VK41../VK81..SERIES: Gas Controls For Combined Valve and Ignition System
VK41../VK81..SERIES: Gas Controls For Combined Valve and Ignition System
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.
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.
Contents
General page
Description ...................................................................... 2
Features .......................................................................... 3
Dimesional ..................................................................... 4
Application ...................................................................... 6
Subject to change without notice. All rights reserved.
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 EN2R-9004 0606R20-NE
EN2R-9004 0606R20-NE 2
Functional options
• Fast open and SOFTLITE versions
• Fully adjustable SOFTLITE option to facilitate the smooth
light-up of burner and for changing over from one gas to
another.
NOTE: SOFTLITE opening is not always available when the
second valve is classified as a class B valve.
• 100 mbar inlet pressure versions available on request
• Throttle valve versions
• Electrical modulation (Modureg) or CVI-m.
• Electrical High-Low control.
• Pilot outlet for IP system
• Gas/Air ratio version available.
3 EN2R-9004 0606R20-NE
EN2R-9004 0606R20-NE
13.4 Adjustable softlite 148 148
9.1
24.1 IN OUT STEP
STEP
Hole Ø 2.6 to connect
ignition control 24.9
1 21.9
34.3
Outlet
Inlet 113 80
4
Pilot outlet M8 x 1-6H
for 4 mm tubing
VK.1..A/C
91 (Standard regulator)
24 24
36.7 36.7
DIMESIONAL DRAWING STANDARD CONNECTION
MIN
24.9
1
V1 V2
84.5
Earth terminal
84.5
115
Molex 1.1 square pin header The cross hatched
(mating connecters 3001 series area is sealing face Pressure feedback
without imperfections 29.3
connection
113
Inlet
G 1/2" or
91 G 3 /4 " End outlet
80
24
32
20.7
36.7 36.7
12
12
11.9 24
30 32
15
Mounting hole (2) for tapping 64.9
screws 3.9 according DIN 7970
30
15 Tolerances according
29.4
to ISO 2768 mK
8
15 ref
105
135
Throttle screw
100
24,1
65
35,7
105
120
Throttle
Throttle screw
91 85
36,7
29,3
5 EN2R-9004 0606R20-NE
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Humidity * This type can also be used for non regulation mode in LP
95% RH max. at 40°C applications when pressure regulator adjustment screw is
clockwise turned down until it stops.
Storage
Versions up to 100 mbar maximum inlet pressure are available
- 30 ... 70°C
on request
Pilot gas connection
Mounting holes
Standard at end outlet: M8 x 1 for 4 mm outer diameter tubing.
Two mounting holes for thread forming M4 screws are located
Pressure feedback connection on the bottom of the gas control.
The servo pressure regulator has an M5 thread connection for
For versions with external thread there are two additional
pressure feedback.
mounting holes for thread forming screws at the inlet side of
Pressure feedback fittings for 4 or 6 mm silicon tube can be
the gas control.
mounted as option.
The four holes at inlet and outlet for mounting a flange on the
Dimensions gas control are provided with M4 thread with min. 6 mm full
See page 4 and 5 thread.
In case of side outlet the three holes for mounting the flange
Outlet pressure range for ON/OFF regulators are provided with M5 thread with a minimum of 6 mm full
1.5 ... 20 mbar thread.
2 ... 37 mbar
5 ... 50 mbar
7 EN2R-9004 0606R20-NE
EN2R-9004 0606R20-NE 8
9 EN2R-9004 0606R20-NE
IP system
24 Vac, 50/60Hz 6.7 6.7 + 3.1 8.0 8.0 + 3.7 309 309 + 143 340 157
220 Vac, 50/60Hz 9.1 4.8 11 5.8 46 24 51 27
240 Vac, 50/60Hz 10.9 5.7 13.1 6.9 50 26 55 29
220Vac, 50/60Hz 7 7 + 2.2 8.3 8.3 + 2.7 31 31 + 11 35 35 + 12.2
240 Vac, 50/60Hz 8.0 8.0 + 2.6 9.6 9.6 + 3.2 35 35 + 12.1 38.4 38.4 + 13.3
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Pin number 1 2 3 4 5
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.
Fig. 2. Mounting of rectifier plug
Electical protection of gas control with rectifier plug
IP 40 IMPORTANT
Warranty claims are not accepted if not the specified
Mounting of rectifier plug plug/rectifier circuit is used.
fig. 2 .
Mounting screw
Torque: 40 Ncm max.
