Honeywell S4565 Series, Production Handbook

Page 1: ...r programmed safe light up and flame supervision of the main burner of the appliance 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 NOTE The Combined Valve and Ignition CVI product concept consists of a specially designed gas valve family in combination with a dedicated ignition control...

Page 2: ...00 series 25 System operation S4565AD BD CD DD PD QD RD SD TD 2000 series 30 Specifications S4565AF BF CF DF PF QF RF TF 33 System operation S4565AF BF CF DF EF PF QF RF TF 35 Application note S4565BF with second main valve control 38 Application note S4565DF TF with external main burner interrupt 39 Specifications S4565PV QV RV TV 42 System operation S4565PV QV RV TV 45 S4575 ignition controls Sp...

Page 3: ...Direct Burner Ignition DBI or Intermittent Pilot ignition IP with a defined safety time for applications with or without fan with flame detection volatile or non volatile lock out optional remote reset fixed waiting times and in case of flame failure recycling of the full start up sequence S4575 Hot Surface Ignition HSI with a defined safety time for applications with or without fan with flame det...

Page 4: ...eries Optional safe separation flame relay output or opto coupler Optional main burner interrupt for S4565BF DF QF TF Volatile or non volatile lock out according to EN 298 EMC filter optional Protective impedance flame rod Under voltage protection Flame relay option Option of separate power supply and heat demand input Optional flame retarding housing UL 94 V0 Electrical connection options Connect...

Page 5: ...AL DRAWING HOUSING Fig 1 Dimensional drawing housing in mm Ignition 72 115 60 50 113 Mounting hole Ø 3 2 Flame detection 30 29 19 Connector pins suitable for Molex 3001 female connectors Note specific housings may deviate from drawing ...

Page 6: ...ING Fig 2 Dimensional drawing old style housing in mm do not use for new designs 111 Connector pins suitable for Molex 3001 female connectors 62 Mounting hole Ø 3 2 69 29 19 18 5 69 110 Ignition Flame detection Note specific housings may deviate from drawing ...

Page 7: ...rews included Order number 45900431 005 Order number 45900431 007 screw included Choose one cover set 1 Choose one cover set 1 Choose one cover set 1 Choose one cover set 1 Cover set with integrated strain relief Order number 45900431 004 screw included Cover set with integrated strain relief flame retarding in accordance with UL 94 V0 Order number 45900431 005 screw included Special housing for I...

Page 8: ... when holding the cover down in direction A rotate it to mount the cable s in the strain relief in direction B Place the gasket on the pins of the gas control and finally fix the whole assembly ignition control and cover with a screw on the gas control wit a torque of 40 Ncm max Use sleeves to connect the flame sensing wire and sparking connection s In case the spark plug connections are not acces...

Page 9: ...sed safety sub system for programmed safe light up and flame supervision of the main burner of the appliance In S4565 series there are versions available for both Direct Burner Ignition DBI and Intermittent Pilot IP ignition systems with a defined safety ignition time The S4575 series are suitable for Hot Surface Ignitors The S4585 series can be used for appliances with Wild Pilot Intermittent Pil...

Page 10: ...e connector Housing degree of protection See accessories for degree of protection page 7 replacement parts and accessories page 66 Timing depending on O S number Self check time Tc 1 5 s Waiting time Tw 0 30 s Safety time Ts 3 5 55 s Extended spark ignition time Tx 0 Ts max Flame sensing Min flame current 0 9 µA Response time on 0 2 s Response time off TFR 1 s optionally other values available Ign...

Page 11: ...31 0402R15 NE CONNECTION DIAGRAM S4565A B P Q Fig 6 Connection diagram S4565A B P and Q Side connections N L Optional LM RS Optional Optional All versions 12 11 10 9 8 7 6 5 4 3 2 1 See note 3 See page 21 Fig 19 ...

