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Honeywell TC 1, Technical Information, Page: 1 / 55

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3 

Edition 08.17

AGA

Technical Information · GB

•  Adjustable test period which can be adapted to different systems
•  Adjustable test instant allows quick system start
•  Maximum safety thanks to self-monitoring electronics

Tightness controls TC

Safety manual for products complying with EN 61508-2

Summary of Contents for TC 1

Page 1: ...B Adjustable test period which can be adapted to different systems Adjustable test instant allows quick system start Maximum safety thanks to self monitoring electronics Tightness controls TC Safety manual for products complying with EN 61508 2 ...

Page 2: ...dure for TC 1 TC 2 TC 3 22 3 1 4 Test instant TC 1 TC 2 TC 3 24 3 1 5 Test instant for Mode 1 testing before burner run 24 3 1 6 Test instant for Mode 2 testing after burner run 25 3 1 7 Test instant for Mode 3 testing before and after burner run 26 3 1 8 Measurement time tM for TC 1 TC 2 TC 3 27 3 1 9 Calculation example for tM 27 3 2 TC 4 28 3 2 1 Connection diagram 28 3 2 2 Test procedure TC 4 ...

Page 3: ...ther classifications 49 8 1 3 Electrical data 49 8 2 Interfaces 50 8 2 1 Electrical wiring 50 8 2 2 Connection terminals 50 8 2 3 Inputs 50 8 2 4 Outputs 51 8 3 SIL and PL for TC 1 TC 2 TC 3 51 9 Maintenance cycles 52 10 Glossary 53 10 1 Tightness control 53 10 2 Valve proving system VPS 53 10 3 Safety interlocks 53 10 4 Diagnostic coverage DC 53 10 5 Operating mode 53 10 6 Hardware fault toleranc...

Page 4: ...lers and on forced draught burners Standards ISO 13577 2 EN 746 2 and EN 676 stipu late tightness controls for capacities over 1200 kW NFPA 86 from 117 kW or 400 000 Btu h in conjunc tion with a visual indicator Pre purge of the combus tion chamber can be dispensed with under certain conditions in accordance with EN 746 2 if a tightness control is used In this case the system must be vented into a...

Page 5: ...re range of 0 to 60 C 32 to 140 F An adapter plate is provided for installation of the TC 2 TC 3 Tightness control TC 3 is a universal device for quick and slow opening gas solenoid valves of any nominal size as well as for motorized valves The tightness test is carried out with the valves installed in TC 3 TC 4 Tightness control TC 4 consists of detection circuitry and can be installed in the con...

Page 6: ...TC Edition 08 17 6 Application TC 1V on a valVario double solenoid valve TC 4 installed separately from the system in a control cabinet ...

Page 7: ...oltage control voltage V1 quick or slow opening valve with start rate V2 pressure regulator with solenoid valve Tightness control TC 1V checks gas solenoid valves V1 and V2 and the pipe between the valves for tightness If both valves are tight the TC forwards the OK enable signal to the automatic burner control unit GFA This opens valves V1 and V2 simultaneously The burner starts V1 V2 VAD VAS PZ ...

Page 8: ...trol CG D or CG V and checks gas solenoid valves V1 and V2 in the combination control for tightness Once the tightness test has been carried out success fully the tightness control forwards the OK enable signal to the automatic burner control unit GFA This opens valves V1 and V2 in the combination control CG simultaneously The burner starts V1 pu 2 CG V1 V2 PZ pu pz TC 1C PZ VP TC 1C 9 OK GFA ...

Page 9: ...ening valves with start rate TC 2 checks gas solenoid valves V1 and V2 and the pipe between the valves for tightness If both valves are tight the TC forwards the OK enable signal to the automatic burner control unit GFA This opens valves V1 and V2 simultaneously The burner starts V2 V1 pu 2 V1 V2 PZ pu pz TC 2 VP TC 2 9 OK GFA ...

Page 10: ...hat the interspace pz is vented dur ing the 3 second opening time This is not guaranteed by the gas pressure regulator downstream of V2 A relief line is thus used to discharge the test volume VP safely into the combustion chamber or into a safe area Auxil iary valve V3 can also be used as a pilot gas valve Since valve V2 remains closed during the test it can also be a slow opening motorized valve ...

