product handbook

VR46../VR86.. series
COMPACT AUTOMATIC COMBINATION GAS CONTROLS
PRODUCT HANDBOOK
APPLICATION
The Compact Automatic has been specially developed for
application in domestic central heating boilers, warm air
furnaces or water heater gas appliances.
The Compact Automatic is used in a system context in
conjunction with either a direct spark ignition (DSI),
intermittent pilot (IP) or Hot Surface Ignition control module
and associated devices to provide programmed safe light-up
and supervision of the main burner of an appliance.
Contents
General
page
Description...................................................................... 2
Feature ........................................................................... 3
Technical
Subject to change without notice. Printed in the Netherlands
Specifications ................................................................. 4
Capacity.......................................................................... 5
Electrical data low voltage ............................................ 15
Performance characteristics ......................................... 16
Dimensional drawing VR46../VR86..A/C, AB/CB.......... 18
Dimensional drawing VR46../VR86..B/D ...................... 19
Dimensional drawing VR46../VR86..A/C, AA/CA.......... 20
Dimensional drawing VR46../VR86..E/T, EA/TA .......... 21
Installation
Installation .................................................................... 22
Adjustments and final checkout .................................... 23
Construction and working principles............................. 24
Various
Quality assurance statement ........................................ 27
Standards and approvals ............................................. 28
Ordering information..................................................... 29
1
EN2R-9003 0504R9-NE
DESCRIPTION
Compact Automatic combination gas controls perform all the
functions required to safely regulate gas flow to the pilot
burner and the main burner of domestic central heating
equipment, warm air furnaces, back boilers and water
heaters.
Standard conditions
• Pinlet 25 mbar nominal pressure, dry air of 20°C
• Pambient 1013 mbar
• Tambient 20°C
• Outlet orifice 2.8 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 and
with a short hose at 5 times the diameter.
• Nominal voltage
• Upright position, i.e. the position when the operators are
on top.
Compact Automatic combination gas controls comprise a
standard body to which a range of sub-assemblies are
factory fitted to give various system options. This makes
boiler system design much easier as technical specifications
and unit dimensions are the same for all system options.
Options include servo pressure regulation, throttle valve,
(switchable) softlite, electrical high-low control and electrical
or mechanical modulation for the complete range of control
applications.
Compact Automatic combination gas controls are available in
line or low voltage versions and in three capacity ratings for
total system versatility. Customer specific voltage models are
also offered
Compact Automatic combination gas control consist of a first
direct electric on/off operator for opening the safety valve of
class A or class B according to EN 161 and a second electric
on/off servo operator valve for opening the main valve of
class B, C or class J according to EN 161; 1997 (for
explanation class J see chapter “Standards and Approvals”
page 40).
Compact Automatic combination gas controls are rated for
gas families MFD Group A (G 110), MFD Group B (G 120),
Natural H (G 20), Natural L (G 25) and LP (G 30).
All measurements are carried out under standard conditions,
unless otherwise is indicated.
EN2R-9003 0504R9-NE
2
FEATURES
Electrical connection options
• Both top face and bottom face AMP electrical connection
on electric on/off operator are available.
• Single plugs are available with cable and strain relief in
several versions (IP 40)
• Seperate plugs on first and second electric on/off operator
are available (IP 40).
• IP 44 connection by means of two DIN connectors is
possible.
• Quick connect 6.3 mm fastons on both coils can be
applied in combination with single cover or separate
covers with strain relief.
• Line voltage on/off servo operators are provided with a
ground screw and washer.
General
• Specially designed for use with gas appliances with a DSI,
HSI or IP system to light the main burner.
• Incorporates time proven design concepts assuring
reliability.
• ON/OFF control of main burner by electric on/off operator
and electric on/off servo operator.
• At inlet side an internal fine mesh screen is incorporated in
the Compact Automatic. This screen is not intended to be
removable for cleaning. When flanges are used,
removable screens can be placed between the flanges
and the Compact Automatic.
• Outlet screen (optional).
• Various closing force models are available: B + B, B + J,B
+ C, A + J and A + C.
• All adjustments are located on the top of the Compact
Automatic.
• 9 mm outer diameter pressure tap at inlet and outlet side
for checking and adjusting burner pressure.
• A wrench boss is incorporated at the inlet side of the
Compact Automatic for pipe fitting.
• Compact Automatic mounting orientation may be within
90_ in any direction from the electric on/off operator
upright position.
• Two threaded mounting holes are at the bottom of the
Compact Automatic for rigid attachment to the appliance.
• Main valve on/off servo operator with DIN faced electrical
connection has two threaded holes at the top for mounting
purposes (e.g. cover).