Page 12: ...s a new sequence after releasing the reset button NOTE 3 If permanent alarm output neon indicator with integral resistor 150 kΩ max 1 mA NOTE 4 If an automatic return high limit thermostat is used the high limit switch in the application needs a longer return time than the trial for igni tion time of the ignition control This in order to provide non volatile lock out Suffix A B P and Q see Fig 7 W...

Page 13: ...13 EN2R 9031 0402R15 NE TIMING DIAGRAM S4565A B P Q Fig 7 Timing diagram S4565A B P and Q Tc Tw Ts Tc Tw TFR ...

Page 14: ... 8 x 0 5 mm spade terminal Flame sensing 4 8 x 0 8 mm spade terminal or 2 8 x 0 5 mm spade terminal for combined high voltage spark flame sensing PCB connectors Molex 3003 series suitable for Molex 3001 female cable connector Housing degree of protection See accessories for degree of protection page 7 replacement parts and accessories page 66 Timing depending on O S number Self check time Tc 0 1 5...

Page 15: ...M S4565C D R T Fig 8 Connection diagram S4565C D R and T P L N Side connections LM RS Optional N LPG N 10 3 7 1 11 8 2 4 5 6 9 12 See note 7 Alternative side connection for models with combined flame de tection high voltage See page 56 Fig 71 ...

Page 16: ... external ignition is switched off After flame establishment a predetermined extended ignition time can be included If flame is not established within the safety time Ts the ignition control locks out If the flame is lost during normal run the ignition control repeats the start sequence with prepurge If no air is proven by the air proving switch within the prepurge time Tp the ignition control sta...

Page 17: ...17 EN2R 9031 0402R15 NE TIMING DIAGRAM S4565C D R T Fig 9 Timing diagram S4565C and R Fig 10 Timing diagram S4565D and T Tc Tp P Ts Tc Tp TFR Tc Tp P Ts PV MV Tc Tp TFR ...

Page 18: ...4 8 x 0 8 mm spade terminal PCB connectors Molex 3003 series suitable for Molex 3001 female cable connector Housing degree of protection See accessories for degree of protection page 7 replacement parts and accessories page 66 Timing depending on O S number Self check time Tc 1 5 s Waiting time Tw 0 30 s Safety time Ts 3 5 25 s Extended spark ignition time 0 Ts depending on elaps of safety time Fl...

Page 19: ...Fig 12 Connection diagram S4565BD and QD 1000 series for gas air application L N LM Optional RS Side connections Optional Optional 12 11 10 9 8 7 6 5 4 3 2 1 See note 10 See page 21 Fig 17 See page 21 Fig 19 L N LM Optional RS Side connections Optional Optional 12 11 10 9 8 7 6 5 4 3 2 1 See note 10 See page 21 Fig 17 See page 21 Fig 19 ...

Page 20: ...S4565PD and QD 1000 series L N LM Optional RS N P Side connections NC NO C Optional 12 11 10 9 8 7 6 5 4 3 2 1 See note 10 See page 21 Fig 17 See page 21 Fig 19 12 11 10 9 8 7 6 5 4 3 2 1 L N LM N Side connections Optional Optional See note 10 See page 21 Fig 19 12 11 10 9 8 7 6 5 4 3 2 1 N L LM Optional Side connections Optional See note 10 See page 21 Fig 17 See page 21 Fig 19 ...

Page 21: ...g to ground Fig 18 Alternative side connection in case of combined flame sensing and sparking single rod Fig 19 Connection for opto coupler output 12 11 10 9 8 7 6 5 4 3 2 1 L N LM Optional P NC NO C Side connections Optional See note 10 See page 21 Fig 17 See page 21 Fig 19 Side connections Side connection 2 1 5V Flame output 10k ...

Page 22: ...ncluded If flame is not established within the safety time Ts the gnition control locks out If the flame is lost during normal run the ignition control repeats start sequence Suffix BD and QD see Fig 21 As AD and PD except flame relay contact or opto is closed after flame detection Suffix CD and RD see Fig 22 When there is a call for heat the fan starts running through the no air position of the a...