Page 11: ...hecks gas solenoid valves V1 V2 the auxiliary valve V3 and the pipe between the valves for tightness If all the gas solenoid valves are tight the tightness control forwards the OK enable signal to the automatic burner control unit GFA The GFA opens the gas so lenoid valves V1 and V2 simultaneously The burner starts A relief line is used to discharge the test volume VP into a safe area Thanks to th...

Page 12: ...es V3 and V4 and the pipe between these valves for tightness Valve V2 can only be checked for tightness when the pressure downstream of V2 approximately corresponds to the atmospheric pressure and the volume down stream of valve V2 is 5 x VP The gas solenoid valve VAS and the pressure switch DGVAS are used to relieve the pressure The pressure switch must be adjusted in such a way so that enough pr...

Page 13: ...approximately corresponds to the atmospheric pressure and the volume down stream of valve V2 is 5 x VP The gas solenoid valve VAS and the pressure switch DGVAS are used to relieve the pressure The pressure switch must be adjusted in such a way so that enough pressure is relieved and no air can get into the pipework Once the tightness test has been carried out success fully TC 3 opens the main valv...

Page 14: ...alves for tightness The external pressure switch DG monitors the pressure between the two valves Once the tightness test has been carried out success fully TC 4 forwards the OK enable signal to the auto matic burner control unit GFA The GFA opens the gas solenoid valves V1 and V2 simultaneously The burner starts 1 2 3 4 5 6 7 8 9 10111213 OK L1 N TC 4 pu 2 V1 V1 V2 V2 pu PZ TC 4 pz VP PZ DG GFA ...

Page 15: ...t the interspace pz is vented dur ing the 2 second opening time This is not guaranteed by the gas pressure regulator downstream of V2 A relief line is thus used to discharge the test volume VP safely into the combustion chamber or into a safe area Since valve V2 remains closed during the test it can also be a slow opening motorized valve VK If all the gas solenoid valves are tight TC 4 forwards th...

Page 16: ...lume VP is supplied via the auxiliary valve V3 The external pressure switch DG monitors the pressure between the gas solenoid valves V1 V2 and the burner valves Once the tightness test has been carried out success fully TC 4 opens gas solenoid valve V1 The TC forwards the OK enable signal simultaneously to the automatic burner control units for the burner valves The burner valves open and the burn...

Page 17: ... VAS and the pressure switch DGVAS are used to relieve the pressure The pressure switch must be adjusted in such a way so that enough pressure is relieved and no air can get into the pipework After the thermostat start up signal ϑ has been applied first DGVAS is checked If the pressure downstream of V2 is correct the VAS closes and the tightness test is started Once the tightness test has been car...

Page 18: ...08 Pursuant to EN ISO 13849 1 Table 4 TC 1 TC 2 and TC 3 can be used up to PL e EU certified pursuant to Directives Gas Appliances Directive 2009 142 EC valid until 20 April 2018 in conjunction with EN 1643 EN 60730 and EN 61000 6 2 Low Voltage Directive 2014 35 EU EMC Directive 2014 30 EU Regulation Gas Appliances Regulation EU 2016 426 valid from 21 April 2018 ...

Page 19: ...y overpressure slam shut valves Designed for applica tions pursuant to NFPA 85 and NFPA 86 www approv alguide com UL listed USA and Canada 120 V Standard UL 353 Limit control Link to Underwriters Laboratories www ul com Tools at the bottom of the page Online Certifications Directory Canadian Standards Association CSA C22 2 No 24 AGA approved AGA Australian Gas Association Approval No 4581 http www...

Page 20: ...C see page 37 Selection OK V2 TC 1 TC 2 V1 V1 inlet valve V2 outlet valve Remote reset by applying control voltage to terminal 11 or via a floating contact between terminals 8 and 11 TC 1 W K TC 1 Q K TC 2 W K or TC 2 Q K Mains voltage 120 V AC or 230 V AC Control voltage 24 V DC see page 37 Selection TC 1 TC 2 V2 V1 OK V1 inlet valve V2 outlet valve Remote reset by applying control voltage 24 V t...

Page 21: ... 120 V AC or 230 V AC see page 37 Selection OK TC 3 Remote reset by applying control voltage to terminal 11 or via a floating contact between terminals 8 and 11 TC 3 W K or TC 3 Q K Mains voltage 120 V AC or 230 V AC Control voltage 24 V DC see page 37 Selection OK TC 3 Remote reset by applying control voltage 24 V to ter minal 11 ...

