Honeywell A4021 Series User manual

VALVE PROVING SYSTEM

PRODUCT HANDBOOK

A4021 Series

UNIVERSAL GAS VALVES

EN2R--9023 9705R0--NE

APPLICATION

The A4021 is a self--checking microprocessor based Valve

Proving System (VPS). The A4021 checks the effective clo-

sure of automatic shut--off valves by measuring the pressure

differential between two valves during the test sequence.

Subbase and pressure switch are required to complete the

system.

When during the test sequence of the A4021 a failing valve is

detected, the A4021 will go into a non--volatile lock--out sta-

tus, generates an alarm and prevents a burner start--up.

The intended application is for gas fired power burners and

other large capacity gas firing installations, where according

to the European norm EN676 a valve proving system can be

used as an alternative for pre--purging the combustion cham-

ber. And for installations with or without pre--purge with a

capacity of more than 1200 kW.

Subject to change without notice. Printed in the Netherlands.

CONTENTS

Application 1................................................................

General 2....................................................................

Application (continued) 2.....................................................................

Features 3...................................................................

Description 4................................................................

Working principle 4..........................................................................

Specifications 7.............................................................

Mechanical 7...............................................................................

Electrical 7.................................................................................

Functional 7................................................................................

Dimensional drawings 9......................................................

Safety Provisions 10..........................................................

Energizing valve 1 and 2 10...................................................................

Use of terminal 12 10.........................................................................

Fail--safe relay drivers 10......................................................................

Anti--recycle--counter 10.......................................................................

Calculations 11...............................................................

General 11..................................................................................

Calculation examples 11.......................................................................

Installation and wiring 12......................................................

Installation 12................................................................................

Mounting Wiring Subbase 12...................................................................

Wiring 12....................................................................................

General considerations 12.....................................................................

Wiring 12....................................................................................

Pressure switch 12...........................................................................

General wiring diagrams 13....................................................

Applications with EC7850 14..................................................

Checkout 17..................................................................

Final checkout of the installation 17.............................................................

Troubleshooting 18...........................................................

Standards and Approvals 19...................................................

Ordering information 20.......................................................

2EN2R--9023 9705R0--NE

GENERAL

Application (continued)

The A4021A can be used for both single and combination

valves with or without pilot valve.

For valves with large nominal sizes, valve proving is possible

by use of auxiliary valves (pre--configuration only, see page 4).

For mounting the A4021 on a typical combination valve as the

VQ400 Series or on a large valve like the VE5000 Series

there is a mounting bracket available (order separately)

According the European standard EN676 a valve proving

system can be used under certain conditions, as an

alternative for pre--purging the combustion chamber. EN676

prescribes a valve proving system for capacity rating over

1,200 kW, see Table 1.

Table 1. Application valve proving systems according EN676

Heat--Input With Pre--Purge Without Pre--Purge

[

]

Main Gas Start Gas Main Gas Start Gas

[

]

≤10% ≥10% ≤10% ≥10%

≤70 2xB B*)2xB 2xAor

2 x B +VPS A**)2xA

>70,≤1200 2xA 2xA 2xA 2xA+VPS 2xA 2xA

>1200 2 x A + VPS 2xA 2xA 2xA+VPS 2xA 2xA

NOTE: A: Automatic shut--off valve approved on EN161, class A

B: Automatic shut--off valve approved on EN161, class B

Valve Proving System required

Valve Proving System as alternative for pre--purge of the combustion chamber

*) For third family gases: two class B valves are required

**) For third family gases: two class A valves are required

Fig. 1. VQ400 combination valve with A4021 valve proving System.

3EN2R--9023 9705R0--NE

FEATURES

•Microprocessor technology

•Based on 7800 SERIES Burner Programmer safety

technology.

−Dynamic relay test

−Safe start test

−Self--diagnostic test

•Testing independent of type of gas at any inlet

pressure.

•Valve proving done by using the line pressure of the

gas.

•Non--volatile lockout.

•Automatic valve proving before heat demand, after

heat--demand or during pre--purge possible.

•Different test--times (per valve) available by different

O.S. numbers.

•Clear visual indication of the test sequence and

faults--causes through 5 LEDs.

•Storage of fault code when line interruption occurs

•Can be applied in all common valve configurations

•2--wire gas pressure switch.

•Output for external alarm signal.

•Optional external remote reset.

