45.801.
190-
1 : 1 GAS/AIR REGULATOR ASSEMBLY GAS CONTROLS
PRODUCT HANDBOOK
APPLICATION
The 1:1 gas/air regulator assembly has been specially
developed for fully premixed gas appliances.
The 1:1 gas/air regulator assembly, can be used on the
following gas controls series:
-- VK41..V/VK81..V
-- VR4..VA/VR8..VA
-- VRB..VA
When used on above mentioned gas controls series, the 1:1
gas/air regulator assembly provides the function of
regulating/modulating the gas pressure drop equal to the air
pressure drop.
Note:
The information of this handbook supplements those of the Product Handbook
-- EN2R--9004 of the VK41../VK81.. series gas controls for combined valve and ignition systems (CVI)
-- EN2R--9033 of the VR400/VR800 series class “A” servo regulated combination valves
-- EN2R--9054 VRB.. series, class “B” servo regulated combination valves
The information of this handbook specifies the today supplementary features and data but also limitations on models
and specifications of the concerned gas controls with the 45.801.190-- integrated 1:1 gas/air regulator assembly.
Subject to change without notice. Printed in the Netherlands.
Contents
General Page
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Performance characteristics . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EN2R--9017 0101R3--NE
45.801.190-
1 : 1 GAS/AIR REGULATOR ASSEMBLY GAS CONTROLS
PRODUCT HANDBOOK
Adjustments and final checkout . . . . . . . . . . . . . . . . . . . . . . 8
Various
Standards and approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Application notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EN2R--9017 0101R3--NE
DESCRIPTION
Description of gas/air 1:1 system
The gas/air control system is designed for (Combi) Boilers, WARNING
Instanteneous Hot Water and Air Heating appliances and High inlet pressures as used for gas G30 or G31, can
other heating appliances. cause oscillation. This is dependent on type of
In the boiler with a fully premixed burner, the air flow is appliance. If oscillation occurs:
controlled by a fan. In a venturi or across a restriction the air -- The oscillation shall not exceed 10 % of the outlet
flow generates an air pressure drop. The high air pressure is pressure, with a stable air pressure signal.
supplied to the gas control. -- The oscillation has to be verified for the complete
In the working mode the gas pressure drops across the main modulation band of the appliance.
burner injector is regulating and/or modulating equal to the air -- Please contact your Honeywell representative if
pressure drop across the air restriction. the maximum of 10 % is exceeded.
The system is electronically controlled to provide programmed All measurements are carried out under standard conditions,
safe light up and is in supervision of the main burner. unless otherwise is indicated.
Conditions VK41../VK81.. series
Description of 1:1 gas/air regulator assembly
Pinlet 25 mbar nominal pressure, dry air of 20 _C
The 1:1 gas/air regulator assembly is based on the servo
Pambient 1013 mbar
regulation principle.
Tambient 20 _C
The 1:1 gas/air regulator assembly has an air pressure
Outlet orifice 4.3 mm
connection and an offset adjustment screw.
Flow indication in m3/h
The 1:1 gas/air regulator equals the gas pressure to the Recording of outlet pressure with a transducer connected
supplied air pressure. With the offset adjustment screw it is to a 1/2” pipe with a length of 10 times the diameter. with a
possible to adjust the offset. (Offset = Pgas -- Pair) short hose at 5 times the diameter.
The 1:1 gas/air regulators 45.801.190--001/--002 are rated for Nominal voltage
the 1st, the 2nd and the 3rd family gases (G110, G120, G20, Sidewards position, i.e. the position when the operators
G25, G30 and G31). are in horizontal position.
The 1:1 gas/air regulators 45.801.190--004 are rated for Conditions VR4../VR8.. and VRB series
the 2nd and the 3rd family gases ( G20, G25, G30 and G31). Pinlet 25 mbar nominal pressure, dry air of 20 _C
Pambient 1013 mbar
Tambient 20 _C
Outlet orifice 12 mm
Flow indication in m3/h
Recording regulated pressure at pressure tap point 3
Nominal voltage
Sidewards position, i.e. the position when the operators
are in horizontal position.
