VK41..V(B)/VK81..

V(B) SERIES
GAS CONTROLS WITH INTEGRATED 1:1 GAS/AIR REGULATOR FOR
COMBINED VALVE AND IGNITION SYSTEM
INSTRUCTION SHEET
VK41..V(B)/VK81..V(B) gas controls hold a first electric on/
off direct operator for opening the safety valve of class B
according to EN161 and a second electric on/off servo
operator of class B or C to EN 161.
The pressure regulator is in accordance with class B
requirement of EN 88.
VK41..V/VK81..V gas controls can handle the three gas
families, manufactured gas, natural gas and LP gas.
VK41..VB/VK81..VB gas controls can handle second family
gas only.

SPECIFICATIONS
Models
VK41.0 series: line voltage gas control with pilot burner
connection, two automatic shut off valves and
pilot burner connection for direct spark
ignition (DSI) or hot surface ignition (HSI)
applications,
VK41.5 series: line voltage gas control without pilot burner
connection, two automatic shut off valves for
direct spark ignition (DSI) or hot surface
APPLICATION ignition (HSI) applications,
VK81.0 series: low voltage gas control with pilot burner
The VK41..V(B)/VK81..V(B) series gas controls with 1:1 gas/ connection, two automatic shut off valves for
air regulator have been developed for application in domestic direct spark ignition (DSI) or hot surface
appliances with premix burners and automatic ignition. ignition (HSI) applications,
For this system, the VK41..V series gas controls have been VK81.5 series: low voltage gas control without pilot burner
designed to have the S4565 series ignition control attached connection, two automatic shut off valves for
directly onto the valve. direct spark ignition (DSI) or hot surface
ignition (HSI) applications,
The combined system then provides programmed safe light
up, flame supervision and regulation of gas flow to the main Suffix letter
burner of the appliance. V: fast opening, with integrated 1 : 1 gas/air regulation
The VK41..V(B)/VK81..V(B) series can as well be used as VB: fast opening, with integrated 1 : 1 gas/air regulation
stand alone in direct burner applications. The plug (order High capacity
Subject to change without notice. All rights reserved

number 45.900.441-) with integrated rectifier circuit then has

to be used. Main gas connection
The VK41..V(B)/VK81..V(B) series are used in a system See table 1, table 2 and table 3.
context in conjunction with fan control and a direct spark 3/ ” and 1/ ” straight or elbow flanges are according to the
8 2
ignition (DSI) control. torsion and bending stress of EN 126 group 2
The VK41..V(B)/VK81..V(B) series are approved in Connections with G 1/2” or G 3/4” external thread fitted with
accordance with european standards. nuts according to ISO 228-1 in combination with applicable
sealing(s) withstand the torsion and bending stress of EN
126 group 1
DESCRIPTION Side outlet (optional) and end outlet (flanged version) can be
fitted direct to a burner manifold.
VK41..V(B)/VK81..V(B) gas controls perform all the functions End outlet or side outlet Quick connection for Mini-Venturi
required to safely regulate gas flow to the main burner of
Pilot gas connection (where applicable)
domestic central heating equipment, warm air furnaces, back
Standard at end outlet: M8 x 1 for 4 mm outer diameter
boilers and water heaters.
tubing.

1 EN1R-9134 0503R20-NE
 M5 x 0,8 (3) Side outlet
37 94,8
6 mm full thread
68,3 Pressure tab

9
24

34 Cap screw/offset adjustment

24 84,5

Hole 2.6 mm to connect ignition control

Side outlet (optional)
Air pressure
Pilot outlet M8 x 1-6H connection
for 4 mm tubing 29

91 87 76
24 24

36,7 36,7

25
24 17 24
Outlet
Inlet Molex 1.1 pin header

18
Tolerances according
64,9
ISO 2768mK 30
29

8
Mounting hole (2) for tapping 105
screws 3.9 DIN 7990 115

Fig. 1. Dimensional drawing

Ambient temperature - for VK41xxVB/VK81xxVB:

