Technical specification Honeywell Combustion Controls srl

Title: Esys S4965V2166

Doc. : S4965V2166_FS

1 - Revisions...........................................................................................................................................................2
2 - Reference standards and Approvals ..............................................................................................................2
2.1 – Standards ..................................................................................................................................................2
2.2 – Approvals...................................................................................................................................................2
3 – Quality assurance statement..........................................................................................................................3
4 - Identification .....................................................................................................................................................3
5- Product description...........................................................................................................................................4
5.1 - General.......................................................................................................................................................4
5.2 – Lay out .......................................................................................................................................................4
5.3 – Technical features .....................................................................................................................................5
5.4 - Timing diagram..........................................................................................................................................9
5.5 - System Parameters list (default settings)................................................................................................10
6 - Modes of operation ........................................................................................................................................11
6.1 - Start up ....................................................................................................................................................11
6.2 - Stand-by (idle) ..........................................................................................................................................11
6.3 - Normal Heating Mode...............................................................................................................................11
6.4 - Test Mode.................................................................................................................................................11
6.5 - APS (Air Pressure Switch) function ..........................................................................................................11
6.6 - Fan speed Control ....................................................................................................................................12
6.7 - Protection and error conditions.................................................................................................................14
6.8 - Ignition sequence .....................................................................................................................................16
7 - Control Panel for Esys ..................................................................................................................................16
8 - History information .......................................................................................................................................17
9 - Installation.......................................................................................................................................................17
9.1 - General remarks.......................................................................................................................................17
9.2 - Electrical connection.................................................................................................................................18
9.3 - Cables and wirings ...................................................................................................................................18
9.4 - Ionisation current check ...........................................................................................................................19
9.5 - Adjustments and final checkout................................................................................................................19
9.6 – EMC guidelines........................................................................................................................................19

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1 - Revisions

Software Date Description of amendments

R344B 08-04-2009 release: C0.02_P0.16_E0.02 (CRC = 0x287F) (OS: S4965V2131)

R344D 08-04-2009 release: C0.03_P0.19_E0.03 (CRC = 0x2119)

2 - Reference standards and Approvals

2.1 – Standards
Esys premix boiler controller meets the requirements laid down in standards-documents:

• EN298:2003
Automatic gas burner control systems for gas burners and gas burning appliances with or without fans

• EN 55014-1
Electromagnetic compatibility – Emissions

• EN 60730 - 1
Automatic electric controls for household and similar use

• Regarding electric safety, the S4965 can be used in appliances according to European Standards for household
electrical requirements EN 60335 series

2.2 – Approvals
The boiler control conforms with the following EC - Directives:

• Gas Appliance Directive (90/396/EEC)

• Low Voltage Directive (73/23/EEC)
• Electro Magnetic Compatibility Directive (89/336/EEC)*

* 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.

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3 – 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 Program and its related
operational procedures and instructions.

The quality system is approved by Gastec against certificate number 9.302/2.

The quality organization 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 authorized equipment.
All inspections (incoming and assembly) are performed by trained personnel and according inspection procedures.

4 - Identification
To ensure product tracking and identification, each board shows:

- Bar code label with production data

- CE0063BR1922 printed on the label
- Label showing firmware version, type and model burner control, programming batch, production date

Honeywell part number Customer part number Notes

S4965V2166 Derived by S4965V2075

(115V with separated flame rod)

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5- Product description
5.1 - General
Controller S4965V2166 is intended to be used for industrial DC-fan applications. It is made for fan assisted, direct burner
ignition applications. The controller operates on 115 Volts, and can drive a gas valve and a DC-fan with PWM control input.
High Limit protection is based on a low voltage switch input (Normally Closed).
The controller can operate in normal heating mode or in Test Mode. Normal heat demand is given by a 115 Volt switch
input, Test Mode is initiated by External Communication.

The S4965V2166 boiler control operates in conjunction with gas valve VK4105V2xxx family.

5.2 – Lay out

Component side view

Fig .1

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5.3 – Technical features

5.3.1 – Connector and connections

Fig .2– Connection Diagram

Remarks
• Earth must be connected to the valve, not to signal ground on X3
• Resistors must be mounted externally by OEM/Installer. No lower resistance values are allowed
• In case of CVBC replacement, following notes need to be considered:
- HL have to be connected to pin X3.10 (24V)
- Pin 9 is a voltage output 24V. The PWM pull up of 10kOhm for 4-wire fan 115VAC need to be connected
to pin 9 (see diagram above)
- Pin 11 is no more 11V voltage output as on CVBC, but 6V voltage output. Due to this the PWM pull up for
3-wire fan 115VAC has a different value (see diagram above)
The detailed table with connections is reported in the following pages.