• High, medium and low capacity models are available.
• Main valve on/off servo operator employs DIN face
electrical connection which are also suitable for AMP
connections.
• The coil of the electric on/off operator is field replacable
and can also be positioned in other directions for better
accessability.
Functional options
• Servo pressure regulator provides stable outlet pressure.
• Pressure feedback ensures constant burner
pressure(optional).
• A throttle valve version is available, where unregulated
valves may be employed.
• Softlite option to facilitate a smooth light up of burners.
• Switchable softlite option for changing over from one gas
to another and vice versa.
• Electrical or mechanical modulation.
• Electrical High-Low control.
• Incorporated pilot filter (optional).
• Pilot outlet for IP system.
• Suitable for use with Gas/Air ratio components.
Gas connection options
• Inlet and outlet connections are straight through and
threaded (standard model).
• Inlet and outlet connections can receive flanges.
• Side outlet options are available for both main and pilot
gas.
• The pilot gas connection for using break away connectors
for various outer diameter tubing is located at the outlet
end of the Compact Automatic (standard model).
• The pilot gas side outlet and special end outlet are
suitable for manifold connections.
• High capacity model has straight through inlet and outlet
with Ø 23 mm bore.
3
EN2R-9003 0504R9-NE
SPECIFICATIONS
NOTE: Specifications for electrical modulation, mechanical
modulation, electrical high low, switchable softlite
and other features are available on request.
Mounting holes
Two M5 mounting holes are located on the bottom of the
Compact Automatic.
Models
See model number chart on page 41
The four holes at inlet and outlet for mounting the flange on
the Compact Automatic are provided with M5 thread with
min. 6.5 mm full thread.
Pipe sizes
- Inlet and outlet 1/2” ISO 7-1 internal parallel pipe thread.
- Inlet 18.6 mm dia and outlet 1/2” ISO 7-1 internal parallel
pipe thread
- Inlet 1/2” ISO 7-1 internal parallel pipe thread and outlet
18.6 mm dia
- Inlet and outlet Ø 23 mm bore (high capacity models only
- Inlet and outlet can also be fitted with straight or elbow
flanges.
Side outlet (optional) can only be fitted with a flange.
Ambient temperature
VR46../VR86..xA:
VR46../VR86..x:
VR46../VR86..xB:
The four holes for mounting the flange to the side outlet are
provided with M4 thread with minimum 6 mm full thread.
Two M4 threaded holes on DIN faced electrical on/off servo
operator are also for mounting purposes.
Minimum regulation capacity
0.31 m3/h
Minimum adjustable capacity (throttle valve only)
0.6 m3/h air at ∆P of 20 mbar
Minimum differential pressure at 0.31 m3/h air
0 ... 70°C
0 ... 60°C
0 ... 60°C
Model*
∆P min (mbar)
VR4601/VR8601XA
1.8
VR4605/VR8605XA
1.8
VR4611/VR8611XA
3.9
VR4615/VR8615XA
3.9
Pressure feedback connection
The servo pressure regulator has an M5 thread connection
for pressure feedback.
VR4621/VR8621XA
3.9
VR4625/VR8625XA
3.9
VR4631/VR8631XA
1.8
Enclosure
IP 40 with covers or plugs
IP 44 with DIN plugs according to DIN 43650
VR4635/VR8635XA
1.8
VR4641/VR8641XA
3.9
Pilot gas connection
Standard at end outlet:
Special connection:
M11 x 1 for 1/4”, 6 mm or
4 mm outer diameter
tubing.
incorporated in the side
outlet.
Dimensions
See Dimensional drawing page 30 thru 33
Maximum operating pressure
The Pmax indication on the housing of the Compact
Automatic is the maximum pressure at which it functions
safely. However, the maximum operating pressure is limited
by the pressure range of the pressure regulator concerned,
see table 2.
Table 2: Maximum operating pressure
Model
with regulation
VR4645/VR8645XA
3.9
VR4601/VR8601X
1.7
VR4605/VR8605X
1.7
VR4611/VR8611X
3.9
VR4615/VR8615X
3.9
VR4621/VR8621X
3.9
VR4625/VR8625X
3.9
VR4631/VR8631X
1.7
VR4635/VR8635X
1.7
VR4641/VR8641X
3.9
VR4645/VR8645X
3.9
VR4601/VR8601XB
1.7
Pressure range
(mbar)
Maximum operating
pressure (mbar)
2 ... 10
2.5 ... 20
30
3 ... 37*
45
VR4605/VR8605XB
1.7
60
VR4611/VR8611XB
3.9
100
VR4615/VR8615XB
3.9
3.9
5 ... 50*
10 ... 60*
without regulation
-
60
VR4621/VR8621XB
with throttle
-
60
VR4625/VR8625XB
3.9
VR4641/VR8641XB
3.9
* This type can also be used for non regulation mode in LP
applications when pressure regulator adjustment screw is
clockwise turned down until it stops.
