product handbook

S4965 SERIES
COMBINED VALVE AND BOILER CONTROL SYSTEMS
PRODUCT HANDBOOK
APPLICATION
The S4965 boiler controls have been developed for application
in gas fired domestic appliances.
The S4965 boiler controls are used in conjuction with the
VK41.. series modulating or non modulating gas controls. (see
Product Handbook EN2R-9025 and EN2R-9004) They provide
both an optimised safety sub-system for programmed safe
light-up and flame supervision of the main burner of the
appliance and a boiler comfort control sub system for
temperature, pump, and 3-way valve control
Bi-directional communication with a MMI enables
comprehensive diagnostics and operation.
For glossary of terms, abbrevations and symbols see
document EN2R-9039
Contents
General
Subject to change without notice. All rights reserved.
Description ......................................................................... 2
Features ............................................................................ 3
Dimensional drawing S4965 boiler control ........................ 4
Technical
Specifications .................................................................... 5
Connection diagram .......................................................... 7
Timing diagram ................................................................ 8
Description of LOCON ...................................................... 9
Description of SQUARE ................................................... 10
General considerations ................................................... 11
Electrical connections and wiring .................................... 12
Adjustments and final checkout ...................................... 13
Various
EMC guidelines ............................................................... 14
Quality assurance statement ........................................... 15
Standards and approvals ................................................ 15
Ordering information ....................................................... 16
1
EN2R-9053 0408R11-NE
DESCRIPTION
The Combined Valve Boiler Control (CVBC) is the
combination of a VK41.. modulating or non-modulating gas
control with an electronic boiler control.
The boiler control consists of an automatic ignition control and
a comfort boiler control.
Most of the standard control functions of a gas fired boiler can
be performed within one single control box which can easily be
clicked on the gas control.
Possible applications are:
• Instantaneous water heaters.
• Floor standing boilers.
• Combi boilers.
• Low Nox boilers.
• Condensing boilers.
• See chapter Features for the standard features which can
be implemented in this control box.
EN2R-9053 0408R11-NE
M
T
SE
RE
2
AR
AL
FEATURES
• Multi trial full sequence ignition control.
• Permanent operation in accordance with EN 298 (2003).
• Non volatile lock-out.
• Self learning ignition sequence; no minimum adjustment,
using LOCON.
• Direct Burner- or Intermittent Pilot operation.
• Integral ignition including emission filter.
• Combined ignition and flame sensing option.
• Phase insensitive flame detection.
• Lock-out at flame simulation.
• Restart after flame loss.
• AC or DC fan control (24 VDC fan needs external trafo).
• Dynamic airflow check.
• Lock-out on no air.
• Automatic fan assisted/atmospheric recognition.
• Integral gas pressure modulation circuitry.
• Pump control.
• 3-way valve control.
• Multi temperature CH and DHW control with DHW priority
setting.
• ∆T control in CH mode
• Flow sensor input for DHW detection and control
• Sensor- or contact switch high limit at control.
• Communication to MMI enabling comprehensive
diagnostics and operation.
• Factory safety parameter settings.
• Installer and OEM comfort boiler control parameter
settings.
• On board transformer and wiring center.
• Integral and/or remote reset and alarm indicator.
• Electrical safety in accordance with EN 60730-1 (2000).
• Replacable fuse
• OpenTherm communication
3
EN2R-9053 0408R11-NE
DIMENSIONAL DRAWING S4965 BOILER CONTROL
X1
X12
X11
18
10
16
5
1 98
14
Material : ABS - V0
6
61
11 3 1
17
Tolerances ± 1 mm
unless noted
115
110
24
16
120
117
82
64
46
12
33
Molex Minifit (for X1) and Microfit (for X11 and X12) can be
used as alternatives
FOR CONNECTORS, USE FEMALE PARTS
Plastic part
Pins
Terminal
X1
TYCO 1-106527-0
10
TYCO 106528-2 (reel)
(for AWG 22-26, insulation
diameter 1,20 - 1,75 mm)
X11
TYCO 794617-6
6
X12
TYCO 1-794617-6
16
X12
TYCO 1-794617-8
18
TYCO 794607 (reel)
TYCO 794611
(for AWG 26-30)
Material : ABS - V0
Tolerances ± 1 mm
unless noted
6,6 ± 0,4
3,3 ± 0,3
68,1 ±0,3
33,4
48,2
74,65
Dimension cover
EN2R-9053 0408R11-NE
4
SPECIFICATIONS
Models
Basically there is one PCB for a number of applications.
