Vk4105G Series: Gas Controls For Combined Valve and Ignition Modulating System
Vk4105G Series: Gas Controls For Combined Valve and Ignition Modulating System
Vk4105G Series: Gas Controls For Combined Valve and Ignition Modulating System
APPLICATION
General
Contents
Page
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gas control
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Performance characteristics . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjustments and checkout . . . . . . . . . . . . . . . . . . . . . . . . 13
Construction and working principles . . . . . . . . . . . . . . . . . 14
Various
Quality assurance statement . . . . . . . . . . . . . . . . . . . . . . .
Standards and approvals . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement parts and accessories . . . . . . . . . . . . . . . .
15
16
17
18
EN2R--9025 0108R6--NE
DESCRIPTION
Valves
The Combined Valve and Ignition modulating (CVI--m) system
controls and performs all the functions required for safe
ignition, flame supervision and for safely regulating the gas
flow to the main burner.
The construction of the VK4105G valve is optimized and
dedicated to function in combination with the S4565.M ignition
control.
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 4.3 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 with a
short hose at 5times the diameter.
Nominal voltage
90_ tilted, i.e. the position when the operators are lying
horizontal.
EN2R--9025 0108R6--NE
FEATURES
Gas connection options
Inlet 18.6 mm and outlet 18.6 mm are straight through
and can receive flanges.
Internal thread (ISO 7--1):
3/ inlet and 3/ end outlet; body length 115 mm.
8
8
1/ inlet and 1/ end outlet; body length 115 mm.
2
2
1/ NPT inlet and flanged end outlet;
2
body length 115 mm.
External thread :
1/ inlet and 1/ end outlet; body length 135 mm
2
2
1/ inlet and standard flanged end outlet;
2
body length 120 mm
3/ inlet and 3/ end outlet; body length 135 mm
4
4
3/ inlet and standard flanged end outlet;
4
body length 120 mm
3/ inlet and standard flanged side outlet;
4
body length 120 mm
The side outlet can only be connected to a flanged burner
manifold.
Pressure feedback fittings for 4 or 6 mm silicon tube can
be mounted.
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 to light the main burner.
VK4105G gas control incorporates time proven design
concepts assuring reliability.
ON/OFF control of main burner by electric operator and
electric servo operator directly energized from ignition
control.
Easy assembly of ignition control on gas control by
plugging it on from the top.
Mounting orientation must be 90_ in any direction from the
electric on/off operator upright position.
Incorporated electric modulating or Hi--Lo regulation.
Throttle for minimum flow setting
Gas control
Closing force: B + J
Servo pressure regulator provides stable outlet pressure.
Pressure feedback on maximum setting 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
Two mounting holes for thread forming screws are at the
bottom of the gas control for rigid attachment to the
appliance.
Electrical connection
The appropriate ignition control can be connected to the
valve by plugging it on.
EN2R--9025 0108R6--NE
13.4
OUT
MIN
24.9
1
V1
87.5
84.5
V2
Earth terminal
84.5
115
Molex 1.1 square pin header
(mating connectors 3001 series)
Inlet
113
91
24
93.5
36.7
24
36.7
24
24
Side outlet
64.7
30
Mounting hole (2) for
tapping screws 3.9
DIN 7990
M5 x 0.8(3)
6 min full thread
12
36.7
29.4
8
105
8 x 3.3 high
2.8
24.1
9.1
24.3
68.3
12
29
EN2R--9025 0108R6--NE
94.8
Hole 2.6 to connect
ignition control
61.6
13.4
OUT
MIN
V1
24.9
53.2
V2
84.5
Earth terminal
84.5
115
Inlet
G 1/2 or
G 3/4
91
Pressure feedback
connection
Outlet
G 1/2 or
G 3/4
80
20.7
36.7
36.7
30
30
Mounting hole (2) for tapping
screws 3.9 according DIN 7970
15
64.7
300.5
15
29.4
80.5
15 ref
1050.7
135
EN2R--9025 0108R6--NE
SPECIFICATIONS
Mounting position
90_ tilted (i.e. with coils horizontal) in any direction from the
upright, deviation 5_ max.
Models
See model number chart on page 17
Main gas connection
Standard see table 2. page 6
Optional see table 3. page 6
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
Pressure feedback connection
The servo pressure regulator has an M5 thread connection for
pressure feedback on maximum pressure setting.
Nominal voltage to
S4565.M 230 V, 50 Hz
VA
VA
7.2
8.7
7.9
9.6
Dimensions
See dimensional drawing page 4 and page 5
Minimum capacity
The minimum rate is adjustable with a throttling screw from
0.2 m3/h air up to 0.92 m3/h air at P = 17 mbar
Outlet pressure range
1.5 ... 32 mbar
Minimum rate range
1.5 ... 7 mbar
Maximum inlet pressure
60 mbar
Modulation characteristics
In fig 1. and fig 2. the modulation performance of the CVI--m
system is reflected at 20 mbar and 37 mbar.