11 EN2R-9004 0606R20-NE
EN2R-9004 0606R20-NE 12
BG1/BG2 VK410./VK810. BP: 50/0 SIZE: 1/2" DATE: 96-06-11 REV: 3 H10
12
11
AIR
G110/120
10
G140
G20
G25
9
G30
8
PRESSURE DROP (mbar)
0
0 1 2 3 4 5 6 7 8
FLOW (m³/h) at 1013 mbar and 15˚C, dry
13 EN2R-9004 0606R20-NE
19
18
AIR
17 G110/120
16 G140
G 20
15
G 25
14 G 30
PRESSURE DROP (mbar)
13
12
11
10
0
0 1 2 3 4 5 6 7 8 9 10
o
F L O W ( m 3 /h) at 1013 mbar and 15 C, dry
EN2R-9004 0606R20-NE 14
BG1/SM2 VK411. / VK811. BP: 50/10 SIZE: 1/2" DATE: 96-06-11 REV: 0 H140
12
11
AIR
10 G110/120
G140
G20
9 G25
G30
8
PRESSURE DROP (mbar
0
0 1 2 3 4 5 6 7 8
FLOW (m³/h) at 1013 mbar and 15˚C, dry
15 EN2R-9004 0606R20-NE
BG1/SM2 VK412./VK812. BP: 50/50 SIZE: 1/2" DATE: 96-06-11 REV: 0 H150
12
11
AIR
10 G110/120
G140
G20
9 G25
G30
8
PRESSURE DROP (mbar
0
0 1 2 3 4 5 6 7 8
FLOW (m³/h) at 1013 mbar and 15˚C, dry
EN2R-9004 0606R20-NE 16
BG1/BG2/THR VK410.E,T/VK810.E,T BP: 50/0 SIZE: 1/2" DATE: 96-06-11 REV: 0 H160
12
11
AIR
10 G110/120
G140
G20
9 G25
G30
8
PRESSURE DROP (mbar
0
0 1 2 3 4 5 6 7 8
FLOW (m³/h) at 1013 mbar and 15˚C, dry
17 EN2R-9004 0606R20-NE
BG1/BG2/THR VK411.E,T/VK811.E,T BP: 50/10 SIZE: 1/2" DATE: 96-06-11 REV: 0 H170
12
11
AIR
10 G110/120
G140
G20
9 G25
G30
8
PRESSURE DROP (mbar
0
0 1 2 3 4 5 6 7 8
FLOW (m³/h) at 1013 mbar and 15˚C, dry
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Fig. 3.
• Ensure the gas flows in the same direction as the arrow on
the bottom of the gas control.
21 EN2R-9004 0606R20-NE
+ 0.2
14 18 - 0.2
+ 0.2
15 18 - 0.2
Pipe diameter: 15 mm
Nut: drawing:........................................ 45.006.583-003 1
7.5 +/- 0.2
“O”-ring size: ∅14.3 x ∅2.4 mm Fig. 9. Pipe end for “O”-ring connection
drawing ................................................ 45.001.583-003
Fastening torque: maximum 50 Nm
minimum 10 Nm
+ 0.2
Pipe end construction: fig. 9 . 15 23.4 - 0.2
Fig. 10. Pipe (dia 15 mm) for flat sealing ring connection
+ 0.2
18 23.4 - 0.2
Fig. 11. Pipe (dia 18 mm) for flat sealing ring connection
WARNING
To avoid decreasing of performance of pressure
regulator by pinching off the pressure feedback tubing,
Fig. 6. External thread connection with nut and “O”-ring it is recommended to use a tube material which will not
With 3/4” nut and flat sealing ring for pipe 15 mm ( fig. 4 .) kink.
Nut: drawing:........................................ 45.006.583-003
Flat sealing ring according to DIN 3535-6 with size
∅24 x ∅16 x 1.5 mm:
drawing ................................................ 45.006.582-001
Fastening torque: maximum 50 Nm
minimum 30 Nm
Pipe end construction: fig. 10 .
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CAUTION
Keep soap and water solution away from electrical
connecetions.
23 EN2R-9004 0606R20-NE
WARNING
Take care that installer is a trained experienced service
man. Turn off gas supply before starting installation.
Disconnect power supply to prevent electrical shock
and/or equipment damage.
Fig. 13.
IMPORTANT
Warranty claims are not accepted if the specified Disassembly of cover with integrated strain relief
plug/rectifier circuit is not used. • Loosen the cover screw.
• Pull up the cover screw by hand, lift the cover slightly and
Wiring push it in the direction of the cables.
• Use cable which can withstand 105°C ambient.