Depending on which components are mounted different
applications can be covered.
Atmospheric combustion
Normal
Application
On /Off
Modulation
Premix combustion
Combustion feedback
(LoCon)
SQUARE
Normal
(Pneumatic
gas/air)
(Electronic gas/air
or Gas addaptive)
Open flue
Fan assistant
Open flue
Fan assistant
Electronics
S4965A
S4965C
-------------
-------------
S4965V
-------------
Gasvalve
VK4105A2/C2
VK4105A2/C2
-------------
-------------
VK4115V2
-------------
Electronics
S4965AM
S4965CM
S4965AL
S4965CL
S4965V
S4965S
Gasvalve
VK4105G1
VK4105G1
VK4105G2
VK4105G2
VK4115V2
VK4105G3
Supply voltage
230 Vac -15% +10%
50Hz ± 2%
Sensors inputs (total maximum 6):
Standard NTC T7335 10k-A material
(see survey S-T7335)
High limit dual sensor 10 kOhm NTC *
(Sensor type : T7336B 1001)
* this sensor needs special input
MicroCom Communication input and output:
input:
logic “0” < 0.8 Vdc
logic “1” > 2 , < 24 Vdc (10 kOhm)
output:
open collector 24 V and 10 mA max
DC output:
depending on OS number:
9Vrac, 5mA max
or 24Vdc, 50mA and 7V, 250mA
Power consumption
5 VA
Humidity
90% RH max. at 40°C (non condensing)
Ambient temperature
-20 ... 60°C
Electrical rating
fusing:
external: 2 A slow, sand filled
optional integral: 2A slow, sand filled
230V output 1 (ac fan or lpg valve):
230 Vac, 0.8 A max, cos ϕ ≤ 0.6
230V output 2 (pump or aux):
230 Vac, 0.8 A max, cos ϕ ≤ 0.6
230V output 3 (3 way or aux):
230 Vac, 0.8 A max, cos ϕ ≤ 0.6
230V output 4 (3 way or aux):
230 Vac, 0.8 A max, cos ϕ ≤ 0.6
Total output (1..4) :
2A
Room thermostat input:
230 Vac, 1 mA or by communication
Gas valve output: :
230Vrac, 50mA
Auxilary input:
12 Vdc, 100 kOhm
Air pressure switch input:
12 Vdc, 100 kOhm
DC fan control output:
5 V 10 mA
High limit switch input:
5 Vdc, 100 kOhm
Water pressure switch input:
12 Vdc, 100 kOhm
Flow sensor input and output:
12 ± 4Vdc, 10 mA max supply open collector input
Alarm output:
12 Vdc, 5 mA or by communication
OpenTherm output and communication:
In accordance with OpenTherm standard
Electrical PCB connectors
High voltage spark:
Flame sensing:
Mains connector:
Low voltage connectors:
2.8 x 0.5 mm faston
or 4 mm round.
4.8 x 0.8 mm faston
10 pole TYCO, AMP-duac
16 or 18 and 6 pole TYCO,
MATE-N-LOCK
Flame sensing
Factory parameter setting:
minimum flame current settable between 0.5 and 5 µA
Response time ON:
< 0.2 s
Response time OFF:
<1s
5
Ignition
Spark voltage:
Spark frequency:
Spark pulse energy:
15 or 20 kV @ 30pF
15 Hz
4 or 15 µAs
Timing
Pre purge time:
Waiting time (Tw):
Pre ignition time:
Safety time (Ts):
Number of retrials:
Flame failure response time:
Stabilisation time:
Post ignition/stabilisation time:
Post purge time:
Pump over run time:
Anti cycling time:
Timing tolerance
0 ... 51 s
0 ... 51 s
0 ... 51 s
0 ... 51 s
0 ... 255
1s
0 ... 51 s
0 ... 51 s
0 ... 51 s
0 ... 600 s
0 ... 255 s
± 5%
EN2R-9053 0408R11-NE
Communication
Bit rate:
Byte format:
2400 baud
1 start, 8 data, 1 stop,
no parity
Bit value “1“:
low line level at connector
Bit value “0“:
high line level at connector
RS232 with additional PC cable (nr. 45.900.419-038).