EN2R-9003 0504R9-NE
* X = suffix letter
4
CAPACITY IN M3/h AIR AT PRESSURE DROP AS SHOWN.
See also the corresponding capacity curves
Safety valve
Model
Remark
Class
Main valve
Seat
(mm)
Class
Seat
(mm)
Capacity ∆P
curve
(mbar)
number
Capacity Inlet
(m3/h)
Straight
2”
1/
1
VR460.XA
VR860.XA
Standard B
11
J
17
C110
2.5
1.95
1/
VR460.XA
VR860.XA
Upgraded B
17
J
17
C210
3
2.7
1
/2”
VR460.XA
VR860.XA
Standard B
11
J
17
C110
2.5
1.4
1
/2”
VR461.XA
VR861.XA
Standard B
11
C
17
C120
5
1.8
1/
VR461.XA
VR861.XA
Upgraded B
17
C
17
5
2.5
VR462.XA
VR862.XA
Standard B
11
B
17
5
VR462.XA
VR862.XA
Upgraded B
17
B
17
C250*
VR463.XA
VR863.XA
Standard A
11
J
17
VR464.XA
VR864.XA
Standard A
11
C
VR461.VA
VR861.VA
Standard B
11
VR464.VA
VR864.VA
Standard A
VR461.V
VR861.V
Outlet
2”
/2 ”
Flange
2”
1/
1
/2”
1
/2 ”
2
1
/2”
1
/2 ”
5
2.5
1/
C110
2.5
1.95
17
C120
5
C
11
F40
11
C
11
Standard B
17
C
VR464.V
VR864.V
Standard A
17
VR460.X
VR860.X
Standard B
VR461.X
VR861.X
2”
2”
1/
1
/2”
1
/2 ”
1.8
1
/2”
1
/2 ”
10
4.2
1/
F40
10
4.2
1
17
C100
10
7.5
1/
C
17
C100
10
7.5
17
J
17
C90
3
Standard B
17
C
17
C100
VR462.X
VR862.X
Standard B
17
B
17
VR463.X
VR863.X
Standard A
17
J
17
VR464.X
VR864.X
Standard A
17
C
VR460.XB
VR860.XB
Standard B
18.5
VR461.XB
VR861.XB
Standard B
VR460.EB
VR860.EB
2”
1/
/2”
1
2”
2”
/2 ”
2”
1/
1
/2”
1
/2 ”
3.1
1
/2”
1
/2 ”
5
3
1/
5
3
C90
3
17
C100
D
17
18.5
C
Standard B
18.5
VR460.TB
VR860.TB
Standard B
VR461.EB
VR861.EB
VR461.TB
VR861.TB
2”
2”
1/
1
/2”
1
/2 ”
3.1
1
/2”
1
/2 ”
5
3
1/
C130
3
4.2
23 mm
23 mm
17
C170
5
4.6
23 mm
23 mm
J
17
C200
3
4.2
23 mm
23 mm
18.5
J
17
C200
3
4.2
23 mm
23 mm
Standard B
18.5
C
17
5
4.0
23 mm
23 mm
Standard B
18.5
C
17
5
4.0
23 mm
23 mm
2”
Side 1)
1/
2”
2”
1) versions with side outlet have 0.3 m3/h less capacity
5
EN2R-9003 0504R9-NE
EN2R-9003 0504R9-NE
6
0
1
2
3
4
5
6
7
8
9
10
11
12
0
1
G 30
Air
G 25
G 20
G 140
G 110/120
1
2
3
4
5
6
3
4
Flow (m3/h at 1013 mbar and 15 C, dry)
2
1
2
5
3
4
6
5
6
7
CAPACITY CURVE C90
_
Pressure drop (mbar)
Pressure drop (mbar)
7
0
1
2
3
4
5
6
7
8
9
10
11
12
0
1
G 30
Air
G 25
G 20
G 140
G 110/120
1
2
3
4
5
6
3
4
Flow (m3/h at 1013 mbar and 15 C, dry)
2
1
2
5
3
6
4
5
6
7
CAPACITY CURVE C100
_
EN2R-9003 0504R9-NE
EN2R-9003 0504R9-NE
8
0
1
2
3
4
5
6
7
8
9
10
11
12
0
1
G 30
Air
G 25
G 20
G 140
G 110/120
1
2
3
4
5
6
3
4
2
Flow (m3/h at 1013 mbar and 15 C, dry)
2
1
5
3
4
5
6
6
7
CAPACITY CURVE C110
_
Pressure drop (mbar)
Pressure drop (mbar)
9
0
1
2
3
4
5
6
7
8
9
10
11
12
0
1
G 30
Air
G 25
G 20
G 140
G 110/120
1
2
3
4
5
6
3
4
2
Flow (m3/h at 1013 mbar and 15 C, dry)
2
1
5
3
4
6
5
6
7
CAPACITY CURVE C120
_
EN2R-9003 0504R9-NE
EN2R-9003 0504R9-NE
10
0
1
2
3
4
5
6
7
8
9
10
11
12
0
1
2
Air
G 25
G 20
G 140
G 110/120
2
3
4
5
6
3
G 30
1
4
6
7
8
9
2
10
Flow (m3/h at 1013 mbar and 15 C, dry)
5
1
11
3
12
4
6
14
5
13
15
CAPACITY CURVE C130
_
Pressure drop (mbar)
Pressure drop (mbar)
11
0
1
2
