1 … 6

Technical descriptionThe DGAI.73 is an automatic gasburner controller as per EN 298 andhas the following features:

• Ionisation flame monitor• Program flow control by electronic

timers• Integrated cyclic spark ignition (de-

pending on model)• Pilot gas valve• Main gas valve• Ignition and flame monitoring with

common electrode or with sepa-rate ignition and ionisation elec-trodes

• A restart is attempted after loss offlame during operation (depend-ing on model)

• Non-volatile lock-out

Automatic gas burnercontroller for gas burn-ers with or without fanDGAI. 73

ApplicationDepending on the model, the DGAI.73automatic gas burner controller isdesigned for igniting and monitoringgas burners with or without fan and isfor intermittent operation. It conformsto EN 298.For application in extended tempera-ture range (-20°C to +60°C)

ApprovalEU type test approval as per EU GasAppliance Directive

DGAI. 73 CE-0085 AT 0063

Prin

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in G

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any

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ruck

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r. 2

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2 … 6

Automatic gas burner controllerDGAI.73The DGAI. 73 is installed in a plas-tic housing with RAST5 terminals.Assembled on a single PCB, theautomatic gas burner controlleruses electronic timers, this ensuresexact operating times, even in thecase of extreme voltage and tem-perature fluctuation or very shortoperating cycles.DGAI. 73 comprises:- the program control module,- the flame monitor which oper-

ates according to the ionisationprinciple,

- the ignition electronics and theintegrated ignition coil (depend-ing on model).

Models without air monitor: When thecontroller signals that heat is required,the ignition is activated after a max.startup delay period of 3 seconds, andthe pilot gas solenoid valve is opened.Models with air monitor: The DGAI.73waits until the contact of the air pres-sure monitor is open. Then the blower isswitched on again and waits until the airpressure monitor switches. At the endof the pre-purging time, the ignition isstarted and the pilot gas valve is opened.The ignition is switched off when thepilot flame signal is generated. At theend of the safety time (SZA), the maingas valve is opened if the flame is lit. Ifthe ignition flame goes out during thesafety time, the ignition is re-activatedinstantly.

If a flame is not formed during thesafety time, the ignition is switched offand interlocked in the fault state. If aloss of flame occurs during operation,all gas solenoid valves are switchedoff during the extinction safety time(SZB). The DGAI. 73 is then inter-locked in the fault state, or an attemptto restart the burner is made.In the case of a normal shut-down, thegas valves are closed. If the flamesignal is simulated before fuel feed isenabled, start-up is disabled for aslong as the flame signal is applied.

Fault remote unlockIn case of fault, the DGAI. 73 is un-locked via an external contact.

Program flow for models with-out air monitoring

Program flow for models withair monitoring

Startup without flame formation

AWZ SZA

ZR

Y1FY2AL

STVZ

ZR

AL

Flame failure during operation without recycling (Mod. TLL)

SZB

Y1FY2

STVZ

Flame failure during operation with recycling (Mod. TCL)

SZB SZA

ZR

Y1FY2

AWZAL

ZR

Y1

Y2AL

Startup with flame formation

F

AWZ SZA

Startup without flame formation

VSZ SZA

Z

R

Y1FY2AL

STVZ

BFPS

Flame failure without recycling

SZB STVZ

R

ZY1

Y2

AL

F

PSBF

Flame failure with recycling

VSZ SZA

R

ZY1

Y2

AL

F

PSBF

Z

Y2F

PS

SZB

ZY1

Y2

Startup with flame formation

F

VSZ SZA

PS

RBF

ZY1

Y2F

PSBF

ZY1

Y2F

PSBF

ZY1

Y2F

PSBF

AL

AWZ Waiting timeBF Blower motorF FlamePS Air pressure switchR1 ControllerAL Fault indicationSTVZ Fault interlock timeSZA Safety timeSZB Extinction safety timeVSZ Pre-purge timeY1 Pilot gas valveY2 Main gas valveZ Ignition

