Honeywell Vk41 series User manual

PRODUCT HANDBOOK

1 EN2R-9004 0606R20-NE

VK41../VK81..SERIES

GAS CONTROLS FOR COMBINED VALVE AND IGNITION SYSTEM

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

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

EN2R-9004 0606R20-NE 2

DESCRIPTION

Valves

The Combined Valve and Ignition (CVI) system controls and

performs all the functions required for safe ignition, flame

supervision and for safely regulating the gas flow to the pilot

and/or main burner.

The CVI consists of a gas valve of the VK41../VK81.. series

and a dedicated ignition control of the series S4565/S4575/

S4585 which is connected directly on to it.

The gas control comprises a standard body to which a range

of features can be factory included to give various functional

options. These functional options include: servo pressure

regulation, throttle valve regulation, fully adjustable SOFTLITE,

gas/air control 1:1 or amplified, electrical high-low or

modulating control to fulfil the complete range of control

applications.

The gas control has a first direct on/off operator for opening

the safety valve of class B according to EN 161 and a second

electric on/off servo operator for control of the main valve of

class B,C or J according to EN 161 (for explanation class J,

see chapter Standards and approvals page 30).

The pressure regulator is in accordance with class B

requirements of EN 88

The gas control can handle the three gas families,

manufactured gas, natural gas and LP gas.

General

All measurements are carried out under standard conditions

listed below unless otherwise is indicated.

Standard conditions

•Pinlet 25 mbar nominal pressure, dry air of 20°C

•Pambient 1013 mbar

•Tambient 20°C

•Outlet orifice 2.8 mm

•Flow indication in m3/h

•Recording of outlet pressure with a transducer connected

to a 1/2” pipe with a length of 10 times the diameter of the

pipe with a short hose at a length of 5 times the diameter of

the pipe.

•Nominal voltage

•Upright position, i.e. the position when the operators are on

top.

3 EN2R-9004 0606R20-NE

FEATURES

General

•All burner control safety functions concentrated in one reli-

able and optimized system.

•Specially designed to provide the optimum system solution

in gas appliances with a DBI or IP system to light the main

burner.

•Both gas control and ignition control incorporate time

proven design concepts assuring reliability.

•ON/OFF control of main burner by electric operator and

electric servo operator directly energized from ignition con-

trol.

•Easy assembly of ignition control on gas control by plug-

ging it on from the top.

•Mounting orientation may be within 90

in any direction

from the electric on/off operator upright position.

Gas control

•Inlet ∅18.6 mm and outlet ∅18.6 mm connections are

straight through and can receive flanges.

•The following closing force models are available: B + J;

B + C; B + B.

•Servo pressure regulator provides stable outlet pressure.

•Pressure feedback ensures constant burner pressure in

relation to combustion chamber pressure.

•All adjustments are accessible from the top.

•9 mm diameter pressure taps on top face for checking inlet

and outlet pressure

•An internal fine mesh screen is incorporated at the inlet of

the gas control. This screen is not removable for cleaning.

•An outlet screen is optional.

•Two mounting holes for self tapping screws are at the bot-

tom of the gas control for rigid attachment to the appliance.

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.

Gas connection options

•Internal thread (ISO 7-1), external thread (ISO-R228) or

flanged connections. See table 4, 5, 6 and 7, page 9.

•Side outlet option for both main and pilot gas.

•The side outlet for pilot and main gas can only be con-

nected to a flanged burner manifold.

•Pilot gas connection for tubing with 4 mm outer diameter is

located at the outlet end of the gas control.

•Pressure feedback fittings for 4 or 6 mm silicon tube can be

mounted.

•End outlet or side outlet

Quick connection for Mini Venturi

Electrical connection options

•The appropriate ignition control can be connected to the

valve by plugging it on.

•Wired plug (IP 40) for connection with a remote ignition

control.

•Rectifier plug (IP 40) for use with any standard DBI ignition

system.

•24 Volt versions available for use in conjunction with other

ignition controls than S4565/S4585 series.

EN2R-9004 0606R20-NE 4

DIMESIONAL DRAWING STANDARD CONNECTION

13.4

Pilot outlet M8 x 1-6H

for 4 mm tubing

Outlet

29.3

36.7

6.3 terminal (3)

148

VK.1..P/Q

(High/Low)

VK.1..A/C

(Standard regulator)

VK.1..E/T

(Throttle)

6.3 terminal (2)

148

VK.1..M/N

(Modureg)

Side outlet

Pressure tap (2)

Adjustable softlite

94.8

68.3

24.9

84.5

115

STEP

Hole Ø 2.6 to connect

ignition control

Throttle

Molex 1.1 square pin header

(mating connectors 3001 series)

113

12.5

Flange thread 1/2"

or 3/8" ISO7-1

16 mm full thread

VK.1..B/D

(Blank plate)

115

105

29.4

64.9

Mounting hole (2) for

tapping screws 3.9

DIN 7970

36.7

24.1

68.3

34.3

9.1

"0"-ring size

Ø 15.55 x Ø 15.55

M5 x 0.8(3)