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Connector Pin Description Connection

HIGH VOLTAGE (115V) CONNECTIONS

X1 1 Molex Minifit Heat Demand input

X1 2 Molex Minifit Alarm Output
X1 3 Molex Minifit Fan Supply - Phase
X1 4 Molex Minifit -
X1 5 Molex Minifit Main Power Line Phase
X1 6 Molex Minifit -
X1 7 Molex Minifit Alarm Output Neutral
X1 8 Molex Minifit Fan Neutral
X1 9 Molex Minifit Main Power Line Neutral
X1 10 Molex Minifit Main Power Line Neutral

SAFETY EXTRA LOW VOLATAGE (SELV) CONNECTIONS

X2 1 Molex Microfit V24

X2 2 Molex Microfit RX serial communication
X2 3 Molex Microfit V6
X2 4 Molex Microfit Ground connection
X2 5 Molex Microfit TX serial communication
X2 6 Molex Microfit -

X3 1 Molex Microfit DC Fan – Tacho input

X3 2 Molex Microfit Reset input
X3 3 Molex Microfit High Limit input
X3 4 Molex Microfit Air Pressure Switch input
X3 5 Molex Microfit DC Fan – Pwm output
X3 6 Molex Microfit -
X3 7 Molex Microfit -
X3 8 Molex Microfit Control Input (0-10V; 4-20mA)
X3 9 Molex Microfit 24 V voltage output
X3 10 Molex Microfit High Limit supply (24V)
X3 11 Molex Microfit V6
X3 12 Molex Microfit Gnd
X3 13 Molex Microfit DC Fan Gnd

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X3 14 Molex Microfit APS Gnd

X3 15 Molex Microfit Gnd
X3 16 Molex Microfit Control Input Gnd

IGNITION CONNECTION

TR1 2.8x0.5mm faston High voltage Trasformer output

FLAME INPUT CONNECTION

X6 4.8x0.8mm faston Flame rod input

5.3.2 – Specifications (nominal data)

Supply voltage
• 115 Vac. +/- 15%
• 47 – 65 Hz

Power consumption
• 2.5 VA

Humidity
• 90% RH max at 40°C (no condensing)

Ambient temperature
• -20° – 60 °C

Electrical rating
• Main inputs: see supply voltage
• Fan Supply: 115 Vac, 0,8 A max, cosφ=0,6
• Alarm Output: 115 Vac, 0,8 A max, cosφ=0,6
• Gas valve output: 155 VDC
• Control Input: 0-10V Voltage input; 4-20mA current input
• Communication input: logic “0” p 0,8 V DC – logic “1” 2 -24 V DC (10 KOhm)
• Communication output: open collector 24 V and 10 mA max

Flame sensing

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• Factory parameter setting: minimum flame current 0,8 µA

• Separated flame rod
Ignition
• Spark voltage: 20 KV
• Spark frequency: 22 Hz
• Spark pulse energy: 15 µAs
• Spark to Earth

As per product handbook: effective spark energy >60% of specified spark energy value.

Timings
• Prepurge time: 10 s
• Preignition time: 3 s
• Safety time: 5 s
• Number of retrials: 3
• Flame failure response time: <1 s
• Post purge time: 10 sec (default value of parameter)
• Stabilization Time: 10 s (default value of parameter)

Communication
• Bit rate: 2400 or 19200 baud
• Byte format: 1 start, 8 data, 1 stop, no parity
• Bit value “1”: low line level at connector
• Bit value “0”: high line level at connector

Length flame sensing/spark cable

• 0,5 m max

Length of wiring for external components

• 1 m max

Product life
• 500.000 cycles for safety and main operator gas valve
• 250.000 cycles at rated loads
• 6.000 lock-out operations with rated loads

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5.4 - Timing diagram

Fig. 3

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5.5 - System Parameters list (default settings)

All the parameters can be accessed with a communication package running on the PC.
Some parameters are available by the installer TSP mode on the MMI or by the OT Room unit.

