Honeywell vk41, vk81 Handbook

PRODUCT HANDBOOK

1 EN2R-9004 0606R20-NE

Subject to change without notice. All rights reserved.

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

EN2R-9004 0606R20-NE 2

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../VK81.. series
and a dedicated ignition control of the series S4565/S4575/
S4585 which is connected directly on to it.

The gas control comprises a standard body to which a range
of features can be factory included to give various functional
options. These functional options include: servo pressure
regulation, throttle valve regulation, fully adjustable

SOFTLITE,

gas/air control 1:1 or amplified, electrical high-low or
modulating control to fulfil the complete range of control
applications.

The gas 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 gas families,
manufactured gas, natural gas and LP gas.

General

All measurements are carried out under standard conditions
listed below unless otherwise is indicated.

Standard conditions

• P

inlet

25 mbar nominal pressure, dry air of 20°C

• P

ambient

1013 mbar

• T

ambient

20°C

• Outlet orifice 2.8 mm

• Flow indication in m

3

/

h

• Recording of outlet pressure with a transducer connected
to a

1

/2” pipe with a length of 10 times the diameter of the
pipe with a short hose at a length of 5 times the diameter of
the pipe.

• Nominal voltage

• Upright position, i.e. the position when the operators are on

top.

3 EN2R-9004 0606R20-NE

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.

• 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 may be within 90

°

in any direction

from the electric on/off operator upright position.

Gas control

• Inlet ∅ 18.6 mm and outlet ∅ 18.6 mm connections are
straight through and can receive flanges.

• The following closing force models are available: B + J;
B + C; B + B.

• Servo pressure regulator provides stable outlet pressure.

• Pressure feedback 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

• An internal fine mesh screen is incorporated at the inlet of
the gas control. This screen is not removable for cleaning.

• An outlet screen is optional.

• 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.

• 100 mbar inlet pressure versions available on request

• Throttle valve versions

• Electrical modulation (Modureg) or CVI-m.

• Electrical High-Low control.

• Pilot outlet for IP system

• Gas/Air ratio version available.

Gas connection options

• Internal thread (ISO 7-1), external thread (ISO-R228) or
flanged connections. See table 4, 5, 6 and 7, page 9.

• Side outlet option for both main and pilot gas.

• The side outlet for pilot and main gas can only be con-

nected to a flanged burner manifold.

• Pilot gas connection for tubing with 4 mm outer diameter is
located at the outlet end of the gas control.

• Pressure feedback fittings for 4 or 6 mm silicon tube can be
mounted.

• End outlet or side outlet
Quick connection for Mini Venturi

Electrical connection options

• The appropriate ignition control can be connected to the
valve by plugging it on.

• Wired plug (IP 40) for connection with a remote ignition
control.

• Rectifier plug (IP 40) for use with any standard DBI ignition
system.

• 24 Volt versions available for use in conjunction with other
ignition controls than S4565/S4585 series.

EN2R-9004 0606R20-NE 4

DIMESIONAL DRAWING STANDARD CONNECTION

13.4

Pilot outlet M8 x 1-6H

for 4 mm tubing

24

Outlet

29.3

36.7

6.3 terminal (3)

148

VK.1..P/Q

(High/Low)

VK.1..A/C

(Standard regulator)

80

VK.1..E/T

(Throttle)

70

6.3 terminal (2)

148

VK.1..M/N

(Modureg)

24

Side outlet

Pressure tap (2)

Adjustable softlite

94.8

68.3

1

6

24.9

84.5

73

84.5

115

STEP

STEP

Hole Ø 2.6 to connect

ignition 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

Ø 18.6

The cross hatched area

is sealing face without

imperfections

32

24

12

OUT

Earth terminal

21.9

IN

62

V1 V2

Tolerances according

to ISO 2768 mK

24

VK.1..M/N

(ModuPlus)

140

5 EN2R-9004 0606R20-NE

DIMESIONAL DRAWING EXTERNAL THREAD CONNECTION

Dimensional drawing VK41.5VE/VK81.5VE (Throttle)

8

15 ref

135

105

29.4

64.9

15

15

30

11.9

36.7

91

Inlet

20.7

30

G1/2" or
G

3/4

"

13.4

1

OUT

MIN

V1 V2

IN

84.5

115

62

24.9

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

Throttle screw

Throttle screw

29,3

EN2R-9004 0606R20-NE 6

APPLICATION

The VK41.. /VK81..series gas control have been specially
developed for application in domestic appliances.

The VK41.. series gas control can be used in a system in
conjunction with a S4565, S4575 or 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 with appropriate
power supply.

7 EN2R-9004 0606R20-NE

SPECIFICATIONS

NOTE: Specifications for electrical modulation, electrical

high low, gas/air and other features are available on
request.

Models

See model number chart on page 31

Main gas connection

• Standard see table 4, page 9.

• Optional see table 5, page 9.

• 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

Pilot gas connection

Standard at end outlet: M8 x 1 for 4 mm outer diameter tubing.

Pressure feedback connection

The servo pressure regulator has an M5 thread connection for
pressure feedback.
Pressure feedback fittings for 4 or 6 mm silicon tube can be
mounted as option.

Dime nsions

See page 4 and 5

Outlet pressure range for ON/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 P

max

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 non regulation mode in LP

applications when pressure regulator adjustment screw is
clockwise turned down until it stops.