3 … 6

Terminal diagram for models with integrated ignition, single probe

Terminal diagram for models with integrated ignition, dual probe

Terminal diagram for models with external ignition

1 2 3

IN

X1

4 5

ST

1 2

PS

3 4

BF

5 6

Y1

7 8

Y2

Y 1 Y 2

X3

IZE

MB

AL RS

X2

R 1

L 1 N PS

M

IE

9 10

BFF 1

N N N N

P

AL External fault indicationBF Blower motorF1 Back-up fuse, max. 6.3 A, slow-blowIE Ionisation electrodeIT Ignition transformer

IZE Ionisation and ignition electrodeMB Wire jumper (cuttable)PS Air pressure switchR1 ControllerRS Remote unlock

X1...X3 Terminal designationY1 Pilot gas solenoid valveY2 Main gas valveZE Ignition electrode

1 2 3

X1

4 5 1 2 3 4 5 6 7 8

Y 1 Y 2

X3

ZE

MB

AL RS

X2

R 1

L 1 N PS

M

9 10

BF IE

F 1

IN ST PS BF Y1 Y2 IE

N N NN

P

1 2 3

X1

4 5 1 2 3 4 5 6 7 8

Y 1 Y 2 ZE

AL RS

X2

R 1

L 1 N PS

M

9 10

BF IEF 1

N

IN ST PS Y1BF Y2 IE

N N N

1 2

N

IT

X3

IT

1 2

X3

IT

GZP

4 … 6

Ionisation flame monitoringAn ionisation electrode serves as aflame probe, and the burner headusually serves as the earth. Pay atten-tion to good flame contact at the burnerhead.The burner head must be securelyconnected to PE to feed back theionisation current.The insulation resistance of the ionisa-tion electrode should exceed 50 MΩ.If a separate ionisation electrode isused (dual probe), jumper MB (on theright-hand side of the terminal) mustbe cut.Jumper MB is not installed with modu-lator B. Therefore, they can only beoperated with separate ignition andionisation electrode, or X2 9-10 mustbe bridged (IE plug).

Measuring the ionisation currentThe intensity of the ionisation currentcan be measured with a DC currentmicroammeter. The current intensityshould not be less than 3 µA in opera-tion. A fault cut-off occurs if the ionisa-tion current drops below approx. 1 µA.To measure the ionisation current, con-nect the micro-ammeter between theionisation electrode and the connector.If a common ignition and ionisation elec-trode (single probe) is used, jumper MBmust be cut so that the ionisation cur-rent can be measured. No jumper MBwith modulator B. On completion of themeasurement, terminals X2/9 and X2/10must be bridged instead of jumper MB.

InstallationThe automatic gas burner controllercan be installed in any position.For application in extended ambienttemperature range (-20°C to +60°C),DGAI.73 mod. WLE... must be installed

Connection to power supplyUse RAST5 connectors to connect theburner to the power supply (see Speci-fications). Wiring must be carried outin compliance with the prevailing localregulations and as shown in the wiringdiagram.

Ignoring the installationand operating instructions

may result in injury to life andlimb or damage to property. Com-pliance with the applicable in-structions is therefore impera-tive. Unauthorised tamperingwith the electronics will renderthe warranty for this equipmentnull and void.

If a fuse is faulty, the safetyof the automatic gas burn-

er controller must be checked,as there is a risk of contact weld-ing due to a short circuit.

CommissioningBefore starting up the burner control-ler, check that all terminals are prop-erly connected. When commission-ing the controller, check the followingsafety functions:- Switch off controllers, monitoring

devices and limiters (if any)- Switching points of gas pressure

switch (if any)- Disconnect flame monitor and ioni-

sation line or short-circuit the elec-trode to earth.

- Air pressure switch

FusesProtect the automatic gas burner con-troller externally using a 6.3A slow-blow back-up fuse or a 10A quick-acting fuse. Pay attention to the per-missible switching capacities.

