Honeywell S4565 Series User manual

PRODUCTION HANDBOOK

1 EN2R-9031 0402R15-NE

S4565, S4575 AND S4585

IGNITION 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 S4565, S4575 and S4585 ignition

controls are used in conjunction with the VK41.. series gas

controls to provide and optimised safety sub-system for

programmed safe light up and flame supervision of the main

burner of the appliance

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.

NOTE: The Combined Valve and Ignition (CVI) product concept consists of a specially designed gas valve family in

combination with a dedicated ignition controls family. This product handbook describes the CVI ignition controls family

S4565, S4575 and S4585 for use in combination with the CVI gas control family VK41.. For details of the CVI gas

controls please refer to Product Handbook EN2R-9004. For an up-to-date copy please contact your nearest

Honeywell office. For glossary of terms, abbrevations and symbols see document EN2R-9039

EN2R-9031 0402R15-NE 2

CONTENTS

General Page

Description 3

Features 4

Dimensional drawing housing 5

Dimensional drawing “old style” housing 6

Accessories for degree of protection IP 20, IP 40, IP X4, IP 44 7

Assembling of IP X4/44 housing 8

Application S4565/S4575/S4585 ignition controls 9

S4565 ignition controls

Specifications S4565A, B ,P, Q 10

System operation S4565A, B, P, Q 12

Specifications S4565C, D, R, T 14

System operation S4565C, D, R, T 16

Specifications S4565AD, BD, CD, DD, PD, QD, RD, TD “1000” series 18

System operation S4565AD, BD, CD, DD, PD, QD, RD, TD “1000” series 22

Specifications S4565AD, BD, CD, DD, PD, QD, RD, SD, TD “2000” series 25

System operation S4565AD, BD, CD, DD, PD, QD, RD, SD, TD “2000” series 30

Specifications S4565AF, BF, CF, DF, PF, QF, RF, TF 33

System operation S4565AF, BF, CF, DF, EF, PF, QF, RF, TF 35

Application note S4565BF with second main valve control 38

Application note S4565DF, TF with external main burner interrupt 39

Specifications S4565PV, QV, RV, TV 42

System operation S4565PV, QV, RV, TV 45

S4575 ignition controls

Specifications S4575A, B, P, Q 50

System operation S4575A, B, P, Q 52

S4585 ignition controls

Specifications S4585D 54

System operation S4585D 57

Various

General considerations 59

Installation

EMC guidelines 60

Electrical connections and wiring 61

Quality assurance statement 62

Standards and approvals 63

Ordering information 64

Overview ignition controls 65

Replacement parts and accessories 66

Cable assemblies 66

3 EN2R-9031 0402R15-NE

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.. series and a

dedicated ignition control of the series S4565, S4575 and

S4585 which is connected directly on to it.

Ignition control

The S4565, S4575 or S4585 220/240 Vac series ignition

controls can be directly electrically connected to a VK41..

series gas control. (S4575 can also be rated 110 ... 120Vac)

The S4565/S4575 ignition controls are not intended for direct

exposure to flame envelope.

S4565, S4575 and S4585 ignition controls give excellent

performance and a high reliability standard. There are

versions available for different ignition systems:

The S4565/S4575 ignition controls are approved on the

North American standard ANSI Z21.20 Automatic Ignition

Systems.

S4565, S4575 and S4585 systems function in accordance

with EN 298.

•S4565

Direct Burner Ignition (DBI) or Intermittent Pilot ignition

(IP) with a defined safety time for applications with or

without fan, with flame detection, volatile or non volatile

lock out, optional remote reset, fixed waiting times and in

case of flame failure recycling of the full start up

sequence.

•S4575

Hot Surface Ignition (HSI) with a defined safety time for

applications with or without fan, with flame detection,

volatile or non volatile lock out, optional remote reset,

fixed waiting times and in case of flame failure recycling of

the full start up sequence.

•S4585

Intermittent Pilot ignition (IP) for atmospheric or fan

assisted applications with the so called ”wild pilot system”

without safety time for ignition, with flame detection on the

pilot flame. Wild pilot system means a safety Ts+ ∞and is

applicable for pilot burners up to 250 Watt

Intermittent Pilot ignition (IP) for atmospheric or fan assisted

applications with the so called ”wild pilot system” *without

safety time for ignition and flame detection on the pilot flame.

The performance and the construction of the ignition control

is optimized and dedicated to the VK41.. series gas controls.