6 mm full thread

Side outlet

(Optional)

Inlet

36.7

M4x0.7-6H(8)

6 min full thread

Ø 18.6

The cross hatched area

is sealing face without

imperfections

OUT

Earth terminal

21.9

V1 V2

Tolerances according

to ISO 2768 mK

VK.1..M/N

(ModuPlus)

140

5 EN2R-9004 0606R20-NE

DIMESIONAL DRAWING EXTERNAL THREAD CONNECTION

Dimensional drawing VK41.5VE/VK81.5VE (Throttle)

815 ref

135

105

29.4

64.9

11.9

36.7

Inlet

20.7

" or

13.4

OUT

MIN

V1 V2

84.5

115

24.9

84.5

Hole Ø 2.6 to connect

ignition control

Earth terminal

94.8

Pressure feedback

connection

29.3

36.7

End outlet

The cross hatched

area is sealing face

without imperfections

113

Molex 1.1 square pin header

(mating connecters 3001 series

Mounting hole (2) for tapping

screws 3.9 according DIN 7970

Tolerances according

to ISO 2768 mK

100

120

105

36,7

35,7

24,1

Throttle Throttle screw

Throttle screw

29,3

EN2R-9004 0606R20-NE 6

APPLICATION

The VK41.. /VK81..series gas control have been specially

developed for application in domestic appliances.

The VK41.. series gas control can be used in a system in

conjunction with a S4565, S4575 or S4585 series ignition

control to provide an optimised safety sub-system for

programmed safe light-up and flame supervision of the main

burner.

When connected with a Honeywell specified rectifier plug and

lead the VK4105 series valve can be used with any standard

220/240 Vac DBI ignition system.

VK81.. series gas controls for 24 Vrac have been developed

for application with other ignition controls with appropriate

power supply.

7 EN2R-9004 0606R20-NE

SPECIFICATIONS

NOTE: Specifications for electrical modulation, electrical

high low, gas/air and other features are available on

request.

Models

See model number chart on page 31

Main gas connection

•Standard see table 4, page 9.

•Optional see table 5, page 9.

•Side outlet can be fitted direct to a flanged burner manifold.

Inlet and outlet with 3/8” or 1/2” ISO 7-1 internal pipe thread

and straight or elbow flanges with 3/8” or 1/2” ISO 7-1 internal

pipe thread are according to the torsion and bending stress of

EN126 group 2

Connections with G 1/2” or G 3/4” external thread fitted with

nuts according to ISO 228-1 in combination with applicable

sealing(s) withstand the torsion and bending stress of EN 126

group 1

Ambient temperature

-15 ... 60°C

Humidity

95% RH max. at 40°C

Storage

- 30 ... 70°C

Pilot gas connection

Standard at end outlet: M8 x 1 for 4 mm outer diameter tubing.

Pressure feedback connection

The servo pressure regulator has an M5 thread connection for

pressure feedback.

Pressure feedback fittings for 4 or 6 mm silicon tube can be

mounted as option.

Dimensions

See page 4 and 5

Outlet pressure range for ON/OFF regulators

1.5 ... 20 mbar

2 ... 37 mbar

5 ... 50 mbar

Minimum regulation capacity

0.31 m3/h air

Minimum differential pressure

Maximum operating pressure

The Pmax indication on the housing of the gas control is the

maximum pressure at which it functions safely.

However, the maximum inlet pressure is limited by the

pressure range of the pressure regulator concerned.

(See table 2.)

*This type can also be used for non regulation mode in LP

applications when pressure regulator adjustment screw is

clockwise turned down until it stops.

Versions up to 100 mbar maximum inlet pressure are available

on request

Mounting holes

Two mounting holes for thread forming M4 screws are located

on the bottom of the gas control.

For versions with external thread there are two additional

mounting holes for thread forming screws at the inlet side of

the gas control.

The four holes at inlet and outlet for mounting a flange on the

gas control are provided with M4 thread with min. 6 mm full

thread.

In case of side outlet the three holes for mounting the flange

are provided with M5 thread with a minimum of 6 mm full

thread.

Table 1: Minimum differential pressure

Model ∆P min (mbar)

VK4105 2.5

VK4115 4

VK4125 4

Table 2: Operating pressure

Model Pressure range

(mbar)

Maximum inlet

pressure (mbar)

with regulation 1.5 ... 20

2 ... 37*

5 ... 50*

without regulation - 60

EN2R-9004 0606R20-NE 8

Capacity

In m3/h air at pressure drop as shown below. See also the capacity curves concerned.

NOTE 1.: Versions with side outlet connection have a 0.2 m3/hair lower capacity.

NOTE 2.: Increased capacity versions are optional for types with suffix letter E, T and V.

NOTE 3.: 3

/4“ external thread versions have a 0.3 m3/hair lower capacity.