No. Description Range Default Data_ID

01 Fan Kp up factor, Proportional Gain 0-127 45 2760

02 Fan Ki up factor, Integral Gain 0-255 245 2804
03 Fan Kp down factor, Proportional Gain 0-127 30 7052
04 Fan Ki down factor, Integral Gain 0-255 248 7088
05 Absolute Maximum Fanspeed (value *50 RPM) 50-153 114 2721
06 Absolute Minimum Fanspeed (value *50 RPM) 20-100 30 2734
07 Ignition Fanspeed (%) 0-100 50 2312
08 Fan Continuous Fanspeed (value *50 RPM) Abs.min- 33 4636
Abs.max
09 Slope Control (value *50 RPM/sec) 0-255 0 1426
10 Prepurge Time (Minutes) 0-255 0 3227
11 Prepurge Time (seconds) 0-60 10 3239
12 Postpurge Time (Minutes) 0-255 0 3240
13 Postpurge Time (seconds) 0-60 10 3265
14 Stabilization time (seconds) 0-255 10 3278
15 Fan Configuration 0-255 2 1437

value Fan Control Modulation

Cont. Type type
0 Off Modulation 0..10V
1 On Modulation 0..10V
2 Off On/Off N/A
3 On On/Off N/A
4 Off Modulation 4..20 mA
5 On Modulation 4..20 mA
16 APS Configuration 0-255 0 5334

value APS test APS test modalità

0 Off -
8 On Not checked during modulation
24 On Checked during modulation
17 APS switching time 1-50 50 7891

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6 - Modes of operation
The controller has a number of basic modes of operation (from lowest to highest priority):
- [3.1] STANDBY, when there is no heat demand or error present
- [3.2] HEATING MODE, when high voltage Heat Demand is given.
- [3.3] TEST MODE, when external testmode heat demand is given.
- [3.4] ERROR/FAULT conditions like over temperature conditions, sensor faults etc

6.1 - Start up
After Power On, manual reset or each 12/24 hours, the control will perform it’s start up routines.
12/24 hour reset depends on whether a heat demand is present. When no heat demand is present the control will perform a
reset 12 hours after the last one. When a heat demand is present, the control will wait until a maximum of 24 hours to
perform the reset.

6.2 - Stand-by (idle)

In STAND-BY mode igniter is off, gas valve is closed and fan is off if fan overrun time is finished and Fan Continuous
option is switched off.

6.3 - Normal Heating Mode

The Normal Heating mode is started when the High Voltage Heat Demand input is closed. When ignition is successful, the
fan can be controlled in a number of ways depending on parameter setting:

- 0-10Volt control, a DC voltage between zero and ten Volt can be applied to connector X12, pins 8 & 16. At zero
Volt the Fan will run on minimum fanspeed. At ten Volt the Fan will run on maximum fanspeed.
- 4-20mA control, with an external resistor of 500Ω 1% placed between connector X12 pins 8 & 16, the fanspeed
can be controlled with a current in the range of 4 to 20 mA. At 4 mA the Fan will run on minimum fanspeed. At
20mA the Fan will run at maximum fanspeed.
- On/Off control, when the option On/Off control is selected, the fanspeed depends on the fanslope control
parameter. When slope control is off (parameter set to zero), the fanspeed will immediately go to maximum.
Otherwise the fanspeed will rise from ignition fanspeed to maximum fanspeed with (value)*50 RPM/Sec.

After a Normal Heating Mode or a Test mode is served, a postventilation is performed, based on parameters value.
If a heat demand arise during the postventilation time, the postventilation is aborted and the heat demand is served.

6.4 - Test Mode

The testmode can be used to manually control the fanspeed of the burner with external communication. The fanspeed can
be controlled between minimum and maximum fanspeed by setting a test level between 0 and 100%.
When ignition is successful, the fan speed will go to the selected fanspeed level according to the following formula:

minimum fanspeed + ((maximum fanspeed-minimum fanspeed)*testmode level)/100

6.5 - APS (Air Pressure Switch) function

If the APS is configured in the control panel the ignition is not started until the APS switch has performed an open
and close sequence. Also the APS check during modulation can be controlled. Please find below in the table the
options and the descriptions.

Function Description
APS Before the ignition is started the APS must have had an
open (during fan off) and close (during fan on) status.