Page 22: ... pu 2 valve V2 is leaking If pressure pz is greater than half the inlet pressure pu 2 valve V2 is tight Valve V2 is opened for the set opening time tL V2 closes again During the measurement time tM the tightness control checks the pressure pz between the valves If pressure pz is greater than half the inlet pressure pu 2 valve V1 is leaking If pressure pz is less than half the inlet pressure pu 2 v...

Page 23: ... V2 is leaking If pressure pz pu 2 valve V2 is tight The tightness test can only be performed if the pres sure downstream of V2 is around atmospheric pressure and the volume downstream of V2 is at least 5 x higher than the volume between the valves If the power fails briefly during the test or during opera tion the TC will restart in accordance with the test pro cedure described above If there is ...

Page 24: ...l OK V1 is active the OK enable signal is forwarded to the automatic burner control unit The tightness test is valid for up to 24 hours If the safe ty interlock input signal OK is not connected during this time the test is started again with the application of the safety interlock input signal Once the test has been completed successfully the OK enable signal is issued L1 ϑ TEST OK Mode 1 t 1 10 6...

Page 25: ...the automatic burner control unit again once the thermostat start up signal ϑ and the safety interlock input signal OK have been re applied The tightness test is valid for 24 hours If the thermo stat start up signal ϑ and the safety interlock input signal OK are connected during this time a new tight ness test must not be carried out before burner run and the OK enable signal is set However if the...

Page 26: ...the valves are tight the LEDs 1 2 Power and 1 2 Power are green Once the safety interlock input signal OK V1 V2 is active the OK enable signal is forwarded to the automatic burner control unit see page 24 Test instant for Mode 1 testing before burner run The second test is carried out after burner run as with Mode 2 The tightness test after burner run starts when the thermostat start up signal ϑ d...

Page 27: ... Without jumper no function The 1 2 Power LED is permanently red The required measurement time tM is calculated from Qmax max flow rate m3 h QL leakage rate l h Qmax m3 h x 0 1 see page 35 Leakage rate QL pu inlet pressure mbar VP test volume l see page 34 Test volume VP for TC 1 TC 2 TC 3 TC 4 Converting units see www adlatus org Measurement time tM tM s 2 5 x pu mbar x VP l QL l h For all combin...

Page 28: ...ct on terminals 8 and 9 signalling contact not internally fused max 1 A for 220 240 V high voltage 264 V max 2 A for 120 V Connect the NO contact on the pressure switch to ter minals 6 and 7 1 2 3 4 5 6 7 8 9 10 11 12 13 L1 V1 L1 V2 OK max 1 A 264 V ϑ L1 N pu 2 5 AT TEST OK V1 1 2 V2 PZ ...

Page 29: ... TEST V1 V2 PZ 2 Test procedure A Test procedure B START Test procedure A If pressure pz is greater than half the inlet pressure pu 2 valve V2 is tight Valve V2 is opened for the opening time tL 2 s V2 closes again During the measurement time tM the tightness control checks the pressure pz between the valves If pressure pz is greater than half the inlet pressure pu 2 valve V1 is leaking If pressur...

Page 30: ... V2 is around atmospheric pressure and the volume downstream of V2 is at least 5 x higher than the volume between the valves The tightness control TC runs program A or Bdepend ing on the initial situation Both valves are checked for tightness respectively but only one valve is opened at a time During the test the TC also checks their fail safe opera tion After a brief power failure during the tigh...

Page 31: ... switched on The tightness test starts with incomingthermostat start up signal ϑ If the valves are tight the green OK LED lights up The OK en able signal is forwarded to the automatic burner control unit L1 ϑ TEST OK OK tp ϑ TEST OK 1 2 OK 1 2 Mode t L1 1 5 6 7 1 5 6 7 t tp TEST 1 2 V1 undicht V2 undicht If the tightness control TC detects a leak on one of the two valves the red LED lights up for ...

Page 32: ...t until the thermostat start up signal ϑ has been applied The tightness test after burner run starts when the thermostat start up signal ϑ drops The OK enable signal is not forwarded to the automatic burner control unit again until the thermostat start up signal ϑ has been re applied ϑ TEST OK OK ϑ TEST OK L1 L1 1 5 6 7 1 5 1 1 2 tp t 1 2 Mode TEST V1 undicht V2 undicht If the tightness control TC...