Fig. 1. Gas/air 1 :1 system
3 EN2R--9017 0101R3--NE
SPECIFICATIONS
Model Minimum operating gas pressure
45.801.190-- 1:1 gas/air regulator 15 mbar
--001: seat with orifice 0.53 mm,
applicable for VK41../VK81.. series Maximum operating gas pressure
--002: seat with throughput opening 1mm, The Pmax 60 mbar or Pmax 100 mbar indication on the
applicable for VK41../VK81.. series housing is the maximum inlet pressure at which the gas
--004: seat with throughput opening 1mm, control functions safely.
applicable for VR4../VR8.. and VRB.. series Offset range
Dimensions --0.4 mbar ... + 0.2 mbar (with coils sidewards)
See fig. 3. page 7 --0.24 mbar ... + 0.36 mbar (with coils on top)
Pressure regulation function Maximum air pressure
Class B according to EN 88 VK41../VK81.. series
8 mbar without outlet gas pressure (before ignition)
Air pressure connection
20 mbar with outlet gas pressure present (after ignition)
Servo pressure regulator has an M5 threaded hole to make VR4../VR8.. and VRB.. series
connection between regulator and appliance.
8 mbar without outlet gas pressure (before ignition)
Outlet pressure 40 mbar with outlet gas pressure present (after ignition)
Outlet pressure is pressure drop across the main burner Accuracy
orifice.
ϖPgas -- ϖPair
Outlet pressure range Typical accuracy = x 100%
ϖPair
code--001/002: 0.5 ... 20 mbar
ϖPair = pressure drop over air restriction
code--004: 0.5 ... 40 mbar ϖPgas = burner orifice pressure drop
Maximum inlet pressure Accuracy includes tap sensitivity, repeatability, inlet pressure
60 mbar for code --001 and--002 dependency, hysteresis and temperature influence and is
100 mbar for code --004 shown on page 6
Minimum regulation capacity
VK41../VK81.. series
0.5 m3/h air at np=0.5 mbar across main burner orifice
at 100 mbar operating pressure maximum
0.7 m3/h air at np=0.5 mbar across main burner orifice
at 60 mbar operating pressure maximum
VR4../VR8.. and VRB.. series
1 m3/h air at np=0.5 mbar across main burner orifice
at 30 mbar operating pressure maximum
4 EN2R--9017 0101R3--NE
PERFORMANCE
VK41..V/VK81..V series
Opening time Design life
Model Time till P0 100 Pa The possible effect of drift over life time (500.000 cycles) is
shown as a dotted line in fig. 2. page 6.
VK4115V/VK8115V <1 s
Life test conditions
VK4125V/VK8125V < 1.5 ιPair at start and at stop: 6 mbar
VK8125V 1028 < 0.5
Conditions: Pi = 3000 Pa
P0 > 100 Pa
Position: coils horizontal or vertical
VR4..VA/VR8..VA and VRB.. series
Opening time Design life
Model Time till P0 100 Pa The possible effect of drift over life time (500.000 cycles) is
shown as a dotted line in fig. 2. page 6.
VR4..VA/VR8..VA <2 s
Life test conditions
VRB..VA < 1.5 ιPair at start and at stop: 6 mbar
Conditions: Pi = 3000 Pa
P0 > 100 Pa
Position: coils horizontal or vertical
5 EN2R--9017 0101R3--NE
_
After 500.000 cycles Ambient temperature range 0 ... 70 C
Before life test Typical dPair at start and stop: 6 mbar
30%
25%
20%
6
15%
Fig. 2. Typical accuracy
10%
TYPICAL ACCURACY = +/_ (αPGAS - αPAIR)/αPAIR X 100%
5%
0%
50 100 150 200
dPgas = burner orifice pressure drop (Pa)
EN2R--9017 0101R3--NE
DIMENSIONAL DRAWING
87
108
VK41..V/VK81..V series VR4..V/VR8..V series
Fig. 3. Dimensional drawing
7 EN2R--9017 0101R3--NE
ADJUSTMENTS, CHECKOUT AND MAINTENANCE
Energize both electric operators in order to have gas input
WARNING to burner and ignite boiler.