3
4
5
6
7
8
9
10
11
12
0
1
2
Air
G 25
G 20
G 140
G 110/120
2
3
4
5
6
3
G 30
1
4
6
7
8
2
9
3
10
Flow (m3/h at 1013 mbar and 15 C, dry)
5
1
4
11
5
12
6
13
14
15
CAPACITY CURVE C170
_
EN2R-9003 0504R9-NE
EN2R-9003 0504R9-NE
12
0
1
2
3
4
5
6
7
8
9
10
11
12
0
1
2
Air
G 25
G 20
G 140
G 110/120
2
3
4
5
6
3
G 30
1
4
6
7
8
2
9
10
Flow (m3/h at 1013 mbar and 15 C, dry)
5
1
3
11
4
12
5
13
6
14
15
CAPACITY CURVE C200
_
Pressure drop (mbar)
CAPACITY CURVE C210
13
EN2R-9003 0504R9-NE
EN2R-9003 0504R9-NE
14
0
1
2
3
4
5
6
7
8
9
10
11
12
13
2
G 110/120
6
1
G 140
5
0
G 20
4
15
14
G 25
Air
G 30
3
2
1
16
17
18
19
20
4
_
2
5
Flow (m3/h at 1013 mbar and 15 C, dry)
3
1
6
3
4
7
5
6
8
CAPACITY CURVE F40
Pressure drop (mbar)
ELECTRICAL DATA LOW VOLTAGE
Table 3:
Model
Voltage (V)
Remark
Operable
voltage
(V)
First solenoid operator
Current (A)
Nominal
VR860.XA
24, 50 Hz
Standard
19.5 ... 27
0.28
VR862.XA
24, 50 Hz
Standard
19.5 ... 27
VR860.XA
24, 50 Hz
Upgraded
19.5 ... 27
VR860.XA
24, 50 Hz
Upgraded, low
consumption
VR860.XA
24, 60 Hz
Standard
VR863.XA
Nominal power
consumption
At 110%
(W)
Main valve operator
Current (A)
Nominal
At 110%
Nominal power
consumption
(W)
0.211
0.242
3.8
0.4
3.5
0.28
0.4
3.5
0.211
0.242
3.8
0.42
0.54
4.8
0.211
0.242
3.8
19.5 ... 27
0.42
0.54
4.8
0.121
0.139
2.1
19.5 ... 27
0.4
0.485
4.9
0.266
0.31
4.7
24, 50 Hz
Valve class
19.5 ... 27
A+D, small coil
0.42
0.54
4.8
0.211
0.242
3.8
VR864.XA
24, 50 Hz
Valve class
19.5 ... 27
A+C, small coil
0.42
0.54
4.8
0.211
0.242
3.8
VR860.X
24, 50 Hz
Standard
19.5 ... 27
0.45
0.56
7
0.211
0.242
3.8
VR860.X
24, 60 Hz
Standard
19.5 ... 27
0.55
0.69
8.3
0.266
0.242
4.7
VR862.X
24, 50 Hz
Standard
19.5 ... 27
0.45
0.56
7
0.211
0.242
3.8
VR863.X
24, 50 Hz
Valve class
19.5 ... 27
A+D, large coil
0.7
0.85
9.1
0.211
0.242
3.8
VR864.X
24, 50 Hz
Valve class
19.5 ... 27
A+C, large coil
0.7
0.85
9.1
0.211
0.242
3.8
VR860.XB
24, 50 Hz
Standard
19.5 ... 27
0.07
0.85
9.1
0.211
0.242
3.8
VR460.XA
230, 50 Hz
Standard
196 ... 253
0.042
0.052
4.8
0.023
0.027
4
VR462.XA
230, 50 Hz
Standard
196 ... 253
0.042
0.052
4.8
0.023
0.027
4
VR460.XA
230, 50 Hz
Upgraded
196 ... 253
0.042
0.052
4.8
0.023
0.027
4
VR460.XA
220, 60 Hz
Standard
187 ... 242
0.045
0.055
4.9
0.021
0.025
3.5
VR463.XA
230, 50 Hz
Valve class
196 ... 253
A+D, small coil
0.042
0.052
4.8
0.023
0.027
4
VR464.XA
230, 50 Hz
Valve class
196 ... 253
A+C, small coil
0.042
0.052
4.8
0.023
0.027
4
VR460.X
230, 50 Hz
Standard
196 ... 253
0.06
0.072
8.35
0.023
0.027
4
VR460.X
220, 50 Hz
Pmax. 130 mbar 187 ... 242
0.057
0.07
8.3
0.021
0.025
3.5
VR460.X
230, 50 Hz
Standard
0.06
0.072
8.35
0.023
0.027
4
VR462.X
230, 50 Hz
VR463.X
230, 50 Hz
Standard
196 ... 253
196 ... 253
0.06
0.072
8.35
0.023
0.027
4
196 ... 253
0.06
0.072
8.35
0.023
0.027
4
VR464.X
230, 50 Hz
Standard
196 ... 253
0.06
0.072
8.35
0.023
0.027
4
VR460.XB
230, 50 Hz
Standard
196 ... 253
0.06
0.072