Page 23: ... 9031 0402R15 NE TIMING DIAGRAM S4565AD BD CD DD PD QD RD TD 1000 SERIES Fig 20 Timing diagram S4565AD PD 1000 series Fig 21 Timing diagram S4565BD and QD 1000 series Tc Tw Ts Tc Tw TFR Ts Tc Tw Tc Tw TFR LPG ...

Page 24: ...EN2R 9031 0402R15 NE 24 Fig 22 Timing diagram S4565CD and RD 1000 series Fig 23 Timing diagram S4565DD and TD 1000 series P Ts Tc Tw Tc Tw TFR P Ts Tc Tw Tc Tw TFR ...

Page 25: ...rminal in spark to ground application Flame sensing 4 8 mm spade terminal PCB connectors Molex 3003 series suitable for Molex 3001 female cable connector Housing degree of protection See accessories for degree of protection page 7 replacement parts and accessories page 66 Timing depending on O S number Self check time Tc 0 2 s Waiting time Tw 0 30 s Safety time Ts 3 5 55 s Extended spark ignition ...

Page 26: ...nnection diagram S4565AD and BD 2000 series for gas air application N Optional RS L Side connections Optional h LM 12 11 10 9 8 7 6 5 4 3 2 1 See page 29 Fig 31 See page 21 Fig 19 h RS and alarm are optional 12 11 10 9 8 7 6 5 4 3 2 1 N Optional RS L Side connections Optional h LM See page 29 Fig 31 See page 21 Fig 19 h RS and alarm are optional ...

Page 27: ...ns Optional LM P 12 11 10 9 8 7 6 5 4 3 2 1 See page 29 Fig 31 See page 21 Fig 19 RS and alarm are optional See page 29 Fig 31 See page 21 Fig 19 RS and alarm are optional N Optional RS L Side connections Optional LM 12 11 10 9 8 7 6 5 4 3 2 1 See page 29 Fig 31 See page 21 Fig 19 RS and alarm are optional N Optional Side connections Optional h LM L 12 11 10 9 8 7 6 5 4 3 2 1 See page 29 Fig 31 Se...

Page 28: ... series Fig 30 Connection diagram S4565SD 2000 series L N Optional Side connections 12 11 10 9 8 7 6 5 4 3 2 1 Optional LM P See page 29 Fig 31 and Fig 32 See page 21 Fig 19 Alarm is optional Side connections Void Not N used L valves L ignition 12 11 10 9 8 7 6 5 4 3 2 1 ...

Page 29: ...lternative side connection in case of combined flame sensing and sparking single rod Fig 33 Alternative side connection in case of combined flame sensing and sparking Fig 34 Alternative side connection in case of sparking to ground Side connections Side connection Side connections Side connections ...

Page 30: ...TE 14 The hour counter is energized when the valve is energized It can be used as an output signal Suffix CD and RD see Fig 37 When there is a call for heat self check period Tc plus waiting period Tw elapse if the air proving switch is in the no air position After Tc Tw the fan starts running When sufficient air flow is proven by the air proving switch the built in igniter and gas valve are switc...

Page 31: ...2R 9031 0402R15 NE TIMING DIAGRAM S4565AD BD CD DD PD QD RD TD 2000 SERIES Fig 35 Timing diagram S4565AD PD 2000 series Fig 36 Timing diagram S4565BD QD 2000 series Tc Tw Ts Tc Tw TFR Ts Tc Tw Tc Tw TFR LPG ...

Page 32: ...EN2R 9031 0402R15 NE 32 Fig 37 Timing diagram S4565CD RD 2000 series Fig 38 Timing diagram S4565DD TD 2000 series P Ts Tc Tw Tc Tw TFR P Ts Tc Tw Tc Tw TFR ...

Page 33: ... 240 Vac 50 60Hz 1 A cos ϕ 0 6 Electrical connection High voltage spark 2 8 x 0 5 mm spade terminal Optional 4 mm round terminal Flame sensing 4 8 x 0 8 mm spade terminal or 2 8 x 0 5 mm spade terminal for combined high voltage spark flame sensing PCB connectors Molex 3003 series suitable for Molex 3001 female cable connector Housing degree of protection See accessories for degree of protection pa...