Adjust CO2 % at the desired value at low output with offset
Adjustments must be made by qualified persons only.
adjustment screw.Turn offset adjustment screw clockwise
If the appliance manufacturer supplies checkout and/ to increase CO2 %.
or service and maintenance instructions carefully Operate boiler on high output.
follow them. (Only modulating applications).
If such instructions are not provided then use the Replace cap screw and tighten pressure taps.
procedure outlined below.
Adjustment can only be made with a special tool.
CHECKOUT
Pressure tap
The gas control is provided with pressure taps of 9 mm outer Final checkout of the installation
diameter for measuring inlet and outlet pressure. After any adjustment check pressure taps and gas
When checking the pressure undo the screw a half turn and connections with an approved leak detection fluid for gas
slip tube over nipple. leakage.
Ensure that screw is retightened after making test. After any adjustment set appliance in operation and
observe several complete cycles to ensure that all burner
components function correctly.
CAUTION
To ensure a safe closing of the valves, it is essential MAINTENANCE
that voltage over the terminals of electric operators is
reduced to 0 Volt. Maintenance and service
Offset adjustment (see fig. 3.) Under normal circumstances no maintenance or service is
required.
Remove cap screw with a torque bit to expose offset
adjustment screw.
Check gas supply pressure to the appliance using a
WARNING
pressure gauge connected to the inlet pressure tap. Screws on the valve that have been sealed must
Start fan and check air flow. never be removed.
8 EN2R--9017 0101R3--NE
STANDARDS AND APPROVALS
The gas/air function on the VK41..V/VK81..V series is
certified by European test certificate CE--0063A/3090/6
9 EN2R--9017 0101R3--NE
APPLICATION NOTES
VK41..V/VK81..V series
Define maximum allowable deviation on αPgas at minimum 1. It is therefore advisable to verify the offset adjustment at
αPair in new appliance for reliability reasons. service interval by CO2 measurement or αPgas (burner
The application parameters can effect the Offset Adjustment orifice pressure drop) at minimum αPair (pressure drop
accuracy during cycling and life cycling of the control system. over air restriction)
These parameters are (in sequence of importance): 2. αPgas measured on pressure tap of combination gas
control (highest pressure) can deviate from real αP (burner
Start pressure and prepurge pressure (the lower the better) orifice pressure drop) due to gas turbulence and/or
Ambient temperature (the lower the better) restrictions in the application.The deviation should be
defined and should be part of the field instructions.The
measurement accuracy should be +/_ 1 Pa
For more information please contact your Honeywell
representative.
VR4..VA/VR8..VA and VRB.. series
Define maximum allowable deviation on αPgas at minimum 3. It is therefore advisable to verify the offset adjustment at
αPair in new appliance for reliability reasons. service interval by CO2 measurement or αPgas (burner
The application parameters can effect the Offset Adjustment orifice pressure drop) at minimum αPair (pressure drop
accuracy during cycling and life cycling of the control system. over air restriction)
These parameters are (in sequence of importance): 4. αPgas measured on pressure tap of combination gas
control (highest pressure) can deviate from real αP (burner
Start pressure (the lower the better) orifice pressure drop) due to gas turbulence and/or
Ambient temperature (the lower the better) restrictions in the application.The deviation should be
defined and should be part of the field instructions.The
measurement accuracy should be +/_ 1 Pa
For more information please contact your Honeywell
representative.
Home and Building Control
Combustion Controls 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
10 EN2R--9017 0101R3--NE