NOTE: S4565SD is not an ignition control but an ignition

circuit and rectifier only

EN2R-9031 0402R15-NE 4

FEATURES

General

•All burner control safety functions concentrated in one

reliable 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.

•Easy assembly of ignition control on gas control by

plugging it on from the top.

•Mounting orientation may be within 90°in any direction

from the electric on/off operator upright position.

Ignition control

•Hybrid technology for high reliability.

•Flame supervision.

•Built-in 2.5 ... 60 Hz ignition.

•Internal or external reset and alarm.

•Accurate safety timer.

•Supply voltages of 220/230 ... 240 V 50/60 Hz in a single

product. (S4575 can also be rated 110 ... 120Vac)

•Full operating sequence after flame loss.

•Extended spark ignition.

•Optional phase neutral independent operation, flame

sensing independent of safety ground potential for

S4565AD ... TD “2000” series and S4575.

•Safety time triggered by Air Pressure Switch (APS) for

S4565AD ... TD “2000” series.

•Optional safe separation flame relay output or opto

coupler.

•Optional main burner interrupt for S4565BF, DF, QF, TF.

•Volatile or non volatile lock-out according to EN 298.

•EMC filter optional.

•Protective impedance flame rod.

•Under voltage protection.

•Flame relay option.

•Option of separate power supply and heat demand input.

•Optional flame retarding housing (UL 94-V0)

Electrical connection options

•Connection to the gas control is made entirely by

plugging the ignition control on.

•Electric connections are positioned on top and are made

by a multiple plug-in connector (IP 20 enclosure if side

connections are accessible).

•The housing can receive a cover for strain relief in order

to have an IP 30 or an IP 40 enclosure,(if side

connections are accessible). When the cover is applied in

combination with the cable seal grommet, sleeves and

gasket the enclosure is IP X4 (IP 44 if side connections

are accessible)

•Ignition and flame detection connections are at the outlet

end of the housing.

•Flame detection is accessible.

•Volt free relay of S4575 is accessible.

•Ignition connection is accessible if fst25 Hz and ignition

and flame sensing is separate.

•Ignition connection AMP 2.8 x 0.5 mm.

•Flame detection connection AMP 4.8 x 0.8 mm in case of

separate ignition and flame sensing.

5 EN2R-9031 0402R15-NE

DIMENSIONAL DRAWING HOUSING

Fig. 1. Dimensional drawing housing in mm

Ignition

115

113

Mounting hole Ø3.2

Flame detection

Connector pins suitable for

Molex 3001 female connectors

Note: specific housings may deviate from drawing

EN2R-9031 0402R15-NE 6

DIMENSIONAL DRAWING “OLD STYLE” HOUSING

Fig. 2. Dimensional drawing “old style” housing in mm (do not use for new designs)

111 Connector pins suitable for

Molex 3001 female connectors

Mounting hole Ø3.2

18.5

110

Ignition

Flame detection

Note: specific housings may deviate from drawing

7 EN2R-9031 0402R15-NE

ACCESSORIES FOR DEGREE OF PROTECTION IP 20, IP 40, IP X4, IP 44

See also Replacement parts and Accessories on page 66.

1) For IP 20 the cable grommet may be left out.

2) Classification valid after correct installation of wires.

3) Only if the spark frequency is larger than 25 Hz or in case

of combined ignition and flame sensing or if the side con-

nections have DC or AC output then additional protection

against electrical shock shall be provided for these con-

nections by the application manufacturer since in such

case the side connections must be considered as hazard-

ous live parts.

IP 00 IP 20 IP 40 IP X4 IP 44

Optional strain relief

Order number: 45900442-007 or- 011: 45900440-001 (

screws included)

Cover set with separate strain relief

Order number: 45900440-001 (screws included)

Order number: 45900431-005

Order number: 45900431-007 (screw included)

Choose one cover set 1)

Cover set with integrated strain relief

Order number: 45900431-004 (screw included)

Cover set with integrated strain relief, flame

retarding in accordance with UL 94 V0.

Order number: 45900431-005 (screw included)

Special housing for IP X4/44

See O.S. card

Color: grey and red

Cable grommet

Order number: 45900442-008

Sleeve

Order number: 45900442-003 or- 006

Gasket

Order number: 45900442-007 or- 011

Choose one set (housing with accessoiries) 2)

Special housing for IP X4/44, flame retarding in

accordance with UL 94 V0

See O.S. card

Color: black

Cable grommet

Order number: 45900442-008

Sleeve

Order number: 45900442-003 or- 006

Gasket

Order number: 45900442-007 or- 011

Additional means for electrical protection of side

outlets

To be provided by the appliance

manufacturer

Use 3)

EN2R-9031 0402R15-NE 8

ASSEMBLING OF IP X4/44 HOUSING

Assembling of the cable connector(s) and cover (see Fig. 3. and Fig.