Measuring instrument connectionfor models with integrated igni-tion (single probe)

Measuring instrument connec-tion for models with integratedignition (dual probe)

For dual probe, jumper MBmust be cut, otherwise the

flame will also be seen by theignition electrode!

1) cf. Measuring the ionisation current

2) cf.Ionisation flame monitoring

100 µF

= 0…100 µA

DGAI.73 + -

1)

X 3

X2/10

X2/9

MB

Measuring instrument connec-tion for models with external ig-nition

= 0…100 µA

DGAI.73 + -

X2/10X2/9

X2/10

X2/9

= 0…100 µA

DGAI.73 + -

X 3

MB 2)

The integrated electronicspark ignition is unsuitable

for igniting conventional gasburners with fan owing to the lowspark frequency and the shortspark duration.Version DGAI. 73 Mod. …-Zshould be used for this purpose.

The effects of leak searchspray and similar sub-

stances may cause dangerousflame-simulating conditions onionisation electrodes and con-ductors, e.g. ionisation amme-ters.Therefore please handle leaksearch sprays and similar sub-stances with extreme care so thatthey are only applied to the leaktest points.If it is not possible to limit the useof these substances, ionisationelectrodes and conductors mustbe protected before applying thesubstances. It is not sufficient tomerely wipe off the leak searchspray substance after application.

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Order dataType

DGAI. 73 Mod. 10.1.0 TCLDGAI. 73 Mod. 10.1.0 TCL-GDGAI. 73 Mod. 5.1.0 TCLDGAI. 73 Mod. 5.1.0 TLLDGAI. 73 Mod. 10.3.30 TCLDGAI. 73 Mod. 10.1.3 TCLDGAI. 73 Mod. 5.1.30 TCLDGAI. 73 Mod. 5.1.30 TCL-GDGAI. 73 Mod. 3.1.30 TLLDGAI. 73 Mod. 3.1.30 TLL-ZDGAI. 73 Mod. WLE 5.1.30 TCLDGAI. 73 Mod. B 10.1.0 TCLDGAI. 73 Mod. 5.1.10 TCL

Program listing for models withoutair monitoring and glow plug ignition

Program listing for models with airmonitoring and glow plug ignition

AWZ Startup delay periodBF Blower motorF FlamePS Air pressure switchR ControllerAL FaultSTVZ Fault interlock timeSZA Startup safety periodSZB Operating safety periodVSZ Pre-purging timeVGZ Glow timeY1 Pilot gas valveY2 Main gas valveZ Ignition

Startup without flame formation

AWZ SZA

ZR

Y1FY2AL

STVZ

ZR

AL

Flame failure without recycling (Mod. TLL)

SZB

Y1FY2

STVZ

ZR

Y1

Y2AL

Startup with flame formation

F

AWZ SZA

Flame failure with recycling (Mod. TCL)

SZB SZA

ZR

Y1FY2

AWZAL

VGZ

VGZ

VGZ

ZY1

Y2

Startup with flame formation

F

VSZ SZA

PS

RBF

ZY1

Y2F

PSBF

ZY1

Y2F

PSBF

ALVGZ

Startup without flame formation

VSZ VGZ

Z

R

Y1FY2AL

STVZ

BFPS

SZA

Startup without flame formation (Mod. TLL)

SZB STVZ

R

ZY1

Y2

AL

F

PSBF

Startup with flame formation (Mod. TCL)

VSZ SZA

R

ZY1

Y2

AL

F

PSBF

Z

Y2F

PS

SZB VGZ

Order No.