8.35
0.023
0.027
4
15
EN2R-9003 0504R9-NE
PERFORMANCE CHARACTERISTICS
Maximum allowable leakage
Each Compact Automatic has been factory tested to meet the
following leakage requirements:
SOFTLITE versions
see table 5 on page 17.
At standard test conditions the adjusted outlet pressure will
be reached between 5 and 20 seconds from start of flow (for
LP gas between 4 and 10 seconds).
- outerwall:
50 cm3/h at test pressure of 150 mbar.
- safety valve:
40 cm3/h at test pressure of 8 and 150 mbar.
- main valve (plus operator inlet valve):
40 cm3/h at test pressure of 8 and 150 mbar.
Oscillation
Maximum oscillation under all circumstances: p 0.5 mbar.
Tap sensitivity of outlet pressure set point
For all gases the maximum deviation may be 1 mbar.
Repeatability of outlet pressure set point
For all gases the maximum deviation from set point is $
0.3 mbar or $ 3% of the set point value, whichever is the
greatest.
Outlet pressure adjustment range capability
Natural/manuf. gas:
2.5 ... 20 mbar.
Natural/LP gas:
3 ... 37 mbar.
LP gas:
5 ... 50 mbar.
10 ... 60 mbar.
Table 4: Total set point shift
Pilot flow
Pilot flow capacity will not be less than 0.1 m3/h at 9 mbar
pressure drop.
Bleed off/recovery time of servo system
The bleed off/ recovery time of the standard SOFTLITE system
shall be within 15 seconds from operator de-energization.
For SOFTLITE system with switchable SOFTLITE adapter the bleed
off/recovery time shall be within 30 seconds from operator
de-energization.
High pressure test
In the ”OFF” condition, the Compact Automatic will withstand
3 bar (air) inlet pressure without damage. Attempts to operate
the Compact Automatic, while in this condition will not
damage it.
Tolerance
2 ... 10
2.5 ... 20
6% of the set point value or 1 mbar
whichever is the greatest
3 ... 37
6% of the set point value or 1.5 mbar
whichever is the greatest
5 ... 50
6% of the set point value or 2.2 mbar
whichever is the greatest
5 ... 50
6% of the set point value or 2.2 mbar
whichever is the greatest
10 ... 60
6% of the set point value or 2.2 mbar
whichever is the greatest
Design life
500.000 cycles for safety and main valve operator.
Cycle frequency max.100 cycles /h.
Operable voltage range
The Compact Automatic will function satisfactory between
85% and 110% of the rated voltage. See table 3. and 4.
Valve closing characteristics
The Compact Automatic 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
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 1 s maximum except fast opening versions with 0.2 mm
inlet orifice and upright position the dead time will be 2.5 s
maximum.
Outlet pressure will reach 50% of the outlet pressure setting
within 1 second from start of flow or 75% within 2 seconds.
Full outlet pressure will be reached within 5 seconds.
Version without regulation or with throttle valve will reach full
outlet pressure within 5 seconds.