5.)

•Use cable with Ø5 ... Ø7 mm.

•Strip length cable: 15 mm

•Grommet inlet nunmbers1, 2, 4 applicable for cable

with Ø5 ... Ø7 mm.

•Grommet inlet number 3 applicable for cable

with Ø4 ... Ø7 mm.

•Mount the connector(s) and bring the cable grommet in

position over the cables and connector.

Fig. 3.

Assembly of strain relief for IP X4/44 protection (see Fig. 4. and Fig.

5.)

Position the cover on the ignition control Then, when holding

the cover down (in direction A) rotate it to mount the cable(s)

in the strain relief (in direction B).

Place the gasket on the pins of the gas control and finally fix

the whole assembly (ignition control and cover) with a screw

on the gas control wit a torque of 40 Ncm max.

Use sleeves to connect the flame sensing wire and sparking

connection(s).

In case the spark plug connections are not accessible,

additional means for electrical protection need to be provided

by the boiler manufacturer if IP 44 is needed. The spark plug

connections must not be removable without the use of a tool.

Fig. 4.

Fig. 5.

Cable grommet

Connector

Special housing for IP X4/44

Fixing screw

Cap

Cable grommet

Gasket

Sleeves

9 EN2R-9031 0402R15-NE

APPLICATION

The S4565, S4575 and S4585 series ignition controls have

been specially developed for application in gas fired domestic

appliances.

The S4565, S4575 and S4585 series ignition controls are

used in conjuction with the VK41.. series gas controls to

provide and optimised safety sub-system for programmed

safe light-up and flame supervision of the main burner of the

appliance.

In S4565 series there are versions available for both Direct

Burner Ignition (DBI) and Intermittent Pilot (IP) ignition

systems with a defined safety ignition time.

The S4575 series are suitable for Hot Surface Ignitors.

The S4585 series can be used for appliances with ”Wild

Pilot”Intermittent Pilot systems. (Wild pilot means a safety

time Ts= ∞and is applicable for pilot burners up to 250 Watt.)

EN2R-9031 0402R15-NE 10

SPECIFICATIONS S4565A, B ,P, Q

Model

Suffix A: atmospheric, direct burner ignition

Suffix B: atmospheric, direct burner ignition,

flame relay output

Suffix P: as A except volatile lock-out

Suffix Q as B except volatile lock-out

Supply voltage

220 ... 240 Vac, 50/60 Hz (-15%, +10%)

Power consumption

4 VA

Humidity

90% RH max. at 40°C non condensing

Storage

- 30 ... 70°C

Ambient temperature

-15 ... 60°C

Electrical rating (see also note 3.)

Alarm: 220 ... 240 Vac, 50/60Hz, 1 A,

cos ϕ > 0.6 or max 1 mA

Flame relay contact: 220 ... 240 Vac, 50/60Hz, 1 A,

cos ϕ > 0.6

Flame opto coupler: +5 V, 10 kΩ

Electrical connection

High voltage spark: 2.8 x 0.5 mm spade terminal

Flame sensing: 4.8 x 0.8 mm spade terminal

PCB connectors: Molex 3003 series suitable for

Molex 3001 female cable connector

Housing (degree of protection)

See:

accessories for degree of protection page 7..

replacement parts and accessories page 66..

Timing (depending on O.S. number)

Self check time (Tc): 1.5 s

Waiting time (Tw): 0 ...30 s

Safety time (Ts): 3.5 ... 55 s

Extended spark ignition time (Tx): 0 ... Tsmax.

Flame sensing

Min flame current: 0.9 µA

Response time on: > 0.2 s

Response time off(TFR): < 1 s

(optionally other values available)

Ignition

Spark voltage: >12 kV at 40 pF load

(depending on O.S. number)

Spark energy: 3 ... 15 µAs

Repetition rate: 2.5 ... 60 Hz

(depending on O.S. number)

Max. spark gap: 3.5 mm

Length flame sensing cable

1 m max.

Length ignition cable

0.5 m max.

Length of wiring for external components

1 m max.

Remark

Optional integrated flame relay available with safe separation

or opto coupler with safe separation.

N.C. contact of flame relay has no safe separation.

WARNING

Opto coupler interface needs a

debounce time > 20 ms in order to prevent noise

caused by transients on mains.

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