Page 33: ...r on the right in the picture The test period tP can be adjusted in intervals TC 410 1 10 s to max 60 s 10 s factory setting 60 s without jumper TC 410 10 100 s to max 600 s 100 s factory setting 600 s without jumper The required test period tP is calculated from Qmax max flow rate m3 h QL leakage rate l h Qmax m3 h x 0 1 see page 35 Leakage rate QL pu inlet pressure mbar VP test volume l see page...

Page 34: ...opening valves see page 38 Project planning information Valves Valve volume VV l Nominal size DN 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 2 65 3 3 VG 80 VK 80 4 80 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...

Page 35: ...ement time is set It is possible to check a specific leakage rate QL using the TC Within the scope of the European Union the maximum leakage rate QL is 0 1 of the maximum flow rate Q n max m3 h Leakage rate QL l h Q n max m3 h x 1000 1000 If a small leakage rate QL is to be detected a long test period measurement time must be set ...

Page 36: ...controlled using the control bar at the bottom of the window as on a DVD player To play the animation you will need Adobe Reader 7 or a newer version If you do not have Adobe Reader on your system you can download it from the Internet If the animation does not start to play you can down load it from the document library Docuthek as an in dependent application ...

Page 37: ...lves R N With Rp internal thread With NPT internal thread 05 pu max 500 mbar W Q K Mains voltage 230 V AC 50 60 Hz 120 V AC 50 60 Hz 24 V DC W Q K Control voltage 230 V AC 50 60 Hz 120 V AC 50 60 Hz 24 V DC 4 2TC 4 4 2 1 Selection table 1 10 T N K TC 410 standard available Order example TC 410 10T 4 2 2 Type code Code Description TC Tightness control 4 In control cabinet 1 Testing before or after ...

Page 38: ... V A S 3 5 0 V A S 2 4 0 V A S 2 5 0 V A S 3 6 5 V A S 1 2 0 Project planning information 5 Project planning information On slow opening valves without start rate or pneumatically oper ated valves the test volume can be supplied or discharged via auxiliary valves if discharge into the furnace chamber is impossible for process reasons 5 1 Selecting the auxiliary valves Example VP 32 45 l 8 44 gal p...

Page 39: ... not store or install the unit in the open air The tightness control TC must not be in contact with masonry minimum distance 20 mm 0 78 inches 5 3 1 TC 1V for solenoid valves for gas VAS VCx The valve actuator cannot be rotated on gas solenoid valves with a proof of closure switch VCx S or VCx G When using a valve pressure regulator combination VCG VCV VCH the pressure regulator must be acti vated...

Page 40: ... to the inlet pressure connection pu the intermediate pressure connection pz and the outlet pressure connection pd of the inlet valve Use a 12 x 1 5 or 8 x 1 pipe for the pipe connections pz pd pz pu TC 3 R Rp TC 3 N NPT 5 3 5 TC 4 On the TC 4 the external pressure switch is mounted on the interspace between the valves to be monitored The TC can be installed separately from the valves For installa...

Page 41: ...ocket can be supplied as an accessory see page 42 Accessories 5 5 Determining the relief line size The nominal diameter of the relief line should be large enough to discharge the test volume VP The cross sec tion of the relief line should be 5 times the sum of the cross sections of all pipes whose volume is intended to be discharged via the relief line ...

Page 42: ...C for monitoring the pressure between the valves to be checked For inlet pressures of 0 5 to 500 mbar 0 2 to 195 WC The switching differential may not exceed 10 of the set switching pressure see Technical Information bulletin Pressure switch for gas DG DG C at www docuthek com Adjustment The external pressure switch is set to half the inlet pres sure pu 2 only NO contact required in order to check...

Page 43: ...ax 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 t...

Page 44: ...20 g 0 92 lbs 7 2 TC 4 Electrical data Mains voltage 110 120 V AC 15 10 50 60 Hz 220 240 V AC 15 10 50 60 Hz 24 V DC 20 Power consumption 10 VA for 110 120 V AC and 220 240 V AC 1 2 W for 24 V DC Fusing fine wire fuse 5 A slow acting H pursuant to IEC 127 also protects the valve outputs and external operating signal Switching current for valves enable output max 5 A External operating signal with ...