Versions up to 100 mbar maximum inlet pressure are available
on request

Mounting holes

Two mounting holes for thread forming M4 screws are located
on the bottom of the gas control.

For versions with external thread there are two additional
mounting holes for thread forming screws at the inlet side of
the gas control.

The four holes at inlet and outlet for mounting a flange on the
gas control are provided with M4 thread with min. 6 mm full
thread.

In case of side outlet the three holes for mounting the flange
are provided with M5 thread with a minimum of 6 mm full
thread.

Table 1: Minimum differential pressure

Model ∆P min (mbar)

VK4105 2.5

VK4115 4

VK4125 4

Table 2: Operating pressure

Model Pressure range

(mbar)

Maximum inlet
pressure (mbar)

with regulation 1.5 ... 20

2 ... 37*
5 ... 50*

30
45
60

without regulation - 60

EN2R-9004 0606R20-NE 8

Capacity

In m3/h air at pressure drop as shown below. See also the capacity curves concerned.

NOTE 1.: Versions with side outlet connection have a 0.2 m

3

/h air lower capacity.
NOTE 2.: Increased capacity versions are optional for types with suffix letter E, T and V.
NOTE 3.:

3

/4“ external thread versions have a 0.3 m3/h air lower capacity.

Model Extention ∆P (mbar) Capacity (m3/h air) Capacit y 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

1

st

valve 2nd valve

Classification Backpressure (mbar) Classification Backpressure (mbar)

VK4100/VK4105
VK8100/VK8105

B50J 0

VK4110/VK4115
VK8110/VK8115

B50C10

VK4120/VK4125
VK8120/VK8125

B50B50

9 EN2R-9004 0606R20-NE

Table 6: Mini-Venturi valve connection

Table 7: Throttle valve (VK....VE only) connection

Table 4: Standard valve connection

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

Table 5: 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-venturi

-135

G

3

/4” - Quick connect

mini-venturi

120

Inlet End outlet Side outlet Body length

(mm)

Flanged Flanged -- 105

G

1

/2” Flanged -- 120

G

3

/4” Flanged -- 120

EN2R-9004 0606R20-NE 10

ELECTRICAL DATA

Table 8: Electrical connection for Direct Burner Ignition systems

Supply voltage Coil indication Rectifier circuit

position

Coil connection ( fig. 1 ) Valve indication

24 Vac, 50/60 Hz 24 Vrac External Series connection pin1 and pin 5 or

plug 45.900.441-029

VK 81.5

24 Vac, 50/60 Hz 24 Vrac In plug Select plug 45.900.441- with rectifier

(See table 11)

VK 81.5

100 Vac, 50/60 Hz 100 Vrac External Series connection pin1 and pin 5 VK 41.5

110 Vac, 50/60 Hz 110 Vrac In S4575 Select plug 45.900.441-033

without rectifier (See table 11)

VK 41.5

In plug Select plug 45.900.441-039

(See table 11)

VK 41.5

External Series connection pin1 and pin 5 VK 41.5

220 ... 240 Vac, 50/60 Hz 220 ... 240 Vrac In S4565 Select plug 45.900.441-033

without rectifier (See table 11)

VK 41.5

In plug Select plug 45.900.441- with rectifier

(See table 11)

VK 41.5

External Series connection pin1 and pin 5 VK 41.5

Table 9: Electrical connection 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

Table 10: Power consumption (W) and current (mA)

Supply voltage Power consumption Current

Nominal voltage 110% nominal voltage Nominal voltage 110% nominal voltage

1

st

operator

1

st

+ 2

nd

operator

1

st

operator

1

st

+ 2

nd

operator

1

st

operator

1

st

+ 2

nd

operator

1

st

operator

1

st

+ 2

nd

operator

DBI system

24 Vac, 50/60Hz -- 9.2 -- 11 -- 424 -- 466

100 Vac, 50/60Hz -- 9.75 -- 11.9 -- 105 -- 115

110 Vac, 50/60Hz -- 8.8 -- 10.8 -- 89 -- 98

220 Vac, 50/60Hz -- 9.4 -- 11.4 -- 48 -- 52

240 Vac, 50/60Hz -- 11.2 -- 13.6 -- 52 -- 57

IP system

24 Vac, 50/60Hz 6.7 6.7 + 3.1 8.0 8.0 + 3.7 309 309 + 143 340 157

220 Vac, 50/60Hz 9.1 4.8 11 5.8 46 24 51 27

240 Vac, 50/60Hz 10.9 5.7 13.1 6.9 50 26 55 29

220Vac, 50/60Hz 7 7 + 2.2 8.3 8.3 + 2.7 31 31 + 11 35 35 + 12.2

240 Vac, 50/60Hz 8.0 8.0 + 2.6 9.6 9.6 + 3.2 35 35 + 12.1 38.4 38.4 + 13.3

11 EN2R-9004 0606R20-NE

Fig. 1. Coil connection

Rectifier plug

The 220/240 V,110V and 24 V versions of the VK4105/
VK8105 series gas controls can be connected to any standard
DBI control 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

IMPORTANTIMPORTANT

Warranty claims are not accepted if not the specified
plug/rectifier circuit is used.

V1

1Pin number 2 3 4 5

V2