Model Extention ∆P (mbar) Capacity (m3/h air) Capacity curve

Number Page

VK410X/VK810X A, B, C, D, M, N, P, Q 3 3.4 H 10 13

E, T 3 2.8 H 160 17

VK411x/VK811x A, B, C, D, M, N, P, Q 5 4.4 H 20 14

E, T 5 3 H 170 18

V, VE 5 3.4 H 140 15

10 5.1

VB 5 4.4 H 20 14

VK412X A, B, C, D, M, N, P, Q 5 2.2 H 150 16

VK412X/VK812X V 5 2.2 H 150 16

10 5.1

Table 3: Valve classification

Model 1st valve 2nd valve

Classification Backpressure (mbar) Classification Backpressure (mbar)

VK4100/VK4105

VK8100/VK8105

B50J 0

VK4110/VK4115

VK8110/VK8115

B50C10

VK4120/VK4125

VK8120/VK8125

B50B50

9 EN2R-9004 0606R20-NE

Table 6: Mini-Venturi valve connection

Table 7: Throttle valve (VK....VE only) connection

Table 4: Standard valve connection

Inlet End outlet Side outlet Body length

(mm)

Flanged Flanged -- 105

Flanged -- Flanged 105

Internal 3/8”

ISO 7-1

-- Flanged 115

Internal 1/2”

ISO 7-1

-- Flanged 115

Internal 1/2”

ISO 7-1

Internal 1/2”

ISO 7-1

-- 115

Table 5: External valve connection (optional)

Inlet End outlet Side outlet Body length

(mm)

G1/2”G

1/2”-- 135

G1/2” Flanged -- 120

G3/4”G

3/4”-- 135

G3/4” Flanged -- 120

G3/4” -- Flanged 120

G3/4” Internal 11/2”

ISO 7-1

-- 120

G1/2” -- Flanged 120

Flanged G 1/2”-- 120

Flanged G 3/4”-- 120

Inlet End outlet Side outlet Body

length

(mm)

Flanged Quick connect

mini-venturi

-120

Flanged - Quick connect

mini-venturi

105

G3/4” Quick connect

mini-venturi

-135

G3/4” - Quick connect

mini-venturi

120

Inlet End outlet Side outlet Body length

(mm)

Flanged Flanged -- 105

G1/2” Flanged -- 120

G3/4” Flanged -- 120

EN2R-9004 0606R20-NE 10

ELECTRICAL DATA

Table 8: Electrical connection for Direct Burner Ignition systems

Supply voltage Coil indication Rectifier circuit

position

Coil connection ( fig. 1 ) Valve indication

24 Vac, 50/60 Hz 24 Vrac External Series connection pin1 and pin 5 or

plug 45.900.441-029

VK 81.5

24 Vac, 50/60 Hz 24 Vrac In plug Select plug 45.900.441- with rectifier

(See table 11)

VK 81.5

100 Vac, 50/60 Hz 100 Vrac External Series connection pin1 and pin 5 VK 41.5

110 Vac, 50/60 Hz 110 Vrac In S4575 Select plug 45.900.441-033

without rectifier (See table 11)

VK 41.5

In plug Select plug 45.900.441-039

(See table 11)

VK 41.5

External Series connection pin1 and pin 5 VK 41.5

220 ... 240 Vac, 50/60 Hz 220 ... 240 Vrac In S4565 Select plug 45.900.441-033

without rectifier (See table 11)

VK 41.5

In plug Select plug 45.900.441- with rectifier

(See table 11)

VK 41.5

External Series connection pin1 and pin 5 VK 41.5

Table 9: Electrical connection for Intermittent Pilot ignition systems

Supply voltage Coil indication Rectifier circuit

position

Coil connection ( fig. 1 ) Valve indication

24 Vac, 50/60 Hz 24 Vrac External Parallel connection pin1/2 and pin 4/5 VK 81.0

220 ... 240 Vac, 50/60 Hz 220 ... 240 Vrac In S4565 and

S4585 types

S4565 and S4585 types VK 41.0

220 ... 240 Vac, 50/60 Hz 220 ... 240 Vrac External Parallel connection pin1/2 and pin 4/5 VK 41.0

Table 10: Power consumption (W) and current (mA)

Supply voltage Power consumption Current

Nominal voltage 110% nominal voltage Nominal voltage 110% nominal voltage

1st

operator

1st + 2nd

operator

1st

operator

1st + 2nd

operator

1st

operator

1st + 2nd

operator

1st

operator

1st + 2nd

operator

DBI system

24 Vac, 50/60Hz -- 9.2 -- 11 -- 424 -- 466

100 Vac, 50/60Hz -- 9.75 -- 11.9 -- 105 -- 115

110 Vac, 50/60Hz -- 8.8 -- 10.8 -- 89 -- 98

220 Vac, 50/60Hz -- 9.4 -- 11.4 -- 48 -- 52

240 Vac, 50/60Hz -- 11.2 -- 13.6 -- 52 -- 57

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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