Page 34: ... TF Side connections L N LPG LM G RS Optional 12 11 10 9 8 7 6 5 4 2 1 3 See note 17 Alternative side connection for models with combined flame detection high voltage See page 56 Fig 71 L N Side connections LM P RS Optional 12 11 10 9 8 7 6 5 4 3 2 1 See note 17 Alternative side connection for models with combined flame detection high voltage See page 56 Fig 71 ...

Page 35: ...nites pilot gas and resulting flame is detected by the flame rod After flame establishment a predetermined extended ignition time can be included then the main valve is switched on If flame is not established within the safety time Ts the ignition control locks out If the flame is lost during normal run the ignition control repeats start sequence Suffix CF and RF see Fig 43 When there is a call fo...

Page 36: ...R 9031 0402R15 NE 36 TIMING DIAGRAM S4565AF BF CF DF EF PF QF RF TF Fig 41 Timing diagram S4565AF and PF Fig 42 Timing diagram S4565BF and QF Ts Tc Tw LPG Tc Tw TFR Text Ts LPG PV MV Tc Tw Tc Tw Tstab TFR ...

Page 37: ...37 EN2R 9031 0402R15 NE Fig 43 Timing diagram S4565CF and RF Fig 44 Timing diagram S4565DF and TF P Ts Tc Tw Tc Tw TFR Text P Ts PV MV Tc Tw Tc Tw TFR Tstab ...

Page 38: ...valve control Fig 46 Timing diagram S4565BF with second main valve control Flame Side connections L N LM RS Optional 12 11 10 9 8 7 6 5 4 2 1 3 2nd main valve Lock out Gas valve See note 17 Alternative side connection for models with combined flame detection high voltage See page 56 Fig 71 Ts LPG PV 1 MV 2 MV Tc Tw Tc Tw Tstab TFR ...

Page 39: ...nd pilot gas valve are switched on The ignition spark ignites pilot gas and resulting flame is detected by the flame rod Ignition is switched off after a predetermined extended ignition time T ext and flame establishment and then the main valve is switched on If flame is not established within the safety time Ts the ignition control locks out If the flame is lost during normal run the ignition con...

Page 40: ...Fig 49 Connection diagram S4565DF TF with external main burner interrupt in atmospheric applications P Ts PV MV Tc Tw Tc Tw TFR MBI Tstab L N Side connections LM RS Optional 22 K CNY 17 3 12 11 10 9 8 7 6 5 4 3 2 1 See note 17 Alternative side connection for models with combined flame detection high voltage See page 56 Fig 71 ...

Page 41: ...41 EN2R 9031 0402R15 NE Fig 50 Timing diagram S4565DF and TF with external main burner interrupt in atmospheric applications P Ts PV MV Tc Tw Tc Tw TFR MBI Tstab ...

Page 42: ...he top of the gas control Housing degree of protection See accessories for degree of protection page 7 replacement parts and accessories page 66 Timing depending on O S number Self check time Tc 0 2 s Waiting time Tw 0 15 s Prepurge time Tp 0 15 s Safety time Ts 3 10 s Number of start trials 1 optional 2 or 3 2 or 3 only in combination with appropriate waiting or prepurge time Flame sensing Min fl...

Page 43: ...ies wired in atmospheric applications Fig 52 Connection diagram S4565RV and TV series Side connections Optional LM L N Status output or relay contact RS 12 11 10 9 8 7 6 5 4 2 1 See page 44 Fig 55 See page 44 Fig 56 Side connections Optional LM Status output or relay contact RS P N N L 12 11 10 9 8 7 6 5 4 2 1 See page 44 Fig 55 See page 44 Fig 56 ...

