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PRODUCT HANDBOOK

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EN2R-9004 0606R20-NE

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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

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Содержание vk41 series

Страница 1: ...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 Feat...

Страница 2: ...as 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 ga...

Страница 3: ...nal 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 10...

Страница 4: ...ion control Throttle Molex 1 1 square pin header mating connectors 3001 series 113 17 12 5 25 Flange thread 1 2 or 3 8 ISO7 1 16 mm full thread VK 1 B D Blank plate 115 105 8 18 30 29 4 64 9 Mounting hole 2 for tapping screws 3 9 DIN 7970 36 7 24 1 24 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 24 91 36 7 M4x0 7 6H 8 6 min full thread 12 24 32...

Страница 5: ... 9 84 5 Hole Ø 2 6 to connect ignition control Earth terminal 94 8 24 12 32 24 Pressure feedback connection 29 3 36 7 32 12 End outlet The cross hatched area is sealing face without imperfections 80 113 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 85 91 36 7 65 35 7 24 1 Throttle ...

Страница 6: ... 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 wit...

Страница 7: ... 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...

Страница 8: ...ity 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 m...

Страница 9: ...External valve connection optional Inlet End outlet Side outlet Body length mm G 1 2 G 1 2 135 G 1 2 Flanged 120 G 3 4 G 3 4 135 G 3 4 Flanged 120 G 3 4 Flanged 120 G 3 4 Internal 11 2 ISO 7 1 120 G 1 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 G 3 4 Quick connect mini ve...

Страница 10: ...tion 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...

Страница 11: ... with a 220 240 Vac 110V or 24 Vac output by using a rectifier plug 45 900 441 See table 11 Electical protection of gas control with rectifier plug IP 40 Mounting of rectifier plug fig 2 Mounting screw Torque 40 Ncm max Fig 2 Mounting of rectifier plug IMPORTANT IMPORTANT Warranty claims are not accepted if not the specified plug rectifier circuit is used V1 1 Pin number 2 3 4 5 V2 ...

Страница 12: ...45 900 441 024 24 2 1260 fig 25 yes inserted fig 21 solder dip 45 900 441 025 220 240 3 600 fig 25 yes no fig 20 130 solder dip 45 900 441 026 220 240 3 1500 fig 25 yes in bag fig 20 50 solder dip 45 900 441 027 220 240 3 580 fig 24 yes inserted fig 21 earth wire 6 5 faston female 45 900 441 028 as 027 but single packed in bag 220 240 3 580 fig 24 yes inserted fig 21 earth wire 6 5 faston female 4...

Страница 13: ...TY CURVE H10 CVI MINIMUM CAPACITY CURVE 0 1 2 3 4 5 6 7 8 9 10 11 12 0 1 2 3 4 5 6 7 8 FLOW m h at 1013 mbar and 15 C dry PRESSURE DROP mbar AIR G110 120 G140 G20 G25 G30 BG1 BG2 VK410 VK810 BP 50 0 SIZE 1 2 DATE 96 06 11 REV 3 H10 ...

Страница 14: ... 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 0 1 2 3 4 5 6 7 8 9 10 h at 1013 mbar and 15 P R E S S U R E D R O P m b a r AIR G110 120 G140 G20 G25 G30 B P 50 10 S IZE 1 2 DATE 14 10 02 RE V 4 S V MV 17 17 VK 411 VK 811 V B MINIMUM CAPACITY CURVE FLOW m3 C dry o ...

Страница 15: ...Y CURVE H140 CVI MINIMUM CAPACITY CURVE 0 1 2 3 4 5 6 7 8 9 10 11 12 0 1 2 3 4 5 6 7 8 FLOW m h at 1013 mbar and 15 C dry PRESSURE DROP mbar AIR G110 120 G140 G20 G25 G30 BG1 SM2 VK411 VK811 BP 50 10 SIZE 1 2 DATE 96 06 11 REV 0 H140 ...

Страница 16: ...Y CURVE H150 CVI MINIMUM CAPACITY CURVE 0 1 2 3 4 5 6 7 8 9 10 11 12 0 1 2 3 4 5 6 7 8 FLOW m h at 1013 mbar and 15 C dry PRESSURE DROP mbar AIR G110 120 G140 G20 G25 G30 BG1 SM2 VK412 VK812 BP 50 50 SIZE 1 2 DATE 96 06 11 REV 0 H150 ...

Страница 17: ...E H160 CVI MINIMUM CAPACITY CURVE 0 1 2 3 4 5 6 7 8 9 10 11 12 0 1 2 3 4 5 6 7 8 FLOW m h at 1013 mbar and 15 C dry PRESSURE DROP mbar AIR G110 120 G140 G20 G25 G30 BG1 BG2 THR VK410 E T VK810 E T BP 50 0 SIZE 1 2 DATE 96 06 11 REV 0 H160 ...

Страница 18: ...E H170 CVI MINIMUM CAPACITY CURVE 0 1 2 3 4 5 6 7 8 9 10 11 12 0 1 2 3 4 5 6 7 8 FLOW m h at 1013 mbar and 15 C dry PRESSURE DROP mbar AIR G110 120 G140 G20 G25 G30 BG1 BG2 THR VK411 E T VK811 E T BP 50 10 SIZE 1 2 DATE 96 06 11 REV 0 H170 ...

Страница 19: ...d 110 of the rated voltage Valve closing characteristics The gas control will close within 1 second from operator de energization at an inlet pressure of 22 5 mbar and minimal 2 5 mbar pressure drop Main valve opening characteristics measured with gas Fast opening versions Under conditions where the supply pressure is at least 2 5 mbar above the outlet pressure setting the dead time shall be 0 5 s...