(see document EN2R-9066)
Cable and wiring length
flame sensing cable and spark cable 0.5 m max.
for external components 0.5 m max., except heat demand
Remote reset
Maximum of 5 resets in 15 minutes
Tolerances and product life
Spark frequency at 230 V line voltage
0.7 fspark ≤ fspark ≤ 1.4 fspark
Spark energy
>0.6 * specified spark energy
Product life
500.000 cycles for safety and main valve operator of gas valve
250.000 cycles at rated loads
6.000 lock out operations with rated loads
EN2R-9053 0408R11-NE
6
CONNECTION DIAGRAM
Tx
COM / GND
in / out
out
out
10*
18*
10
6
16*
5
1
8*
9*
out
N
out
out
L
in / N
COM / GND
in / out
9
1*
6
4
3
1
1*
in / out
in / out
in / out
in / out
in / out
in / out
in / out
in / out
in / out
in / out
Vdc (output)
Rx
* : depending on OS number
230Vac
Safety Extra Low Voltage (SELV)
Fig. 1. General connection diagram CVBC
Due to software parameters and hardware jumpers,
specific configurations can be made.
See OS# specific connection diagram !
Connection diagram is mounted on the back of the
housing
IN/OUT can only be configured as input or output.
Fig. 3. Side connection CVBC for sparking to ground
Fig. 2. Side connection CVBC for closed loop sparking
Fig. 4. Side connection CVBC for combined ignition and
flame sensing
7
EN2R-9053 0408R11-NE
TIMING DIAGRAM
P
DBI +
IP pilot
IP
main valve
Alarm
Tpre purge
Tpre ignition
Tstab
Tpre purge
Fig. 5. General timing diagram CVBC
EN2R-9053 0408R11-NE
8
Tpre ignition
Ts
Tpost purge
DESCRIPTION OF LOCON
LOCON is based on the phenomena that the ionisation flame
current in an atmospheric boiler is almost linear with burner
load. (see fig. 7)
Using this property the critical minimum pressure and ignition
pressure adjustment can be avoided.
If a throttle is used for maximum pressure regulation no
adjustment is needed.
Only injectors have to be changed if LPG is needed.
LOCON means Load Control.
LOCON is able to measure and control the load of a gas fired
heating appliance.
LOCON is suitable for atmospheric (with or without fan)
modulating boilers.
Features are:
No or minimum adjustments of VK4105G2000 valve at the
production of the combiboiler.
Improvement of the DHW temperature control performance.
Easy swap from LPG to natural gas
( see fig. 6.for the control flow diagram )
LOCON loop
temp.
setpoint
+
temp.
control
-
PI control
Valve current control
Burner
+
Heat exchanger
ionisation current
NTC temperature sensor information
Fig. 6. LOCON control flow diagram
I flame (P0)
throttle-adjustment
at Pi-nom
I flame-max
P0 max
I flame (P0) ign
I flame (P0) max
B min B ign
B max
Boilerload
Fig. 7. Ionisation flame current versus the boiler load
REMARK: Electrode postition and choice is important.
In cooperation with Polidoro, Honeywell has made
a standard solution.
New applications require Honeywell approval.
9
EN2R-9053 0408R11-NE
DESCRIPTION OF SQUARE TECHNOLOGY
SQUARE is based on the phenomena that the ionisation
current is a measure of the gas quality at a specific range of
the burner load in a fully premix burner.