Page 44: ...ernative side connection in case of sparking to ground Fig 56 Connection for opto coupler output Fig 57 Alternative side connection for external AC1A199 01 igniter N Side connections Optional LM Status output or relay contact P N L 12 11 10 9 8 7 6 5 4 2 1 See page 44 Fig 55 See page 44 Fig 56 Side connections Side connections 2 1 5V Flame output 10k Side connections AC1A199 01 ...

Page 45: ...o air position After Tc the fan starts running When sufficient air flow is proven by the air proving switch the built in igniter and gas valve are switched on The ignition spark ignites gas and resulting flame is detected by the flame rod After flame establishing a predetermined extended ignition time can be included If flame is not established within the safety time Ts the ignition control locks ...

Page 46: ...QV RV TV During the start sequence the status output gives status information of the S4565PV QV RV TV The status information can be found under chapter SPECIFICATIONS paragraph Opto coupler status output on page 41 If the signal of the status output does not correspond to the specifications the comfort boiler control can shut off the ignition control Fig 58 Status output application 1 2 11 10 12 6...

Page 47: ... 9031 0402R15 NE TIMING DIAGRAM S4565PV QV RV TV Fig 59 Timing diagram S4565PV series Fig 60 Timing diagram S4565QV series Tc Tw Ts Tc Tw TFR Text Number of retrials Ts Tc Tw Tc Tw TFR Text Number of retrials ...

Page 48: ...EN2R 9031 0402R15 NE 48 Fig 61 Timing diagram S4565RV series Fig 62 Timing diagram S4565TV series P Tc Ts Tc TFR Text Number of retrials Tc Tc Ts TFR Text Number of retrials P ...

Page 49: ...49 EN2R 9031 0402R15 NE Fig 63 Timing diagram S4565RV with prepurge Fig 64 Timing diagram S4565TV with prepurge Tc Tp Ts TFR Tc Tp Text Number of retrials P Tc Tp Tc Tp Ts TFR Text Number of retrials P ...

Page 50: ...cessories for degree of protection page 7 replacement parts and accessories page 66 Timing depending on O S number Self check time Tc 1 5 s Glowing time Tg 0 30 s Safety time Ts 3 5 25 s Extended ignition time Text 0 Ts depending on elaps of safety time Flame sensing Min flame current for optional phase independent versions 0 5 µA for phase dependent versions 0 9 µA Response time on 0 2 s Response...

Page 51: ...iagram S4575A B P and Q for gas air application LM Side connections RS L N Optional Optional 24 240 V 12 11 10 9 8 7 6 5 4 3 2 1 See page 21 Fig 19 Reset switch and alarm are optional LM Side connections RS L N Optional Optional 24 240 V 12 11 10 9 8 7 6 5 4 3 2 1 See page 21 Fig 19 Reset switch and alarm are optional ...

Page 52: ...uffix A and P see Fig 67 When there is a call for heat the HSI starts glowing during glowing time Tg After the glowing time Tg the gas valve is switched on The igniter ignites gas and resulting flame is detected by the flame rod After flame establishment a predetermined extended ignition time can be included If flame is not established within the safety time Ts the ignition control locks out If th...

Page 53: ...53 EN2R 9031 0402R15 NE TIMING DIAGRAM S4575A B P Q Fig 67 Timing diagram S4575A P Fig 68 Timing diagram S4575B Q Tg Ts Tg TFR Text Ts Tg Tg TFR Text ...

Page 54: ...protection See accessories for degree of protection page 7 replacement parts and accessories page 66 Timing depending on O S number Self check time Tc 1 5 s Safety time Ts infinite Flame sensing Min flame current 1 0 A Response time on 0 2 s Response time off TFR 1 0 s Phase Phase mains trafo input 220 240 0 1 VA Ignition Spark voltage 12 kV at 40 pF load depending on O S number Repetition rate 1 ...

Page 55: ...ication L N Side connections LM NF Optional 12 11 10 9 8 6 5 3 2 1 Alternative side connection for models with combined flame detection high voltage See page 56 Fig 71 P L N Side connections LM NF Optional 12 11 10 9 8 6 5 3 2 1 LM Limiter P Air proving switch NF No flame indicator Alternative side connection for models with combined flame detection high voltage See page 56 Fig 71 ...

