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GAS CONTROLS FOR COMBINED VALVE AND IGNITION SYSTEM
VK41../VK81..SERIES
APPLICATION
The Combined Valve and Ignition (CVI) system has been
developed for application in gas fired domestic central heating
boilers, combi boilers and warm air furnaces or water heater
appliances with an automatic ignition system.
For this system, the VK41../VK81.. series gas controls have
been designed to have the S4565/S4575/S4585 series
ignition control attached directly on to the valve.
The combined system then provides programmed safe light
up, flame supervision and regulation of gas flow to the main
burner and/or pilot burner of the appliance.
The VK41.5/VK81.5 series gas controls (without pilot outlet)
can also be used alone in direct burner ignition applications.
A plug (order number 45.900.441- ) with integrated rectifier
circuit then has to be used on the gas control.
Description ...................................................................... 2
Features .......................................................................... 3
Dimesional ..................................................................... 4
Application ...................................................................... 6
Technical
Specifications .................................................................. 7
Electrical data .............................................................. 10
Capacity curves ....................................................... 13-18
Performance characteristics .......................................... 19
Installation ..................................................................... 21
Electrical connections and wiring .................................. 24
Adjustments and checkout ............................................ 25
Construction and working principles ............................. 26
Various
Quality assurance statement ......................................... 29
Standards and approvals .............................................. 30
Ordering information ..................................................... 31
Replacement parts and accessories ............................. 32
1
PRODUCT HANDBOOK
Contents
page
EN2R-9004 0606R20-NE
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Table of Contents
Related Manuals for Honeywell vk41 series
Summary of Contents for Honeywell vk41 series
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Page 1: Table Of Contents
VK41../VK81..SERIES GAS CONTROLS FOR COMBINED VALVE AND IGNITION SYSTEM PRODUCT HANDBOOK APPLICATION The Combined Valve and Ignition (CVI) system has been developed for application in gas fired domestic central heating boilers, combi boilers and warm air furnaces or water heater appliances with an automatic ignition system. -
Page 2: General
DESCRIPTION Valves General All measurements are carried out under standard conditions The Combined Valve and Ignition (CVI) system controls and listed below unless otherwise is indicated. performs all the functions required for safe ignition, flame supervision and for safely regulating the gas flow to the pilot Standard conditions and/or main burner. -
Page 3: Features
FEATURES General Gas connection options • All burner control safety functions concentrated in one reli- • Internal thread (ISO 7-1), external thread (ISO-R228) or able and optimized system. flanged connections. See table 4, 5, 6 and 7, page 9. • Specially designed to provide the optimum system solution •... -
Page 4: Dimesional
DIMESIONAL DRAWING STANDARD CONNECTION EN2R-9004 0606R20-NE... - Page 5 DIMESIONAL DRAWING EXTERNAL THREAD CONNECTION 94.8 Hole Ø 2.6 to connect 13.4 ignition control 24.9 84.5 Earth terminal 84.5 The cross hatched Molex 1.1 square pin header area is sealing face (mating connecters 3001 series Pressure feedback 29.3 without imperfections connection Inlet "...
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Page 6: Application
APPLICATION The VK41.. /VK81..series gas control have been specially When connected with a Honeywell specified rectifier plug and developed for application in domestic appliances. lead the VK4105 series valve can be used with any standard 220/240 Vac DBI ignition system. -
Page 7: Specifications
SPECIFICATIONS NOTE: Specifications for electrical modulation, electrical Minimum differential pressure high low, gas/air and other features are available on Table 1: Minimum differential pressure request. ∆P min (mbar) Model Models VK4105 See model number chart on page 31 VK4115 VK4125 Main gas connection •... - Page 8 Capacity In m /h air at pressure drop as shown below. See also the capacity curves concerned. ∆P (mbar) Model Extention Capacity (m /h air) Capacity curve Number Page VK410X/VK810X A, B, C, D, M, N, P, Q H 10 E, T H 160 VK411x/VK811x...
- Page 9 Table 4: Standard valve connection Table 5: External valve connection (optional) Inlet End outlet Side outlet Body length Inlet End outlet Side outlet Body length (mm) (mm) Flanged Flanged ” ” Flanged Flanged ” Flanged Internal ” Flanged ” ” ISO 7-1 ”...