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No APS The ignition is started without checking the APS status

APS mod. Check (only enabled if APS function is The APS is also checked during modulation. If the APS
enabled) switches off a restart is performed.
No APS mod. Check (only enabled if APS function is The APS is not checked during modulation. If the APS
enabled) switches off nothing will happen, the control remains
modulating. At the next heat demand, the APS is
checked again.

With the APS switching time parameter the maximum time can be set on which the control may wait until the APS
opens or closes. If the expected state of the APS is not fulfilled within this time, a lockout error will be set and a
reset is required.

The error code for all APS related errors is ‘Error 4’.

Note : If the APS is not configured in the software, but an APS switch is connected to the CVBC and this is closed
or closing during operation ‘Error 4’ is also triggered.

6.6 - Fan speed Control

The following flowchart shows how the fanspeed is controlled during a complete burner sequence. The basic states are:

-standby, fan is off or at Fan Continuous speed when this option is selected
-prepurge
-ignition
-run state, fanspeed is controlled by modulation input, on/off control or test mode fanspeed.
-postpurge

The desired fanspeed in Fan Continuous and Ignition mode can be independently programmed.

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6.7 - Protection and error conditions

Several checks are included to protect the boiler and its environment. High Limit situation is constantly monitored, safety
times are constantly compared etc. Any violation of (programmable) limits (and/or internal thermostat functions) will lead to
an error/fault or warning condition. Severe error (igniter lockout) will cause a lockout condition which can only be cleared by
the reset key on the controller itself, or via a closed contact on the reset input. In case of lockout and blocking conditions,
Fan will not operate.
Complete list of errors is given as following:

Error code Description

LOCKOUT ERRORS
01 Flame lockout after several ignition trials
02 False Flame lockout
03 High Limit error
04 APS related Errors. (APS not opening, APS not closing, unexpected APS connection).
05 Fan Tacho Signal error
08 Flame circuit error
09 Valve driver circuit error
21 ADC error
25 CRC error

BLOCKING ERRORS

34 Low mains voltage

Error codes can be divided in 2 groups:

1. Lock-out condition codes

2. Blocking condition codes

Lock out condition codes

Lock out condition codes are all codes from 1 till 30. The meaning of the error numbers is as following:

FAULT 1 = Lock out signal after no flame and all ignition trials are expired. This error condition is stopping the boiler and to
get to the normal operation again, manual/remote reset is required. By using the local reset key, number of resets are not
limited. However all remote resets (communication) are limited to 5 resets per hour.

FAULT 2 = False Flame error - when a flame current is detected in illegal situations (gas valve closed, safety time passed),
error 2 will be generated.

FAULT 3 = High limit error – If switch opens, the error is set.

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FAULT 4 = APS Error – If the APS is configured and the APS does not open or close within the configured time limits Error
4 is generated. If the APS is not configured but an APS switch is detected on the input Error 4 is also generated.

FAULT 5 = Fan Tacho Error – if the measured fanspeed is not within 900 RPM of the requested fanspeed in 20 seconds,
error 5 will be generated.

FAULT 8 = Flame circuit error - during normal operation of the ignition controller, flame circuit is regularly checked. This
check has predictable behaviour and several steps. If check fails, error 8 will be set.

FAULT 9 = Valve circuit error - during normal operation of the ignition controller, valve circuit is regularly checked. This
check has predictable behaviour and several steps. If check fails, error 9 will be set.

FAULT 21 = A/D error

FAULT 25 = Matching error on CRC codes

Blocking codes

The boiler controller recognises also the fault situations that can block the heat demands but do not lead to lockout
condition. When the error condition becomes resolved, error will disappear but will be also written into the history data.
Blocking errors are distinguished with codes from 30. If this is the case, error code will flash on the status display. The
meaning of the code is as follow:

FAULT 34 = Low Mains voltage (less than 75V± 5V = Voff) will trigger this error. When Mains brought back to Voff*1.05,
error is resolved in 10 seconds.

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6.8 - Ignition sequence

In case of valid heat demand request, ignition sequence will be started. In case of failed ignition, controller will try to re-
ignite for number of times. If no successful ignition after programmed number of retrials, flame lockout error will be
indicated.

7 - Control Panel for Esys

A Control Panel for Esys has been develop to obtain different parameters configurations of the control board.
In the following picture the default settings are shown:

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8 - History information
The controller board has a possibility to register fault codes and to write some additional history information in non-volatile
memory:

1. Error codes (buffer of the 8 last errors). Every error code has it's time information (coupled with total hours).
2. Total number of burner switching (successfully finished burner sequence with flame on)
3. Total number of lockouts
4. Number of burner "on" hours
5. Total number of hours with power supply on

The history information can be accessed via external communication by using the CVI3 communication protocol.