EN2R-9003 0504R9-NE
Pressure range
(mbar)
16
Table 5: Main valve (class D only) opening characteristics SOFTLITE versions
SOFTLITE
3
5
7
9
10
number
Inlet pressure
(mbar)
Kind of gas
20
G 20/25
3
5
7
9
10
5
7
9
10
37
G 30/31
5
7
9
10
5
7
9
10
5
7
9
10
50
G 30/31
Applicable for
switchable
softlite adapter
Dead time (s) max
Outlet pressure
(mbar) 1.5 s after
start of flow**
Upright
position
Horizontal
position
no
2.0***
1.5
1.5
1.5
1.5
1.7
1.2
1.2
1.2
1.2
2.0 ... 4.0
2.5 ... 6.0
4.5 ... 7.5
6.5 ... 9.0
9.0 ... 15.0
yes
1.8***
1.3
1.3
1.3
1.3
1.5
1.0
1.0
1.0
1.0
2.0 ... 3.5
3.0 ... 5.5
5.0 ... 7.0
7.0 ... 9.0
9.5 ...15.0
no
2.5
1.8
1.8
1.8
1.8
1.5
1.5
1.5
1.0 ... 4.5
2.5 ... 6.5
4.5 ... 8.0
7.5 ...14.5
yes
2.0
1.5
1.5
1.5
1.4
1.2
1.2
1.2
1.5 ... 4.0
3.0 ... 6.0
5.0 ... 7.5
8.0 ... 14.0
no
3.3
1.5
1.5
1.5
2.4
1.2
1.2
1.2
1.0 ... 4.5
2.5 ... 6.5
3.5 ... 8.0
6.5 ...14.5
yes
2.5
1.3
1.3
1.3
1.8
1.0
1.0
1.0
1.5 ... 4.0
2.5 ... 5.5
4.0 ... 7.5
7.5 ... 14.0
** For suffix T with throttle full open
*** In case of closed combustion chamber with negative
pressure, deadtime is 1.5 s
17
EN2R-9003 0504R9-NE
DIMENSIONAL DRAWING VR46../VR86..A/C, AB/CB
EN2R-9003 0504R9-NE
18
DIMENSIONAL DRAWING VR46../VR86..B/D
19
EN2R-9003 0504R9-NE
DIMENSIONAL DRAWING VR46../VR86..A/C, AA/CA, AB/CB,VA
EN2R-9003 0504R9-NE
20
DIMENSIONAL DRAWING VR46../VR86..E/T, EA/TA
21
EN2R-9003 0504R9-NE
INSTALLATION
Perform gas leak test
Warning
Warning
Take care that installer is a trained experienced
service person.
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY OR
DEATH
Turn off gas supply before starting installation.
Disconnect power supply to prevent electrical shock
and/or equipment damage.
Check for gas leaks with a rich soap and water
solution any time work is done on a gas control.
Mounting position
The Compact Automatic can be mounted 0 to 90 degrees in
any direction from the upright position (from the position
when the operators are on top).
Gas leak test
• Paint all pipe connections upstream of the gas control with
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 or 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.
Main gas connection
• Take care that dirt cannot enter the Compact Automatic
during handling.
• Use a sound taper fitting with thread according to ISO 7-1
(BS 21) or a piece of new, properly reamed pipe, free from
swarf.
• Do not thread or tighten the pipe or pipe fitting too far (see
table below). Otherwise valve distortion and malfunction
could result.
Pipe size (inch)
Max. length of pipe thread (mm)
1
18.6
/2
CAUTION
Keep soap and water solution away from electrical
connections.
• Apply a moderate amount of good quality thread
compound to the pipe or fitting only, leaving the two end
threads bare. PTFE tape may be used as an alternative.
• Ensure the gas flows in the same direction as the arrow on
the bottom of the Compact Automatic.
Electrical connection
CAUTION
Pressure feedback connection
Switch off power supply before making electrical
connections.
Warning
Never jumper the terminals of low voltage Compact
Automatic since this may burn out the room
thermostat heat anticipator.
To avoid decreasing of performance of pressure
regulator by pinching off the pressure feedback
tubing, it is to be recommended to use a metal
tubing.
Take care that wiring is in accordance with local
regulations.
Pilot gas connection at outlet side (if applicable)
• Square off the end of tubing and remove burrs.
• Slip compression fitting over tubing.
• Insert tubing into Compact Automatic housing until it
bottoms, slide fitting into place and turn finger tight.
• Use a wrench to tighten fitting about 11/2 turn beyond
finger tight to shear of the olive. Do not use jointing
compound.
• Connect other end of tubing to pilot burner according to
the manufacturer’s instructions.