4EN2R--9023 9705R0--NE

DESCRIPTION

The A4021 valve proving system checks the effective closure

of the valves

before

burner start--up (pre--configuration) or

the end of

a heat demand (post--configuration). The

configuration can be set by means of wiring the A4021 in two

different ways, see Fig. 2. and 3.

The flow chart (Fig. 5. ) and sequence diagram (Fig. 6. )

explain the procedure during the valve proving.

An external pressure switch monitors the pressure between

both valves. The pressure switch must be set to half the inlet

pressure in order to test both valves with the same sensitivity.

After a short interruption of the mains supply during valve

proving or during RUN, the A4021 restarts automatically.

The A4021 valve proving system can be used with several

pilot--valve configurations, like intermittent and interrupted

pilot systems and 3--valve configurations as well.

A4021 ignition

controller

H.D

LGPS

Fig. 2. Valve proving

pre--configuration

A4021 ignition

controller

LGPS H.D

Fig. 3. Valve proving

post--configuration

V1 V2

heat

demand

burner

Pinlet

L.G.P.S. G.P.S.

gas

air

Servo Motor MT4000 Series

Combi--valve VQ400 Series

Valve Proving System

A4021 Series burner--controller

7800 SERIES

Gas pressure switches

C6058A Series

Fig. 4. System set--up .

Working principle

The A4021 valve proving system is based on the pressure

status--principle. This means that the valves are checked by

means of measuring (on/off) the pressure in the gas--pipe

between the two safety--valves. This system will only work

when there is sufficient gas--pressure (line--pressure).

Therefore a Low Gas Pressure Switch (LGPS) is part of the

installation. When the line--pressure (Pinlet) is too low the

LGPS will disable the valve proving system.

The section between the two valves is filled with gas

(high--pressure status) by opening valve--1 (upstream valve)

and the pipe is emptied (low--pressure status) by closing

valve--1 and opening valve--2 (down--stream). When one of

the valves is leaking this will mean that either the pressure

will not maintain the high--pressure status or the low--pressure

status at the end of the test period.

For this method of testing, the test time is a function of three

parameters.

−inlet pressure

−volume between the valves.

−maximum burner capacity.

The test time can be calculated as given on page11. Different

test times are available by different O.S. numbers.

5EN2R--9023 9705R0--NE

stabilization

time (3 sec.)

pressure

=low?

open valve 2

(5 sec.)

wait

(22 sec.)

open valve 1

(5 sec.)

pressure

=low?

stabilization

time (3 sec.)

pressure

=high?

wait

(22 sec.)

pressure

=high?

enable

ignition

controller

error + lock--out

yes

test valve 1

test valve 2

self test

=OK?

yes

manual reset

pin 12

connected

enable

ignition

controller

yes

self test

=OK?

each 4 hours

yes

STANDBY

RUN

start

Fig. 5. General flow chart valve proving (given timings

for A4021A1002/1010

Table 2. Sequence timings for normal operation

State Description Time1) (s)

0STANBY infinite2)

1self--test + memory test <2

2 V2 powered 5

3waiting for pressure to get low 3

4wait 22

5 valve 1 powered 5

6waiting for pressure to get high 3

7wait 22

8waiting for ignition controller to start indefinite3)

9RUN period, every 4 hours self--test

10 alarm, “error during test valve 1” indefinite

11 alarm, “valve 1 failing/leaking”5) indefinite

12 alarm, “error during test valve 2” indefinite

13 alarm, “valve 2 failing/leaking”5) indefinite

14 alarm, “error heat demand” indefinite

15 alarm, “self--test error”4) indefinite

1) Timings depending on O.S. numbers, shown

A4021A1002/1010

2) STANDBY can be infinite time period

3) Depending on pre--purge and start--up time of the used

ignition controller

4) When during the test sequence a fault is discovered by the

A4021, the system will go into a non--volatile lock--out and

generate an alarm “self test error” (see also

Troubleshooting section).The “self test error” also occurs

when the anti--recycle--counter reaches the value 10, see

also page 10 of the Product handbook.

5) Leakage ≥0.1 % of maximum flow rate.

WARNING

No standard valve proving after lock--out of the

ignition controller.

Valve proving after lockout maybe required, this can

be achieved by special wiring diagrams. E.g. when a

DTSP switch is used to reset the ignition controller

and interrupting the heat--demand for the A4021A.