SQUARE is the abbreviation of Self adaptive, Quality, User
friendly, Adjustment free, Reliable, Environmental friendly.
SQUARE is able to control the load and burning process of a
fully premix heating appliance under varying gas quality
conditions. See fig. 8.
After calibration based on this phenomena, the burner can be
influenced by means of a micro bridge flow sensor. see fig. 8.
If the gasvalve is closed, the micro bridge acts as an airflow
meter in order to measure the chimney resistance.
Features are :
• Gas adaptive control over the full natural gas band, with a
modulation range of 1:5
• Electronic gas-air at a constant gas quality with a
modulation range of 1:10
• Automatic chimney lenth compensation
AIR
Pmix
Pair=1013hPa
FAN
u-bridge
GAS
CVI-M
Pgas
Fig. 8. schematic SQUARE system
EN2R-9053 0408R11-NE
10
GENERAL CONSIDERATIONS
To ensure reliable long term operation, mount the boiler
control at a position in the appliance with a low ambient
temperature and a low radiation.
The boiler control should be externally fused.
High temperatures will affect product life.
NOTE 1.: When first starting the boiler control has a self
check time of about 10 seconds.
NOTE 2.:
Electrical rating of connected controls should be
appropriate for the load that is switched by the
boiler control.
NOTE 3.:
Disconnect the boiler control from mains before
performing a dielectric strength test.
NOTE 4.:
When first starting, the control can be in the lockout condition; reset the boiler control.
NOTE 5.:
The flame connection pin of all types is not
protected against electrical shock.
NOTE 6.:
An automatic return high limit thermostat can be
used.
Gold contacts for high limit thermostat are
required.
NOTE 7.:
The modulation function of the S4965 boiler
control units is checked during the start up safety
check. As a result the gas technical safety of the
appliance provided with a S4965 boiler control
unit can rely on the proper functioning of the
adjustable gas outlet pressure during ignition of
this boiler control unit.
This means that due to a safe ignition pressure
level, the safety time of the boiler can be
extended.
NOTE 8.:
Exhaust temperature protection may only be used
in non safety critical applications.
NOTE 9.:
Remote reset function may only be used in
applications where a maximum of five resets per
15 minutes is allowed.
WARNING
Honeywell is not responsible for damage and/or injury
due to mis wiring.
After installation boiler control can become wet due to
condensation. Do not connect wet device to mains.
11
EN2R-9053 0408R11-NE
ELECTRICAL CONNECTIONS AND WIRING
WARNING
Take care that installer is a trained experienced service
person.
Disconnect power supply to prevent electrical shock
and/or equipment damage.
IMPORTANT
Wiring must be in accordance with local regulations.
The appliance manufacturer’s 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.
At the first start the boiler control can be in lock-out;
depress reset button to free control.
CAUTION
Do not connect the boiler control to power supply when
it is not connected to the gas control.
Wiring
• Use leadwire which can withstand at least 105°C ambient.
• Use leadwire which is proven against moisture.
• Wiring between boiler control and spark sensing probe
should have good quality insulation, suitable for the
temperatures encountered.
• Keep high voltage spark wire at least 10 cm. away from
other wires.
• Conduct spark wire as close as possible along shield metal
or metal pipes.
Fusing
The boiler control has to be externally fused at maximum 2A
slow sand filled.
This can be done externally or optional integrated.
The integrated fuse has to be mounted and demounted as
follows:
Demount:
Press with screw driver the fuse cover
against spring inside fuse holder and
turn 90° to left. Release screw driver.
Fuse holder including fuse can be taken
out.
Mount:
Mount new fuse in fuse cover and place
total in fuse holder. Press cover carefully
against spring in fuse holder, and turn
90° to right.
Spark gap
Max. allowable spark gap 3.5 mm (recommended 3 mm.)
EN2R-9053 0408R11-NE
12
ADJUSTMENTS AND FINAL CHECKOUT
Final checkout
After installation and any adjustment start the appliance and
observe a complete cycle to ensure that all burner
components function correctly.
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.