Closing time
< 1 second
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
Internal 1/2
NPT
Internal 1/2
NPT
----
115
Electrical data
Power consumption: see table 1.
Max modulation current at nominal voltage: 30 mA
Valve classification
1st valve: class B, 50 mbar backpressure
2nd valve: class J, 0 mbar backpressure
Maximum operating pressure
The Pmax = 60 mbar indication on the housing of the gas
control is the maximum pressure at which it functions safely.
Inlet
End outlet
Side outlet
Body length
(mm)
G 1/2
G 1/2
----
135
1/
2
Flanged
----
120
3/
4
3/
4
----
135
G 3/4
Flanged
----
120
G 3/4
----
Flanged
120
EN2R--9025 0108R6--NE
17
15
13
Poutlet (mbar)
11
1
0
10
20
30
40
50
60
70
80
PWM (%*)
downward nominal curce
upward nominal curve
* HI--Lo versions:
Hi--Lo contact open corresponds to 0% PWM
Hi--Lo contact closed corresponds to 100% PWM
Fig. 1. Tolerance graph modulating performance at 20 mbar inlet pressure,
(VK4105G + S4565.M)
37
35
33
31
29
Poutlet (mbar)
27
25
23
21
19
17
15
13
11
9
7
5
3
0
10
20
30
40
50
60
70
80
90
100
PWM (%*)
EN2R--9025 0108R6--NE
PERFORMANCE CHARACTERISTICS
Oscillation
The difference between maximum and minimum outlet
pressure must be equal or less than 0.5 mbar.
Test conditions:
-- maximum inlet pressure in accordance with regulator
range.
-- outlet orifice 2.8 dia (this means 0.3 m3/h air at 2 mbar
outlet pressure)
-- recording of outlet pressure with a transducer connected
to a 1/2 pipe with a length of 10 d. with a short hose
at 5 d.
-- attenuation X--Y recorder must be switched on zero.
--other pressure gauges or flow meters must be
disconnected.
-- Ambient temperature 20 _C
Operable voltage
230 V, 50 Hz
Pressure
range (mbar)
Tolerance
1.5 ... 32
Design life
500.000 cycles for safety and main valve operator.
Cycle frequency maximum100 cycles /hour.
EN2R--9025 0108R6--NE
INSTALLATION
Gas controls for flange connection
IMPORTANT
Take care that installer is a trained experienced
service person.
Turn off gas supply before starting installation.
Disconnect power supply to prevent electrical shock
and/or equipment damage.
Do not remove seals over inlet and outlet until the
device is ready to be installed.
Take care that dirt cannot enter the gas control
during handling.
IMPORTANT
Fastening torque flat sealing ring only applicable for
type Klingersil C4324
Olives for this application are not supplied by
Honeywell
Torque of olive applications may differ depending on
olive dimensions.
Mounting position
90_ tilted (i.e. with coils horizontal) in any direction from the
upright, deviation 5_ max.
3/
8
14
1/
2
18.6
With 1/2 nut and flat sealing ring for pipe 14 mm (see fig 4.)
Nut: order number: . . . . . . . . . . . . . . . . 45.900.447--005
Flat sealing ring according to DIN 3535--6 with size
18 x 12 x 1.5 mm
order number . . . . . . . . . . . . . . . . . . . . . 45.900.447--007
Fastening torque: maximum 40 Nm
minimum 25 Nm
Pipe end construction: see fig.: 7.
With 1/2 nut and flat sealing ring for pipe 15 mm (see fig 4.)
Nut: order number: . . . . . . . . . . . . . . . . 45.900.447--004
Flat sealing ring according to DIN 3535--6 with size
18 x 12 x 1.5 mm
order number . . . . . . . . . . . . . . . . . . . . . 45.900.447--007
Fastening torque: maximum 40 Nm
minimum 25 Nm
Pipe end construction: see fig.: 8.
Fig. 3.
Ensure the gas flows in the same direction as the arrow on
the bottom of the gas control.
EN2R--9025 0108R6--NE
With 3/4 nut and flat sealing ring for pipe 18 mm (see fig 4.)
Nut: order number: . . . . . . . . . . . . . . . . 45.900.447--002
Flat sealing ring according to DIN 3535--6 with size
24 x 16 x 1.5 mm
order number . . . . . . . . . . . . . . . . . . . . . 45.900.447--006
Fastening torque: maximum 50 Nm
minimum 30 Nm
Pipe end construction: see fig.: 11.