226 968229 121226 969226 970226 965226 967226 964229 120226 966226 971229 711229 713227 821

Classificationas per EN 298

ATCLXNATCLXNATCLXNATLLXNFTCLXNFTCLXNFTCLXNFTCLXNFTLLXNFTLLXNFTLLXNATLLXNFTCLXN

Connecteur set srew type

226 936226 933226 936226 936226 934226 934226 934226 933226 934226 933226 934226 936 Mod. B... no jumper MB226 934

Safety timeStart Operatingup

10 s 1 s10 s 1 s 5 s 1 s 5 s 1 s10 s 3 s10 s 1 s 5 s 1 s 5 s 1 s 5 s 1 s 5 s 1 s 5 s 1 s10 s 5 s 1 s

Type

DGAI. 73 Mod. 10.1.0 TCLDGAI. 73 Mod. 10.1.0 TCL-GDGAI. 73 Mod. 5.1.0 TCLDGAI. 73 Mod. 5.1.0 TLLDGAI. 73 Mod. 10.3.30 TCLDGAI. 73 Mod. 10.1.3 TCLDGAI. 73 Mod. 5.1.30 TCLDGAI. 73 Mod. 5.1.30 TCL-GDGAI. 73 Mod. 3.1.30 TLLDGAI. 73 Mod. 3.1.30 TLL-ZDGAI. 73 Mod. WLE 5.1.30 TCLDGAI. 73 Mod. B 10.1.0 TCLDGAI. 73 Mod. 5.1.10 TCL

Startupdelay period

5 s5 s5 s5 s-------5 s-

Pre-purgingtime

----30 s 3 s30 s30 s30 s30 s30 s30 s10 s

Extinctionsafety time

-10 s-----30 s-----

Restart Air moni-toring

Externalignition

6 … 6

Automatic gas burner controller forgas burners with and without fanDGAI. 73

Dimensions SpecificationsNominal voltage 230V -15% +10%Frequency 50 HzPower consumption approx. 5 VAInternal strip conductor fuse 2A, non-interchangeableBack-up fuse max. 6,3 A slow-blow/

10 A quick-actingSwitching capacities:Ignition 230 VAC/1 A (only for mo-

dels with external ignition)Ignition gas valve 230 VAC/1 AMain gas valve 230 VAC/1 AOverall switching capacity max. 2 ABlower motor 230 VAC/2 AFlame monitor ionisationIonisation current/operation > 3 µASwitch-off sensitivity < 1 µA (> 0.5 µA)Short-circuit current limitation approx. 100 µAIgnition cycle sparks

(only for models withintegrated ignition)

Ignition voltage approx. 15 kVIgnition frequency approx. 15 HzDistance betweenelectrodes 3 mm to 4 mmIgnition wire length max. 1 mFault remote unlock Remote unlockDegree of protection IP 20 - IP 40 must be

ensured by installationAmbient temperature 0°C to 60°C

WLE -20…+60°CConnectivity RAST5, encodedPE connection separateWeight 0.35 kg1) Lumberg: Insulation displacement terminal 3623.../

screw-type terminal 3611...

We reserve the right to make any changes in the interest of technical progress.

114

78

46

130

106

14,2

4,2Ø

MBX 1 X 2

X 3

67

47,5

DGAI. 73 Table of connectors

Function Slot No. No.of Code Con-poles nector No.

Pilot gas valve Y1 02 ...1) 02 K51Main gas valve Y2 02 ...1) 02 K53Blower motor BF 02 …1) 02 K49Power supply IN 02 …1) 02 K51Ion. measuring connection IE 02 …1) 02 K50Air pressure switch PS 02 …1) 02 K12High-voltage con- X3 01 Fast-Onnection 2,8 x 0,8 mmExternal fault display/ ST 03 …1) 03 K66unlockIgnition transformer IT 02 …1) 02 K44

Head Offices and FactoryKarl Dungs GmbH & Co.Siemensstraße 6-10D-73660 Urbach, GermanyTelephone +49 (0)7181-804-0Fax +49 (0)7181-804-166

Postal addressKarl Dungs GmbH & Co.Postfach 12 29D-73602 Schorndorf, Germanye-mail info@dungs.comInternet www.dungs.com