• Use cable which is proven against moisture. Fusing
In order to prevent unsafe conditions at too high current, the
• Wiring between ignition control and spark sensing probe
ignition controls S4565, S4575 and S4585 series have an
should have good quality insulation, suitable for the temper-
integral non replaceable fuse.
atures encountered. This fuse will be blown long before the maximum 16 A external
fuse switches off.
Assembling of the cable connector(s) for IP 20 protection
Follow the sequence as mentioned under Assembling of the Spark gap
cable connector(s) for IP 44 protection" except the assembling Max. allowable spark gap 3.5 mm
of the grommet.
Supply voltage polarity
Assembling of the cable connector(s) for IP 44 protection ( fig. 12 .)
• Use cable with Ø 5 ... Ø 7 mm.
• Strip length cable: 15 mm WARNING
• Grommet inlet numbers1, 2, 4 applicable for cable If ignition control seems to operate normally but does
with Ø 5 ... Ø 7 mm. not detect flame, check for right polarity of power supply
• Grommet inlet number 3 applicable for cable (line, neutral).
with Ø 4 ... Ø 7 mm.
• Mount the connector(s) and bring the cable grommet in
position over the cables and connector. Checking flame current
• The minimum value should be in accordance with specified
value.
Connector • To check flame current connect a DC micro-Ampèremeter
between flame sensing wire and flame sensing rod.
• If flame current is insufficient check that flame sensing rod
Grommet is fully enveloped by the flame and that burner is reliable
grounded to ignition control.
• If there is no sufficient flame current due to phase-phase
mains it is recommanded to use a AT7030A or AT7030B
flame detection transformer. See also instruction sheet
EN1R-9136 for AT7030 transformer.
2
3
4 WARNING
1 Short µA meter during ignition, to prevent damage of
Fig. 12. the µA meter in single rod application.
EN2R-9004 0606R20-NE 24
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SOFTLITE ON position,
SOFTLITE gas only, main valve partially open SOFTLITE ON position, main valve open
Fig. 16. Servo pressure regulation SOFTLITE models
27 EN2R-9004 0606R20-NE
Example: 30
SOFTLITE curve VK41../VK81..
C
A MAX A 10
D
B B
E
MIN
C C
0
0 5 10 15
D D
E MIN E Time (seconds)
Fig. 18. Adjustable SOFTLITE
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VK 4 1 0 0 A 9999
31 EN2R-9004 0606R20-NE
FLANGE ASSEMBLIES
FITTING
Description Material Packing quantity Ordernumber
Compression fitting M8 x 1 for 4 mm pilot tube connection Brass 200 45.900.402-019
Compression fitting M10 x 1 for 6 mm pilot tube connection1) Brass 200 45.900.402-020
Compression fitting M11 x 1 for 6 mm pilot tube connection1) Brass 200 45.900.402-002
Pressure feedback fitting for 4 mm tube Brass 200 45.900.402-010
Pressure feedback fitting for 6 mm tube Brass 200 45.900.402-011
Pressure feedback fitting for 4 mm tube Polyamide 6.6 100 45.900.402-031
Pressure feedback fitting for 6 mm tube Polyamide 6.6 100 45.900.402-034
1)
Only applicable for VK41../VK81..R
EN2R-9004 0606R20-NE 32
MISCELLANEOUS
Description Packing Ordernumber
quantity
Cap throtlle valve 1000 45.900.431-008
Gasket for mounting between the gas control and ignition control 2000 45.900.442-007
Gasket for mounting between the gas control and ignition control 192 45.900.442-011
Screw for plug rectifier (45.900.441-xxx) 8000 45.900.445-007
Plug for connecting on coil of the gas control 500 45.900.445-009
PLUGS
Cable wiring DBI applications Cable wiring IP applications
220/240 Volt applications: 3 x 0.75 mm 2 220/240 Volt applications: 4 x 0.75 mm2
110 Volt applications: : 3 x 0.75 mm 2
24 Volt applications: 2 x 0.50 mm 2 For details for specific plug codes, see table 11, page 12
Strip length
Brown
Cable length
30
50
80 cable lenght
3 pin rast 5 connector
Lunberg nr. 362303K10
Brown wire connected to st 4-1
Blue wire connected to st 4-2
Fig. 21.
50
Fig. 23.
33 EN2R-9004 0606R20-NE
47.8
31 34.5
27.5
35 12.5
45.7
35 7.8 30.5
10.2
15
11.7 30.5
Fig. 24.
Fig. 25.
Manufactered for and on behalf of the Environmental and Combustion Controls Division of Honeywell Sàrl, Ecublens, Route du Bois 37, Switzerland by its Autorized Representative:
EN2R-9004 0606R20-NE 34