18 +0.2
--0.2
14
1
Fig. 7. Pipe (dia 14 mm) for flat sealing ring connection
Fig. 5. External thread connection with nut and olive
4
18 +0.2
--0.2
15
1
Fig. 8. Pipe (dia 15 mm) for flat sealing ring connection
23.40.15
15 +0.10
--0.05
15
1.50.1
7.50.2
Fig. 9. Pipe end for O--ring connection
23.4 +0.2
--0.2
15
1
Fig. 10. Pipe (dia 15 mm) for flat sealing ring connection
23.4 +0.2
--0.2
18
Fig. 6. External thread connection with nut and
O--ring
5
1
Fig. 11. Pipe (dia 18 mm) for flat sealing ring connection
With 3/4 nut and flat sealing ring for pipe 15 mm (see fig 4.)
WARNING
To avoid decreasing of performance of pressure
regulator by pinching off the pressure feedback tubing,
it is recommended to use a tube material which will not
kink.
10
EN2R--9025 0108R6--NE
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY OR
DEADTH
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 leaks, which could cause flasback
in the appliance vestibule. Light the main burner.
With the main burner in operation, paint all pipe joints
(including adapters) and gas control inlet and outlet with
with a rich soap and water solution an approved leak
detection fluid.
If another gas leak is detected, tighten adapter screws,
joints and pipe connections.
Replace the part if gas leak can not be stopped.
CAUTION
Do not bend tubing at gas control after compression
fitting has been tightened, as this may result in gas
leakage at the connection.
CAUTION
Keep soap and water solution away from electrical
connections.
11
EN2R--9025 0108R6--NE
ELECTRICAL CONNECTION
Electrical connection details
See Product Handbook EN2R--9028
IMPORTANT
Disconnect power supply to prevent electrical shock
and/or equipment damage.
Wiring must be in accordance with local regulations.
The appliance manufacturers instructions should
always be followed when provided. If such
instructions are not provided see the connection
diagrams for typical systems.
Before installing or replacing any control check that
type number is correct for the application.
Ensure combustion chamber is free of gas before
start up.
Conduct a thorough check out when installation is
completed.
12
EN2R--9025 0108R6--NE
WARNING
Adjustments must be made by qualified persons only.
If the appliance manufacturer supplies checkout and/
or service and maintenance instructions carefully
follow them. If these instructions are not provided then
use the procedure outlined below.
NOTE: For adjustment of additional electrical minimum setting
and/or gas outlet pressure during ignition see
appropriate Product Handbook of ignition control.
Final checkout
After installation and any adjustment start the appliance and
observe a complete cycle to ensure that all burner
components function correctly.
Pressure tap
The gas control is provided with a pressure tap of 9 mm outer
diameter. at inlet and outlet side.
When checking the pressure undo the screw a half turn and
slip tube over nipple.
Ensure that screw is retightened after making test.
13
EN2R--9025 0108R6--NE
M
N
D
G
F
B
A
E
J
14
EN2R--9025 0108R6--NE
15
EN2R--9025 0108R6--NE
Standards:
The VK4105G has been designed to meet the European
Standards:
EN 88: Pressure govenors
EN 126: Multifunctional controls.
EN 161: Automatic shut off valves
The safety shut off valve meets class B requirements.
The servo operated main valve meets class J requirements.
A class J valve as mentioned in EN 161; 1997 is equal or
better than a class D valve as mentioned in EN 297 and
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 Compatability
standards for non--industrial appliances.
16
EN2R--9025 0108R6--NE
ORDERING INFORMATION
When ordering specify:
Model number of CVI gas control component required: see
model number chart below.
The correct pilot burner for the installation concerned: refer
to Honeywell ignition products guide EN0R--0038.
VK 4 1 0 5 G 9999
Specification number
4: line voltage
17
EN2R--9025 0108R6--NE
Configuration
O--ring
g
Screws
Packing
gq
quantity
y
(
(pcs)
)
Order number
Straight Elbow
3/
8
3/
8
3/
8
3/
8
1/
2
BSP.Pl
--
YES
YES
200
45.900.400--101
BSP.Pl1)
--
YES
YES
200
45.900.400--103
BSP.Pl1)
--
YES
NO
200
45.900.400--129
BSP.Pl2)
--
YES
YES
200
45.900.400--128
BSP.Pl
--
YES
YES
200
45.900.400--102
1/
2
1/
2
1/
2
1/
2
1/
2
1/
2
1/
2
BSP.Pl
--
NO
NO
200
45.900.400--106
BSP.Pl
--
YES
NO
200
45.900.400--131
BSP.Pl1)
--
YES
YES
200
45.900.400--104
BSP.Pl1)
--
NO
NO
200
45.900.400--108
BSP.Pl1)
--
YES
NO
200
45.900.400--130
NPT
--
YES
YES
200
45.900.400--122
--
YES
YES
200
45.900.400--132
--
YES
YES
200
45.900.400--123
NPT1)
18.4 mm
1)
2)
18
EN2R--9025 0108R6--NE