Heat demand

Line voltage

Lock--out

(Ignition controller)

Reset ign. control.

power--up start

heat--demand end

heat--demand lock--outstart

heat--demand resetburner controller

Leak test

GPS

Valve V1

Vent valve

(normally open)

Valve V2

Leak test

GPS

Valve V1

Vent valve

(normally open)

Valve V2

PRE

POST

CONFIG

start whithout valve proving !

Fig. 6. System sequence of A4021A in post and pre--configuration.

6 EN2R--9023 9705R0--N

7EN2R--9023 9705R0--NE

SPECIFICATIONS

Mechanical

Model

A4021A

Dimensions

Refer to Fig. 7.

For mounting bracket dimensions refer to Fig. 8.

Weight

Including subbase: 0.65 Kg

Mounting

ZL030001 subbase.

The subbase can be assembled by 2 screws on a panel.The

cover can be removed by loosening one screw. For mounting

hole dimensions see Fig. 7. installation drawing.

Orientation

There are no restrictions in the orientation.

Environmental ratings

Ambient temperature range:

Operating :--10 ... 60 °C

Storage :--40 ... 80 °C

Humidity: :0 -- 95% RH at 40 °C (non--condensing)

Vibration :0.5 G environment

Electrical

Supply voltage

Line voltage: 220 ... 240 Vac, 50 Hz

100 ... 120 Vac, 50 Hz

Refer to Table 3.

Other voltage ranges and frequencies are available on

request.

Fusing

The A4021A should be externally fused to prevent damage to

the valve proving system, wiring or peripherals

External fuse: 16 A slow max.

Internal fuse: 5 A slow max.

Power consumption

Maximum 4.5 VA

Electrical ratings

Valve outputs: 4A, cos. ϕ0.7

Vent valve output: 1A, cos. ϕ0.7

Ignition controller output: 4A, cos. ϕ0.7

Alarm output: 2A, cos. ϕ0.7

Electrical connection

4WiringconduitaccordingtoPG11areprovidedinthe

subbase. M3.5 screw terminals, including earth connection.

Enclosure

IP40

Functional

Field adjustments (calibration)

None

Test--times

Depending on O.S. number.

For A4021A1002 and A4021A1010 per valve: 25 s.

Other test times available on request.

Total test--time (depending on test time per valve)

For model A4021002 and A4021A1010: approx. 65 seconds

Reset

NON--volatile lock--out

Manual, with push--button on controller or with remote reset

button.

Design life

> 10 years or 250.000 cycles.

Recommended pressure switch

C6058A gas pressure switch

8EN2R--9023 9705R0--NE

Table 3. Connections for A4021A pre-- and post configuration with contact ratings

Terminal

Abbreviations Direction Description Ratings

(

o. pre post

(

...

ac,

depending on O.S. number)

1NO NO input Normally Open contact of the pressure

switch (high pressure) n.a.

2RESET RESET input Input for external reset connect with

momentary switch to line n.a.

3LINE LINE power--input Line voltage input for valve proving

system. n.a.

4 N N power--input Neutral input for valve proving system. n.a.

5 N N power Neutral for external devices. n.a.

6 N N power Neutral for external devices. n.a.

7V2--IN V2--IN input Valve--2 voltage from ignition controller n.a.

8V2--OUT V2--OUT output Output connect with Valve--2 4A

9HD LGPS input Heat--demand input (pre--configuration)

or LGPS input (post--configuration) n.a.

10 ALARM ALARM input Alarm input 4A

11 ALARM ALARM output Alarm output 2A

12 RB RB input Read back signal for: heat--demand

(post-- config.) ign. contr. (pre--config.) 4A

13 VENT VENT output Normally open valve output 1A

14 IGNCTR HD output Heat call signal to ignition controller,

when there is a heat call and the valve

proving has taken place

15 V1--IN V1--IN input Valve--1 voltage from ignition controller 2A

16 V1--OUT V1--OUT output Output connect with Valve--1 4A

NOTE: cos. ϕ= 0.7 for all outputs

9EN2R--9023 9705R0--NE

DIMENSIONAL DRAWINGS

67543218

9 10111213141516

PG11

Fig. 7. Mounting dimensions of A4021A and subbase in millimeters

74.5

60.5

8.5 34.5

86.5

∅4.5 (4x)

90°

103

∅20

Fig. 8. Mounting bracket A4021A for VQ400 and VE5000 Series in millimeters.

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