Страница 20: ...he set point value whichever is the greatest Design life 500 000 cycles for safety and main valve operator Cycle frequency maximum 100 cycles hour Total set point shift For other versions see the applicable handbook Temperature sensitivity VK41 81 VE type 15 70 C 4 of flow Table 14 Total set point shift servo regulator on off version Pressure range Tolerance 1 5 20 2 37 6 of the set point value or...

Страница 21: ...ative Tighten gas control using the right open end wrench fig 3 Fig 3 Ensure the gas flows in the same direction as the arrow on the bottom of the gas control Gas controls for flange connection Insert O ring in the groove of each flange If necessary grease O ring slightly to keep it in place Mount gas control between flanges using the four screws for each flange Gas controls with external thread c...

Страница 22: ...001 Fastening torque maximum 50 Nm minimum 30 Nm Pipe end construction fig 10 With 3 4 nut and flat sealing ring for pipe 18 mm fig 4 Nut drawing 45 006 583 002 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 11 Fig 7 Pipe dia 14 mm for flat sealing ring connection Fig 8 Pipe dia 15 m...

Страница 23: ...TY DAMAGE SEVERE INJURY OR DEATH Check for gas leaks with a rich soap and water solution any time work is done on a gas control Gas leak test Paint all pipe connections upstream of the gas control with a rich soap and water solution Bubbles indicate a gas leak If a gas leak is detected tighten the pipe connection Stand clear while lighting the main burner to prevent injury caused from hidden gas l...

Страница 24: ... and bring the cable grommet in position over the cables and connector Fig 12 Assembly of cover with integrated strain relief fig 13 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 Finally fix the whole assembly ignition control and cover with a screw on the gas control with a torque of 40...

Страница 25: ...ressure tap Turn the flow adjustment screw with a screw driver in clockwise direction to decrease and turn counter clockwise to increase the gas flow Check of SOFTLITE The SOFTLITE pressure is factory set Check burner performance at this pressure observing burner ignition and flame characteristics Burner should ignite promptly and without flash back to orifice and all ports should remain lit Cycle...

Страница 26: ...m via the feedback channel When the force operated by the pressure is greater than that preset by the adjustment screw the regulator valve opens relieving some of the working pressure This reduces the force against the main valve spring allowing the main valve to close proportionately Thus the main valve limits the outlet or burner pressure to the preset level As a result outlet pressure is contin...

Страница 27: ... to a preset level partially opening the main valve fig 16 As soon as it reaches the start level it overcomes the SOFTLITE spring pressure The resultant move of the SOFTLITE diaphragm inhibits the increase of working gas pressure on the main valve diaphragm Only when the SOFTLITE spring has been totally compressed does the working gas pressure increase rapidly once again until the regulator set po...

Страница 28: ...18 Adjustable SOFTLITE MAX MIN A B E D C A B E D C 0 0 10 20 30 5 MAX A A B B C C D D E E MIN 10 15 Time seconds Outlet pressure mbar Example SOFTLITE curve VK41 VK81 SOFTLITE spring 5 mbar Gas family LP Gas G30 G31 Inlet pressure 37 mbar Adjustable SOFTLITE setting positioning ...

Страница 29: ...isation is responsible for defining maintaining improving and verification of the quality systems in the field of design production process and field quality service Assembly processes are guided by work instructions Patrol inspections form part of the assembly processes At the end of the assembly phase all gas controls are leakage and performance tested adjusted Assembly inspection is performed b...

Страница 30: ...EN 483 and class D valves as mentined in other standards According to bending stresses the gas control meets the highest requirements group 2 The pressure govenor meets class B performance Regarding electric safety the gas control can be used in appliances according to European Standard for household electrical requirements EN 60335 series The gas control also meets all Electro Magnetic Compatabil...

Страница 31: ...regulator B fast opening without regulator C SOFTLITE opening with regulator D SOFTLITE opening without regulator E fast opening with throttle F Integrated gas air 1 1 with venturi mixing system M fast opening with Modureg N SOFTLITE opening with Modureg P fast opening with High Low Q SOFTLITE opening with High Low R fast opening with regulator and suitable for gas air application T SOFTLITE openi...

Страница 32: ...ng 200 45 900 400 131 1 2 BSP Pl X YES 10 45 002 776 041 1 2 BSP Pl1 X YES 200 45 900 400 104 1 2 BSP Pl1 X NO 200 45 900 400 108 1 2 BSP Pl1 X Only O ring 200 45 900 400 130 1 2 BSP Pl1 X YES 10 45 002 776 042 1 2 NPT X YES 200 45 900 400 122 3 4 NPT1 X YES 200 45 900 400 146 Ø 18 4 mm X YES 200 45 900 400 123 Description Material Packing quantity Ordernumber Compression fitting M8 x 1 for 4 mm p...

Страница 33: ... point OFF 10 1 AgNi contacts green sealing 48 45 900 438 110 Switch point ON 15 5 1 switch point OFF 13 1 AgNi contacts blue sealing 48 45 900 438 2091 Description Packing quantity Ordernumber 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 01...

Страница 34: ... du Bois 37 Switzerland by its Autorized Representative Automation and Control Solutions Combustion Controls Europe Honeywell BV Phileas Foggstraat 7 7821 AJ Emmen The Netherlands Tel 31 591 695911 Fax 31 591 695200 http europe hbc honeywell com Fig 24 Fig 25 31 47 8 27 5 34 5 9 3 35 15 35 11 7 7 8 12 5 39 15 5 20 1 24 8 45 7 30 5 10 2 30 5 ...

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