Maintenance and service
Under normal circumstances no maintenance or service is
required.
Adjustment of gas pressure.
• The gas pressure can be adjusted after the S4965
automatic ignition control has been mounted on the
VK4100/VK4105 gas valve.
• Depending on the O.S. number the different values of the
gas pressure must be adjusted.
• Adjustments can be executed with the help of a PC tool and
a communication link between the S4965 and the PC tool.
• Adjustment is described in an O.S. number specific
instruction sheet.
Checking flame current
• The minimum value should be in accordance with specified
value.
• To check flame current connect a DC micro-Ampèremeter
between flame sensing wire and flame sensing rod.
Short micro-Ampèremeter during ignition to prevent
damage of the micro-Ampèremeter in single rod
applications.
• Meter connections polluted with e.g. alkaline substances
lying close to earth can cause flame current simulation.
Make sure no false flame current can flow from meter
connections to earth.
• If flame current is insufficient check that the flame sensing
rod is fully enveloped by the flame and that the burner and
the boiler control are reliable grounded.
13
EN2R-9053 0408R11-NE
EMC GUIDELINES
The position of the ignition cable has to be determined for lowest emission.
Do not lead ignition cable close to other cabling.
To suppress Radio Frequency Interference (RFI) the boiler
control including spark ignition cable should be mounted in
sufficient shielded environment.
EN2R-9053 0408R11-NE
14
QUALITY ASSURANCE STATEMENT
Products are manufactured under an ISO 9001 (1994) based
and certified Quality System.
The quality system is described in the Honeywell Combustion
Controls Center Quality Assurance Programme and its related
operational procedures and instructions.
The quality system is approved by Gastec against certificate
number 9.302/2.
The quality organisation 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.
Assembly inspection is performed by employees of the quality
control department, using their own authorised equipment.
All inspections (incoming and assembly) are performed by
trained personel and according inspection procedures.
STANDARDS AND APPROVALS
Approvals
The boiler control conforms with the following EC - Directives:
• Gas Appliance Directive (90/396/EEC)
• Low Voltage Directive (73/23/EEC)
• Electro Magnetic Compatability Directive (89/336/EEC)*
Standards
The S4965 has been designed to meet the European
Standards:
• EN 298 (2003): Automatic gas burner control systems.
• EN 60730-1: Automatic electric controls for household and
simular use.
Regarding electric safety, the S4965 can be used in
appliances according to European Standard for household
electrical requirements EN 60335 series
S4965 systems function in accordance with EN 298.
S4965A, AM, AL .......................................... code A/M/C/L/X/K
S4965C, CM, CL, V ..................................... code F/M/C/L/X/K
* Conformity with Electro Magnetic Compatibility Directive
regarding emission for non industrial appliances can be
assumed for all selected Ordering .Specification (O.S.).
numbers. However conformity can only be declared as part
of the appliance.
Regarding immunity, all controls comply with the levels for non
industrial appliances.
15
EN2R-9053 0408R11-NE
ORDERING INFORMATION
When ordering specify:
• Model number of CVI ignition components required: see
model number chart below.
• Order numbers of replacement parts and accessories
required.
NOTE:
boiler controls, replacement parts and
accessories will be available under ”TRADELINE”
label. Ask your wholesaler for details.
NOTE:
An up-to-date product survey, with details of all
new and existing products in these series, is
available. Contact your local Honeywell sales
representative for more information.
• Cover should be ordered seperately :
order nr: 45.900.431-014 (the same screw can be used)
Ordering Specification number
S 4 9 6 5 X 9999
S:
Residential market
4:
line voltage
9:
family code
Specification number
See page 5
6:
direct spark ignition or intermittent
pilot with safety time
5:
CVI system boiler control
Fig. 9. Model number chart S4965
Home and Building Control
Combustion Control Center Europe
Honeywell BV
Phileas Foggstraat 7
7821 AJ Emmen
The Netherlands
Tel.: +31 (-)591 695911
Fax: +31 (-) 591 695200
http://europe.hbc.honeywell.com
EN2R-9053 0408R11-NE
16