Use lead wire which can withstand 105°C ambient.
The electric on/off operator is provided with 6.3 mm quick
connect terminals suitable for 6.3 mm receptacles (e.g.
”Series 250” AMP fasteners).
The electric on/off servo operator is provided with:
both 6.3 mm terminals suitable for 6.3 mm receptacles
(e.g. ”Series 250” AMP fasteners) and screw terminals,
or is provided with:
quick connect terminals suitable for 6.3 mm receptacles
(e.g. ”Series 250” AMP fasteners) or for a female
connector according to DIN 43650.
CAUTION
Do not bend tubing at Compact Automatic after
compression fitting has been tightened, as this may
result in gas leakage at the connection.
Wiring
Follow the instructions supplied by the appliance
manufacturer.
Pilot gas connection at side outlet (if applicable)
The pilot outlet connection at the side is only applicable with
a special flange.
EN2R-9003 0504R9-NE
22
ADJUSTMENTS AND CHECKOUT
Outlet pressure adjustment throttle versions (see page 37)
• Energize both electric operators in order to have gas input
to burner.
• Check input to the appliance using a clocking gas meter or
alternatively a pressure gauge connected to the outlet
pressure tap.
• Turn the flow adjustment screw with a screw driver either
way until the burner pressure required is recorded on the
pressure gauge.
IMPORTANT
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.
CAUTION
Check of slow opening (SOFTLITE)
The SOFTLITE pressure is factory set.
To ensure a safe closing of the valves, it is essential
that voltage over the terminals of both electric
operators is reduced to 0 Volt.
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 burner several times (wait 15 seconds
between cycles to allow servo system to resume slow open
action). Repeat check of slow opening after allowing the
appliance to cool down.
Outlet pressure adjustment servo regulated versions
(see page 32 or 36)
• Disconnect pressure feedback connection (if applicable)
• Energize both electric operators in order to have gas input
to burner.
• Check gas input to the appliance using a clocking gas
meter or alternatively a pressure gauge connected to the
outlet pressure tap.
• Remove pressure regulator cap screw to expose pressure
regulator adjustment screw.
• Slowly turn adjustment screw with a small screw driver
until the burner pressure required is recorded on the
pressure gauge. Turn adjustment screw clockwise to
increase or counter-clockwise to decrease gas pressure to
the burner.
• For non-regulating mode (LP gas) turn adjustment screw
clockwise until it stops.
• Replace pressure regulator cap screw.
• Connect pressure feedback connection (if applicable).
Final checkout of the installation
Set appliance in operation after any adjustment and observe
several complete cycles to ensure that all burner components
function correctly.
23
EN2R-9003 0504R9-NE
CONSTRUCTION AND WORKING PRINCIPLES
Servo pressure regulation working. See fig. 1.
The Compact Automatic features the positive servo system,
i.e. the main gas valve is closed by spring pressure in the
normal shut down position and can only be opened when gas
pressure is sufficient to overcome the spring force. This
valuable built in safety feature ensures the main valve wil
automatically close in the event of power or gas supply
failure.
When the force operated by the pressure is greater than that
preset by the adjusment 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 continuously maintained by
comparing it to the preset pressure and adjusting the position
of the main valve accordingly. This means that a constant
outlet pressure is maintained regardless of inlet pressure
variations.
The heart of the system is the servo pressure regulator which
consists of a pressure relief valve integrated in a regulator
diaphragm which is fitted above and controls the main valve.
At shut down, the small volume of working gas in the
regulator and in the diaphragm chamber is dumped into the
main outlet chamber.
When the direct on/off operator and servo on/off operator are
energized, inlet gas flows through the servo orifice and
through the open operator valve into the servo system and
into the regulator. This servo gas moves the main valve
diaphragm upwards enough to open the main valve. As soon
as the main valve has opened, the outlet pressure generated
by the Compact Automatic will be sensed by the regulator
diaphragm via the feedback channel.
A reference pressure feedback connection further regulates
the outlet pressure by compensating for differences in the air
pressure in the combustion chamber and at the valve.
If pressure regulation working is not needed, the regulator
spring can be blocked by turning the adjustment screw down
until it stops or the pressure regulation is removed. In these
cases the full servo gas pressure opens the main valve as far
as the pressure drop allows.
ON position
Fig. 1. Servo pressure regulator working
EN2R-9003 0504R9-NE
24
SOFTLITE working
Some burners function well using fast opening valve with the
pressure build up as shown in fig. 5. However, other burner/
appliance combinations need a means of improving their
ignition characteristics by providing quieter ignition and
reducing flame roll-out. The SOFTLITE mechanism achieves this
by changing the profile of the outlet pressure curve as shown
in fig. 2.