-15 ... 70°C 1.0 m3/h air at ∆p=0,5 mbar across main burner orifice at
Dimensions 60 mbar operating pressure maximum
See fig. 1. Minimum operating gas pressure
Pressure regulation function 15 mbar
Class B according to EN 88 Maximum operating gas pressure
Air pressure connection 60 mbar : VK411x / VK811x (Class B+C)
30 mbar : VK412x / VK812x (Class B+B)
Servo pressure regulator has an M5 threaded hole to make
30 mbar : VK41xxVB / VK81xxVB (Class B+C)
connection between regulator and appliance.
The Pmax 60 mbar indication on the housing is the maximum
Outlet pressure inlet pressure at which the gas control functions safely.
Outlet pressure is pressure drop across the main burner Maximum air pressure
orifice.
8 mbar without outlet gas pressure (before ignition)
Outlet pressure range 20 mbar with outlet gas pressure present (after ignition)
0.5 ... 20 mbar Offset range
Maximum inlet pressure -0.4 mbar ... + 0.2 mbar (with coils sidewards)
60 mbar -0.24 mbar ... + 0.36 mbar (with coils on top)
Minimum regulation capacity
- for VK41xxV/VK81xxV:
0.5 m3/h air at ∆p=0,5 mbar across main burner orifice at
30 mbar operating pressure maximum
0.7 m3/h air at ∆p=0,5 mbar across main burner orifice at
60 mbar operating pressure maximum

EN1R-9134 0503R20-NE 2
 VK4110/VK4115 Class B Class C
VK8110/VK8115
Inlet End outlet Side outlet Body length
(mm) VK4120/VK4125 Class B Class B
VK8120/VK8125
Flanged Flanged -- 105
Flanged -- Flanged 105 Timing
Closing time: ≤ 1 s
Internal 3/8” -- Flanged 115
Opening time: see table
ISO 7-1
Internal 1/2” -- Flanged 115
Model Time till Po >= 100 Pa
ISO 7-1
VK4115V/VK8115V <1s
Internal 1/2” Internal 1/2” -- 115
ISO 7-1 ISO 7-1 VK4115VB/VK8115VB < 1.5 s
VK4125V/VK8125V < 1.5 s
Table 1. Standard valve connection
Inlet End outlet Side outlet Body length Mounting holes
(mm) Two mounting holes at the bottom for thread forming screws.
G 1/2” G 1/2” -- 135 The four holes at inlet and outlet for mounting a flange on the
1
G /2” Flanged -- 120
gas control are provided with M4 thread with min. 6 mm full
thread.
G 3/4” G 3/4” -- 135 In case of side outlet the three holes for mounting the flange
G 3/4” Flanged -- 120 are provided with M5 thread with a minimum of 6 mm full
thread.
G 3/4” -- Flanged 120
G 3/4” Internal 11/2” -- 120 Electrical data
ISO 7-1
Coil indication Supply voltage
G 1/2” -- Flanged 120
220/240 Vrac 220 V, 50/60 Hz using rectifier
Flanged G 1/2” -- 120 240 V, 50/60 Hz using rectifier
Flanged G 3/4” -- 120 110 Vrac 110 V, 50/60 Hz using rectifier

Table 2. External thread valve connection 24 Vrac 24 V, 50/60 Hz using rectifier

Electrical connection
Molex 1.1 square pin header
Inlet End outlet Side outlet Body The 24 V and 220/240 V versions gas controls can be
length connected to any standard DBI control with a 24 Vac, or
(mm) 220/240 Vac output by using a rectifier plug 45.900.441-
Flanged Quick connect - 120
mini-venturi
Flanged - Quick connect 105
mini-venturi
G 3/4” Quick connect - 135
mini-venturi
G 3/4” - Quick connect 120
mini-venturi