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Page 10: Electrical Data
ELECTRICAL DATA Table 8: Electrical connection for Direct Burner Ignition systems Supply voltage Coil indication Rectifier circuit Coil connection ( fig. 1 ) Valve indication position 24 Vac, 50/60 Hz 24 Vrac External Series connection pin1 and pin 5 or VK 81.5 plug 45.900.441-029 24 Vac, 50/60 Hz... - Page 11 Pin number Fig. 1. Coil connection Rectifier plug The 220/240 V,110V and 24 V versions of the VK4105/ VK8105 series gas controls can be connected to any standard DBI control with a 220/240 Vac, 110V or 24 Vac output by using a rectifier plug 45.900.441- See table 11.
- Page 12 Table 11: Rectifier plugs Order number Supply Wires Cable Plug Cable end voltage length Vac unless (mm) config Rectifier screw config strip Special Finish specified length (mm) 45.900.441-011 220/240 fig. 25 in bag fig 20 solder dip 45.900.441-012 fig. 25 in bag fig 22 45.900.441-013...
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Page 13: Capacity Curves
CAPACITY CURVE H10 (CVI) MINIMUM CAPACITY CURVE BG1/BG2 VK410./VK810. BP: 50/0 SIZE: 1/2" DATE: 96-06-11 REV: 3 G110/120 G140 FLOW (m³/h) at 1013 mbar and 15˚C, dry EN2R-9004 0606R20-NE... - Page 14 CAPACITY CURVE H20 (CVI) MINIMUM CAPACITY CURVE V K 411 ../V K 811 .. ,V B RE V: 4 S V /MV: 17/17 B P: 50/10 S I ZE: 1/2" DATE: 14-10-02 G110/120 G140 G 20 G 25 G 30 F L O W ( m /h) at 1013 mbar and 15 C, dry...
- Page 15 CAPACITY CURVE H140 (CVI) MINIMUM CAPACITY CURVE BG1/SM2 VK411. / VK811. BP: 50/10 SIZE: 1/2" DATE: 96-06-11 REV: 0 H140 G110/120 G140 FLOW (m³/h) at 1013 mbar and 15˚C, dry EN2R-9004 0606R20-NE...
- Page 16 CAPACITY CURVE H150 (CVI) MINIMUM CAPACITY CURVE BG1/SM2 VK412./VK812. BP: 50/50 SIZE: 1/2" DATE: 96-06-11 REV: 0 H150 G110/120 G140 FLOW (m³/h) at 1013 mbar and 15˚C, dry EN2R-9004 0606R20-NE...
- Page 17 CAPACITY CURVE H160 (CVI) MINIMUM CAPACITY CURVE BG1/BG2/THR VK410.E,T/VK810.E,T BP: 50/0 SIZE: 1/2" DATE: 96-06-11 REV: 0 H160 G110/120 G140 FLOW (m³/h) at 1013 mbar and 15˚C, dry EN2R-9004 0606R20-NE...
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Page 18: Capacity Curves
CAPACITY CURVE H170 (CVI) MINIMUM CAPACITY CURVE BG1/BG2/THR VK411.E,T/VK811.E,T BP: 50/10 SIZE: 1/2" DATE: 96-06-11 REV: 0 H170 G110/120 G140 FLOW (m³/h) at 1013 mbar and 15˚C, dry EN2R-9004 0606R20-NE... -
Page 19: Performance Characteristics
PERFORMANCE CHARACTERISTICS Maximum allowable leakage 110% of the rated voltage. Each gas control is factory tested to meet the following Table 12: Operable voltage range leakage requirements: • outerwall: 50 cm /h at test pressure of 150 mbar. Rated voltage Operable voltage •... - Page 20 Oscillation Total set point shift Maximum oscillation under all circumstances: 0.5 mbar. Table 14: Total set point shift servo regulator on/off ± version* Tap sensitivity of outlet pressure set point Pressure range Tolerance For all gases the maximum deviation may be 1 mbar. 1.5 ...
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Page 21: Installation
INSTALLATION Gas controls for flange connection IMPORTANT IMPORTANT • Insert ”O”-ring in the groove of each flange. If necessary Take care that installer is a trained experienced grease ”O”-ring slightly to keep it in place. service man. • Mount gas control between flanges using the four screws Turn off gas supply before starting installation. - Page 22 With ” nut and olive ( fig. 5 .) With ” nut and flat sealing ring for pipe 18 mm ( fig. 4 .) Pipe diameter: 15 mm Nut: drawing: ........45.006.583-002 Nut: drawing:........45.006.583-003 Flat sealing ring according to DIN 3535-6 with size ∅24 x ∅16 x 1.5 mm Fastening torque: maximum 50 Nm minimum 30 Nm...
