
louk out
Burner starts, - Stray light on flame detector
flame not established, - No ignition or no fuel
lock out
Burner starts, - Dirty or faulty flame detector
flame established, - Insufficient light on detector
after safety time, - Sensitivity adjustment
lock out too low on IRD
DKO 974/976 DKO 974 N/976N

5
*
*
CIRCUIT AND TIMING DIAGRAM DKO 974
CIRCUIT AND TIMING DIAGRAM DKO 976
BLOCK DIAGRAM DKO 974/976
term. 2
term. 1
term. 9
blue
black
brown
IRD 1010
UVD 970
IRD-/UVD-CONNECTION
IRD-/UVD-CONNECTION
term. 2
term. 1
term. 9
blue
black
brown
IRD 1010
UVD 970
FZMV1
OV SA
max. 10 A fast
6 A slow
V2 ZM V1 SA
FOV
12B34 56789A
EV
EV
black
blue
N
N
ST RT
HS
Ph
HS ST RT
Ph
µC
rz rv1b rs
RZ RV1 RV2 RS
12 345 6B7 89 A
rv2
rv1a
max. 10 A fast
6 A slow
black
blue
ta tv tf ts tn
ta tv1 tf ts tn tv2
FT
FT
Flame
amplifier
Reset
Reset and
lock out
Power
supply
monitoring
Fault display
Information
system
EEPROM
Oscillator
µC
Watchdog
Mains
monitoring
Power
supply
HS Mains switch
ST Limit thermostat
RT Control thermostat
EV External reset and lock out button
F Flame detector MZ 770 S
(IRD 1010/UVD 970 see separate diagram)
Z Ignition
M Burner motor
V1, V2 Solenoid valves
OV Oil preheater
FT Release thermostat oil preheater
* With burners without fuel heaters term.
4 and 6 have to be connected with a link
SA External lock out signal
ta Pre-heat-time oil preheater
tv1 Pre-purge and pre-ignition time
tf stray light monitoring
ts Lock out safety time
tn Post-ignition time
tv2 Delay time to oil V2
HS Mains switch
ST Limit thermostat
RT Control thermostat
EV External reset and lock out button
F Flame detector MZ 770 S
(IRD 1010/UVD 970 see ssparate diagram)
Z Ignition
M Burner motor
FT Release thermostat oil preheater
* For burners without fuel heaters term.
4 and 6 have to be connected with a link
V1 Oil solenoid valve
OV Oil preheater
SA External lock out signal
ta Pre-heat-time oil preheater
tv Pre-purge and pre-ignition time
tf stray light monitoring
ts Lock out safety time
tn Post-ignition time
12 3 4 5 6 7 8 9A
BLOCK DIAGRAM DKO 974/976
rz rv1b rs
345 6B7
rv2
µC
RZ RV1 RV2 RS
DKO 974/976 DKO 974 N/976N

6
A Honeywell Company
Satronic AG
Brüelstrasse 7
Postfach 324
CH-8157 Dielsdorf
DKO 974/976
DKO 974 N/976 N
DKO 974/976 AND SOCKET
SHAFT MZ 770 S
7,5
HOLDER FOR MZ 770 S
35
45,5
13
4,5
8,5 8
ø18
12,3 ø14
67,5
16
13
ø8,0
23,5
PHOTORESISTOR MZ 770 S
62,5
4,5
38,5
24
86
PG 11
60
24
30
30
44
M4
Earth
Reset button
57-60
25 35
30 Underside cable
entry ø16 mm
16
HOLDER M74 FOR IRD OR UVD
ø 14
35 3
ø20
48
4,5
26
4
7
ORDERING INFORMATION
ITEM DESIGNATION ITEM NO.
Control box DKO 974 Mod. 05 0314005
or DKO 976 Mod. 05 0316005
or DKO 974 N Mod. 05 0314705
or DKO 976 N Mod. 05 0316705
Socket Wiring base S98 75310
Insert plate PG-Plate 70502
optional Cable entry plate 70501
Flame detector MZ 770 S 50001
optional MZ 770 S with shaft 51001
optional IRD 1010 right 16501
IRD 1010 end-on 16502
IRD 1010 left 16503
optional UVD 970 16702
Support for flame detector Holder for MZ 770 S 59101
optional Holder M 74 for IRD or UVD 59074
Connection cable Plug type, 3 core cable, 0.6 m with tag wire ends 7236001
Connection cable Plug type, 2 core cable, 0.5 m with tag wire ends 7225001
The above ordering information refers to the standard version.
Special versions are also included in our product range. Specifications subject to change without noticSocket
Slide-in plate
VARIATION IRD
right
axial
UVD 970 IRD 1010
29 50
UVD = 29
IRD = 44
21,8
ø13,5
UVD = 89
IRD = 104
29
21,8
left