SOFTLITE with
adapter
Fast open
Outlet pressure (mbar)
SOFTLITE
An extra diaphragm and spring are inserted below the main
diaphragm. When the electric servo operator valve is opened,
working gas enters the SOFTLITE module via the inlet orifice,
and is fed into the space between the diaphragms. Working
gas pressure rapidly increases to a preset level, partially
opening the main valve (See fig. 3.).
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.
Only when the SOFTLITE spring has been totally compressed
does the working gas pressure increase rapidly once again
until the full fire position is reached.
0
Time (s)
Fig. 2. Opening characteristics
OFF position
SOFTLITE
SOFTLITE
ON position,
gas only, main valve partially open
SOFTLITE
ON position, main valve open
Fig. 3. Servo pressure regulation SOFTLITE models
25
EN2R-9003 0504R9-NE
Throttle valve working (See fig. 4. )
The throttle valve is situated after the main valve and can be
adjusted by a screw. With the throttle the outlet pressure can
be adjusted in relation to the inlet pressure.
The throttle screw has a rotation reduction of 4 : 1 to the
throttle and can be fully rotated.
Trottle open
Trottle closed
Fig. 4. Throttle adjustment
EN2R-9003 0504R9-NE
26
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.
At the end of the assembly phase, all gas controls are
leakage and performance tested/adjusted.
Assembly inspection is performed by employees of the
quality control department, using their own equipment.
All inspections (incoming and assembly) are performed by
trained personel and according inspection procedures.
27
EN2R-9003 0504R9-NE
STANDARDS AND APPROVALS
Standards
The Compact Automatic has been designed to meet the
European Standards:
Approvals
The Compact Automatic conforms with the following
Directives:
• EN 88: Pressure governors
• EN 161: Automatic shut-off valves
• EN 126: Multifunctional controls.
• Gas Appliance Directive (90/396/EEC)
• Low Voltage Directive (73/23/EEC)
• Electro Magnetic Compatability Directive (89/336/EEC)
The safety shut off valve meets class A or B requirements
depending on model number.
The fact that the Compact Automatic is certified to european
standards EN 88, EN 161 and EN 126 means that the
Compact Automatic meets more stringent requirements than
laid down in the essential requirements stated in the
directives and therefore meet the requirements in all EC and
EFTA countries.
The servo operated main valve meets class J requirements in
case of VR4601/VR8601 and VR4605/VR8605 and meets
class C requirements in case of VR4615/VR8615.
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.
Details per O.S. number can be found in the Approvals List.
In addition our controls have been certified by DIN-DVGW in
Germany. The registration number specific for each O.S.
number is mentioned on the label of the control.
According to bending stresses the Compact Automatic meets
the highest requirements (group 2).
The pressure governor meets class B performance.
Regarding electric safety, the Compact Automatic can be
used in appliances according to European Standard for
household electrical requirements EN 60335 series.
The Compact Automatic also meets all Electro Magnetic
Compatability standards for non-industrial appliances.
EN2R-9003 0504R9-NE
EC -
28
ORDERING INFORMATION
NOTE: Most models of valves, replacement parts and
accessories will be available under ”TRADELINE”
label. Ask your wholesaler for details.
When ordering specify:
• Model number of Compact Automatic required: see fig. 6.
• Inlet and outlet pipe sizes required: note pipe sizes
determines capacity.
• The correct pilot burner for the installation concerned:
refer to Honeywell ignition products guide EN0R-0038.
• Order numbers of replacement parts and accessories
required, i.e. flanges, compression fittings: see
replacement parts/accessories.
Ordering Specification number
VR 4 6 0 1 A (A) 9999
VR: dual valve
Specification number
4: line voltage
8: low voltage
A: Low capacity model
B: High capacity model
6: Compact/Compact Automatic
family
A:
B:
C:
D:
E:
G:
H:
M:
N:
P:
Q:
T:
R:
fast opening with regulator
fast opening without regulator
softlite opening with regulator
softlite opening without regulator
fast opening with throttle valve
fast opening with combi plate
softlite opening with Modulec
fast opening with Modureg
softlite opening with Modureg
fast opening with High-Low
softlite opening with High-Low
softlite opening with throttle valve
fast opening and suitable for
gas/air application
V: fast opening with integrated
1:1 gas/air regulation
Valve classification
0: Class B + J
1: Class B + C
2: Class B + B
3: Class A + J
4: Class A + C
5: Class A + B
6: Class A + A
1: Pilot outlet
5: No pilot outlet
Fig. 5. Model number chart
29
EN2R-9003 0504R9-NE
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-9003 0504R9-NE
30