- Page 23 Pilot gas connection (if applicable) Perform gas leak test • Square off the end of tubing and remove burrs. • Slip compression fitting over tubing. WARNING • Insert tubing into gas control housing until it bottoms, slide FIRE OR EXPLOSION HAZARD CAN CAUSE fitting into place and turn finger tight.
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Page 24: Electrical Connections And Wiring
ELECTRICAL CONNECTIONS AND WIRING Assembly of cover with integrated strain relief ( fig. 13 .) IMPORTANT IMPORTANT Position the cover on the ignition control. Then, when holding Wiring must be in accordance with local regulations. the cover down (in direction A) rotate it to mount the cable(s) in The appliance manufacturer’s instructions should the strain relief (in direction B). -
Page 25: Adjustments And Checkout
ADJUSTMENTS AND CHECKOUT adjustment (see page 4) SOFTLITE IMPORTANT IMPORTANT pressure can be increased from the rated SOFTLITE Adjustments must be made by qualified persons only. to optimise the ignition or to change over to another SOFTLITE If the appliance manufacturer supplies checkout and/ gas type. -
Page 26: Construction And Working Principles
CONSTRUCTION AND WORKING PRINCIPLES Servo pressure regulation relieving some of the working pressure. This reduces the force against the main valve spring allowing the main valve to close The VK4100/VK8100 series gas controls features the positive proportionately. Thus the main valve limits the outlet (or servo system, i.e. - Page 27 SOFTLITE Fast open Some burners function well using a fast opening valve with the pressure build up as shown in fig. 15. However, other burner/ SOFTLITE appliance combinations need a means of improving their ignition characteristics by providing quieter ignition and reducing flame roll-out.
- Page 28 Fig. 17. Safety valve and main valve open position Example: curve VK41../VK81.. SOFTLITE spring: 5 mbar SOFTLITE Gas family: LP Gas (G30, G31 Inlet pressure: 37 mbar Adjustable setting positioning SOFTLITE Time (seconds) Fig. 18. Adjustable SOFTLITE EN2R-9004 0606R20-NE...
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Page 29: Quality Assurance Statement
At the end of the assembly phase, all gas controls are leakage and certified Quality System. and performance tested/adjusted. The quality system is described in the Honeywell Combustion Assembly inspection is performed by employees of the quality Controls Center Quality Assurance Programme and its related control department, using their own authorised equipment. -
Page 30: Standards And Approvals
STANDARDS AND APPROVALS Standards Approvals The gas control has been designed to meet the European The gas control conforms with the following EC - Directives: • Gas Appliance Directive (90/396/EEC) Standards: • Low Voltage Directive (73/23/EEC) EN 88: Pressure govenors •... -
Page 31: Ordering Information
”TRADELINE” label. Ask your wholesaler for details. model number chart below. • The correct pilot burner for the installation concerned: refer to Honeywell ignition products guide EN0R-0038. Ordering Specification number VK 4 1 0 A 9999... -
Page 32: Replacement Parts And Accessories
REPLACEMENT PARTS AND ACCESSORIES Contents Replacement parts and accessories page Flange assemblies............32 Fitting ................32 Gas pressure switch ............. 33 Miscellaneous ............... 33 Plugs ................33 FLANGE ASSEMBLIES Connection size Configuration ”O”-ring and Packing quantity Order number screws (pcs) Straight Elbow ”... - Page 33 GAS PRESSURE SWITCH Description Packing quantity Ordernumber Switch point ON: 15.5 1; switch point OFF: 13 1, gold plated contacts, red sealing 45.900.438-107 ± ± Switch point ON: 15.5 1; switch point OFF: 13 1, AgNi contacts, blue sealing 45.900.438-109 ±...
- Page 34 15.5 20.1 24.8 47.8 34.5 27.5 12.5 45.7 30.5 10.2 30.5 11.7 Fig. 24. Fig. 25. M a n u f a c t e r e d f o r a n d o n b e h a l f o f t h e E n v i r o n m e n t a l a n d C o m b u s t i o n C o n t r o l s D i v i s i o n o f H o n e y w e l l S à r l , E c u b l e n s , R o u t e d u B o i s 3 7 , S w i t z e r l a n d b y i t s A u t o r i z e d R e p r e s e n t a t i v e : A u t o m a t i o n a n d C o n t r o l S o l u t i o n s C o m b u s t i o n C o n t r o l s E u r o p e H o n e y w e l l B V...