Page 45: ...2 External pres sure switch for TC 4 Test period tP TC 410 1 10 to 60 s adjustable Set at the factory to 10 s TC 410 10 100 to 600 s adjustable Set at the factory to 100 s Ambient temperature 15 to 60 C 5 to 140 F no condensation permitted Storage temperature 15 to 40 C 5 to 104 F Mechanical data Enclosure IP 40 5 knock out holes for M16 plastic cable glands Screw terminals 2 5 mm2 AWG 14 Housing ...

Page 46: ...ow TC is ready for operation safety interlock input signal interrupted 1 2 Power green TCisreadyforoperation activesafetyinterlock inputsignal 1 2 Power green V1 is tight 1 2 Power yellow V1 is untested 1 2 Power yellow Tightness test is running on V1 1 2 Power red V1 is leaking 1 2 Power green V2 is tight 1 2 Power yellow V2 is untested 1 2 Power yellow Tightness test is running on V2 1 2 Power r...

Page 47: ...d pu pz pz 135 5 5 217 8 5 84 3 3 92 3 6 40 1 6 95 3 7 46 8 1 8 Rp NPT Rp NPT OK TEST 1 2 113 4 4 70 2 8 ø 5 0 2 85 3 3 35 1 4 75 3 TC 1 TC 2 TC 3 TC 4 Inlet pressure connection pu intermediate pressure connection pz and the outlet pressure connection pd 7 5 Converting units see www adlatus org ...

Page 48: ...ilure PFHD 17 5 x 10 9 1 h General Mean probability of dangerous failure PFHD Auxiliary valves with valve block on TC 3 0 2 x 10 9 1 h Type of subsystem Type B to EN 61508 2 Operating mode High demand mode pursuant to EN 61508 4 Continuous operation to EN 1643 Mean time to dangerous failure MTTFd 1 PFHD Safe failure fraction SFF 97 5 Pursuant to EN ISO 13849 1 Table 4 TC 1 TC 2 and TC 3 can be use...

Page 49: ...eristic of automatic action type 2 AD pursuant to EN 60730 2 5 Section 6 4 104 Switching off the safety relevant output signals the safety relevant output signals are switched off via relays This is a shut down with micro switch pursuant to EN 60730 1 Sections 6 4 3 2 and 6 9 2 Fault lock out Non volatile fault lock out action type 2 V pursuant to EN 60730 2 5 Section 6 4 101 8 1 2 Other classific...

Page 50: ...equirements of SELV Protected extra low voltage PELV If the TC 1 TC 2 TC 3 is supplied with PELV all con nected cables must not be longer than 10 m 8 2 2 Connection terminals Supply and control signal terminals Mains voltage control voltage 24 V DC 120 V AC or 230 V AC power is supplied to the TC via connection terminals 1 L1 and 3 N Further terminal assignment see connection diagrams 120 V AC or ...

Page 51: ...at 24 V DC 120 V AC or 230 V AC mains voltage and control voltage max 5 A resistive load at 120 V AC 230 V AC mains voltage and 24 V DC con trol voltage max 100 mA 8 3 SIL and PL for TC 1 TC 2 TC 3 Safety function The basic safety function of the TC 1 TC 2 TC 3 is to check that automatic shut off valves have closed effec tively by detecting leakage Classification Class C regulating and control fun...

Page 52: ...TC Edition 08 17 52 Maintenance cycles 9 Maintenance cycles 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 ...

Page 53: ...e application The burner start enable signal is issued via the safety interlock out put terminal 6 10 4 Diagnostic coverage DC Measure of the effectiveness of diagnostics which may be determined as the ratio between the failure rate of detected dangerous failures and the failure rate of total dangerous failures NOTE Diagnostic coverage can exist for the whole or parts of a safety related system Fo...

Page 54: ...lure PFHD Value describing the likelihood of dangerous failure per hour of a component for high demand mode or con tinuous mode Unit 1 h see EN 13611 A2 10 8 Mean time to dangerous failure MTTFd Expectation of the mean time to dangerous failure see EN ISO 13849 1 ...

Page 55: ... Use To get to know the product To choose a product Planning To look for information My scope of functions Technical department Sales No answer Remarks Elster GmbH Postfach 2809 49018 Osnabrück Strotheweg 1 49504 Lotte Büren Germany Tel 49 541 1214 0 Fax 49 541 1214 370 hts lotte honeywell com www kromschroeder com Contact The current addresses of our international agents are available on the Inte...

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