Page 56: ...tion high voltage using AT7030A flame detection transformer Fig 72 Alternative side connection for models with flame sense input 230Vac output for external ignition transformer S7030 Special applications input ignition control N L 2 1 Ph1 Ph2 Side connection 230 Vac N S7030 Ignition transformer ...

Page 57: ... fan is energized through no air position of air proving switch after self check time Tc When sufficient air flow is proven by air proving switch a built in igniter and pilot gas valve are swiched on The ignition spark ignites gas and resulting flame is detected by the combined flame ignition rod Ignition is switched off immediately after flame is established and main gas valve is then energized I...

Page 58: ...EN2R 9031 0402R15 NE 58 TIMING DIAGRAM S4585D Fig 73 Timing diagram S4585D Tc P PV MV NF TNF TNF Tc TFR ...

Page 59: ... be appropriate for the load that is switched by the ignition control NOTE 23 Power interruptions will cause program restart NOTE 24 The flame connection pin of all types is protected against electrical schock The gas pressure switch as mentioned in this instruction sheet is a functional device NOTE 25 If the ignition control incorporates an EMC filter disconnect the ignition controller from mains...

Page 60: ...on cable has to be determined for lowest emission Do not lead ignition cable close to other cabling To suppress Radio Frequency Interference RFI the ignition control including spark igniter cabling should be mounted in sufficient shielded environment ...

Page 61: ...ls have an integral non replaceable fuse This fuse will be blown long before the maximum 16 A external fuse switches off Spark gap Max allowable spark gap 3 5 mm Supply voltage polarity WARNING If ignition control without the phase neutral independent operation feature seems to operate normally but does not detect flame check for right polarity of power supply line neutral Checking flame current T...

Page 62: ...st 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 u...

Page 63: ...e A M C L X N S4565BF code A T C L X N S4565CF code F M C L X N S4565DF code F T C L X N S4565PF code A M C V X N S4565QF code F M C V X N S4565RF code A T C V X N S4565TF code F T C V X N S4575A B code A M C L X N S4575C D code F M C L X N S4575P Q code A M C V X N S4575R T code F M C V X N S4585D code F T R R X N or A T R R Y N NOTE S4565SD is not an ignition control but an ignition circuit and ...

Page 64: ...formation Fig 74 Model number chart S 4 5 6 X XXXX Ordering Specification number 5 X Without letter and followed by 2xxx 1xxx high limit connection D1xxx dual spark D2xxx optional phase neutral independant with high limit connection F1xxx flame relay for IP fan assited with prepurge lock out on no air frost resist M modulation on CVI T TTB A atmospheric B atmospheric flame relay C fan assisted D f...

Page 65: ...I Yes Yes Yes Non volatile S4565 PD DBI Yes Yes No Volatile S4565 QD DBI Yes Yes Yes Volatile S4565 RD DBI Yes Yes No Volatile S4565 TD DBI Yes Yes Yes Volatile S4565 AF DBI Yes Yes No Non volatile S4565 BF IP Yes Yes No Non volatile S4565 C CF DBI Yes Yes No Non volatile S4565 D DF IP Yes Yes No Non volatile S4565 PF DBI Yes Yes No Volatile S4565 PV QV DBI Yes Yes Yes Volatile S4565 QF IP Yes Yes...

Page 66: ...r S4585D 50 45 900 419 025 Molex cable for S4565AD BD DD PD QD RD SD TD 50 45 900 419 022 Molex cable for S4565C D R T and S4565AF BF CF DF EF PF QF RF TF 50 45 900 419 024 Molex cable for S4565AD BD DD PD QD RD TD 2000 series S4565BM DM S4565PV QV RV TV and S4575A B P Q 50 45 900 419 033 Molex cable for S4565AD and PD 2000 series 50 45 900 419 034 ...