Table 3. Mini-Venturi valve connection

∆p = 5 mbar, 1013 mbar and 15 °C)
Capacity (∆
VK4110V/VK8110V: 3.2 m3/h air
VK4115V/VK8115V: 3.4 m3/h air
VK4125V/VK8125V: 2.2 m3/h air
VK4115VB/VK8115VB: 4.4 m3/h air

NOTE: Versions with side outlet connection only have a Fig. 2. Mounting of rectifier plug
0.2 m3/h air lower capacity.
Versions with external thread connection have a
0.3 m3/h air lower capacity. IMPORTANT
Capacity curves are available on request. Warranty claims are not accepted if not the
specified plug/rectifier circuit is used.
Valve classification
Electical protection of gas control with rectifier plug
Type Class IP 40
1st valve 2nd valve

3 EN1R-9134 0503R20NE
Mounting of rectifier plug Main gas connection
See fig. 2.
Gas controls with internal thread
Mounting screw of rectifier plug
Torque: 40 Ncm max. • Take care that dirt cannot enter the gas control during
handling.
• Use a sound taper fitting with thread according to ISO 7-1
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 distortion and malfunction could
result.
Pipe size (inch) Max. length of pipe thread (mm)
3
/8 14
1
/2 18.6
• Apply a moderate amount of good quality thread
Pin number 1 2 3 4 5
compound to the pipe or fitting only, leaving the two end
Fig. 3. Coil connection threads bare.If permitted by local safety regulations PTFE
tape may be used as an alternative.
• Tighten gas control using the right open end wrench.
Current and power consumption at nominal voltage See fig. 4.
Voltage Current (mA) Power
consumption (W)
220 V, 50/60 Hz 48 9.4
240 V, 50/60 Hz 52 11.2
110 V, 50/60 Hz 89 8.8
24 V, 50/60 Hz 424 9.2

INSTALLATION
IMPORTANT
Take care that installer is a trained experienced
service person.
Turn off gas supply before starting installation.
Disconnect power supply to prevent electrical shock
and/or equipment damage.
Do not remove seals over inlet and outlet until the
device is ready to be installed. Fig. 4.
If M5 air pressure connection is not to be used, it is
recommanded to push a dust cap into the hole. • Ensure the gas flows in the same direction as the arrow
Mounting position on the bottom of the gas control.
The gas control can be mounted 0 to 90° in any direction Gas controls for flange connection
from the upright position, i.e. from the position when electric
coils are on top. • Insert ”O”-ring in the groove of each flange. If necessary
grease ”O”-ring slightly to keep it in place.
• Mount gas control between flanges using the four screws
for each flange.

EN1R-9134 0503R20-NE 4
Gas controls with external thread connection q With 3/4” nut and “O”-ring (see fig 7.)
Pipe diameter: 15 mm
WARNING Nut: drawing: ......................................45.006.583-003
“O”-ring size: ∅14.3 x ∅2.4 mm
Fastening torque flat sealing ring only applicable for drawing .......................................45.001.528-048
type Klingersil C4324 Fastening torque: maximum 50 Nm
minimum 10 Nm
n With1/2” nut and flat sealing ring for pipe 14 mm (see fig 5.) Pipe end construction: see fig.: 10.
Nut: drawing:......................................45.006.583-005
Flat sealing ring size: ∅18 x ∅10 x 1.5 mm:
drawing.......................................45.006.582-002
Fastening torque: maximum 40 Nm
minimum 25 Nm
Pipe end construction: see fig.: 8.
o With 1/2” nut and flat sealing ring for pipe 15 mm (see fig 5.)
Nut: drawing:......................................45.006.583-004
Flat sealing ring size: ∅18 x ∅10 x 1.5 mm
drawing.......................................45.006.582-002
Fastening torque: maximum 40 Nm
minimum 25 Nm
Pipe end construction: see fig.: 9.