9 - Installation
9.1 - General remarks
• After installation, ensure total protection equal to at least IP40 level as specified in EN60730-1.
• A high environment temperature affects the operational life of the product. Fit the board in a position with minimum
environmental temperature and expose to as little radiation as possible.
• The board does not contain repairable parts. Repair affects device safety and is not permitted.
• The connected devices must display appropriate electrical properties for the loads controlled by the board.
• If an automatic reset safety thermostat is connected in line with the gas valve operators, the reset timer of this
device must be greater than the time taken by the burner control to perform a new ignition attempt. This is to
ensure that a non-volatile lockout does not take place if the thermostat cuts-in.
• In the event of shutdown with a consequent situation of non-volatile lockout of the burner control, wait at least five
seconds before resetting the system.
• 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: 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.

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9.2 - Electrical connection

• The device must always be connected with the power turned off.
• The device must be connected in accordance with current legislation.
• The device manufacturer’s instructions (for boiler, etc.) must always be followed.
• Check that the type, times and code are always as specified before installing or replacing the device.
• Ensure that the combustion chamber is free of gas before turning on the device.
• Ensure effective connection between the device earth terminal, the metal burner case and the electrical equipment
protective earth.
• Carry out a complete final check when the installation is complete.

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 lead wire which can withstand at least 105°C a mbient.
• Use lead wire which is proven against moisture.
• W iring between boiler control and spark sensing probe should have good quality insulation, suitable for the
temperatures encountered.
• Gas valve should be connected to protective earth.
Fusing
• Ext. fuse 2A slow sand filled
Spark gap
• Max. allowable spark gap 3.5 mm (recommended 3 mm.)

9.3 - Cables and wirings

• Respect maximum connection cables length requirements.
• Use connection cables with appropriate insulation, working temperatures and moisture resistance.
• Plan separate routes for cables that connect loads at low voltage (SELV) and loads at mains voltage (HT). Avoid
connecting high and low voltage cables together.

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• The ignition cable must be laid so that it is separate from all the other connection cables. Use short connections to
minimise the emission of electromagnetic interference.
• The flame sensor/ignition output is not protected against the danger of electric shocks. The connection cable and
flame sensor must both be protected against direct contact.
• Do not use multiple cables to connect more than one external device using a single cable. The use of a multiple
cable to attach several external devices supplied with high and low voltage is expressly prohibited.
• The flame control earth terminal and/or the earth lead of the second spark generator output must be connected to
the metal earth of the burner by the shortest route and the path must be different from that followed by the other
wiring.

9.4 - Ionisation current check

• The current value must be greater than the specified minimum.
• If the ionisation current is too low, check that the electrode is fully immersed in the flame and that the burner and
the flame control are properly connected to the protection earth.

9.5 - Adjustments and final checkout

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.

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.
• As in normal operation the flame current is measured during 50% of the time, the read out value is half of the real
value. The read out value has to be multiplied by 2 to get the real value.
• 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.
Final checkout

After installation and any adjustment start the appliance and observe a complete cycle to ensure that all burner components
function correctly.
Maintenance and service
Under normal circumstances, no maintenance or service is required.

9.6 – EMC guidelines

• The position of the ignition cable has to be determined for lowest emission. In general conduct ignition cable along metal
pipes or shield metal for lowest loop area
• Do not lead ignition cable close to other cabling.

Description Ope. App. Date Rev.

Changed Absolure Minimum Fanspeed limits from [10;40] to [20;100] SHavranek 30-04-2009 0

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Technical specification Honeywell Combustion Controls srl
Title: Esys S4965V2166

Doc. : S4965V2166_FS

• To suppress Radio Frequency Interference (RFI) the boiler control including spark ignition cable should be mounted in
sufficient shielded environment.
• High frequency radiated emission can be reduced by a 1K spark ignition plug.
• Do not lead flame cable close to other cabling.
• Do not lead DC fan commutation cable close to other cabling.
• Keep high voltage spark wire at least 10 cm. away from other wires.

Description Ope. App. Date Rev.

Changed Absolure Minimum Fanspeed limits from [10;40] to [20;100] SHavranek 30-04-2009 0

Page. 20 / 20