Fig. 7. External thread connection with nut and “O”-ring

r With 3/4” nut and flat sealing ring for pipe 15 mm (see fig 5.)
Nut: drawing: ......................................45.006.583-003
Flat sealing ring size: ∅24 x ∅16 x 1.5 mm
drawing .......................................45.006.582-001
Fastening torque: maximum 50 Nm
minimum 30 Nm
Pipe end construction: see fig.: 11.
s With 3/4” nut and flat sealing ring for pipe 18 mm (see fig 5.)
Nut: drawing: ......................................45.006.583-002
Flat sealing ring size: ∅24 x ∅16 x 1.5 mm
drawing .......................................45.006.582-001
Fig. 5. External thread connection with nut and flat Fastening torque: maximum 50 Nm
sealing ring minimum 30 Nm
Pipe end construction: see fig.: 12.
p With 3/4” nut and olive (see fig. 6.)
Pipe diameter: 15 mm
+ 0.2
Nut: drawing:......................................45.006.583-003 14 18 - 0.2
Fastening torque: maximum 50 Nm
minimum 30 Nm 1
Pipe end construction: square off end of tubing and
remove burrs. Fig. 8. Pipe (dia 14 mm) for flat sealing ring connection

+ 0.2
15 18 - 0.2

Fig. 9. Pipe (dia 15 mm) for flat sealing ring connection

23.4 – 0.15

+ 0.10
15 15
Fig. 6. External thread connection with nut and olive - 0.05

1.5 – 0.1
7.5 – 0.2

Fig. 10. Pipe end for “O”-ring connection

5 EN1R-9134 0503R20NE
 CAUTION
15
+ 0.2
23.4 - 0.2 Keep soap and water solution away from electrical
connections.
1
Electrical connections
Fig. 11. Pipe (dia 15 mm) for flat sealing ring connection IMPORTANT
Disconnect power supply to prevent electrical shock
and/or equipment damage.
Wiring must be in accordance with local regulations.
The appliance manufacturer’s instructions should
18
+ 0.2
23.4 - 0.2 always be followed.
Before installing or replacing any control check that
1 type number is correct for the application.
Ensure combustion chamber is free of gas before
Fig. 12. Pipe (dia 18 mm) for flat sealing ring connection start up.
Conduct a thorough check out when installation is
completed.
Pilot gas connection at outlet side (if applicable) At the first start the ignition control can be in lock-
• Square off the end of tubing and remove burrs. out; depress reset button to free the ignition control.
• Slip compression fitting over 4 mm tubing. Wiring
• Insert tubing into automatic gas control housing until it • Use leadwire which can withstand 105 °C ambient.
bottoms, slide fitting into place and turn finger tight. • Use leadwire which is proven against moisture.
• Use a wrench to tighten fitting about 11/2 turn beyond • Wiring between ignition control and spark sensing probe
finger tight to shear of the olive.Do not use jointing should have good quality insulation, suitable for the
compound. temperatures encountered.
Connect other end of tubing to pilot burner according to the Fusing
manufacturer’s instructions. In order to prevent unsafe conditions at too high current, the
ignition control has an integral non replaceable fuse.
CAUTION This fuse will be blown long before the maximum 16 A
external fuse switches off.
Do not bend tubing at gas control after compression
fitting has been tightened, as this may result in gas Spark gap
leakage at the connection. Max. allowable spark gap 3.5 mm
Perform gas leak test Supply voltage polarity

WARNING WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE If ignition control seems to operate normally but does
PROPERTY DAMAGE, SEVERE INJURY OR not detect flame, check for right polarity of power
DEATH supply (line, neutral).
Check for gas leaks with a rich soap and water Checking flame current
solution any time work is done on a gas control. • The minimum value should be in accordance with the
Gas leak test specified value of the ignition control.
• Paint all pipe connections upstream of the gas control • To check flame current connect a DC micro-Ampèremeter
with with a rich soap and water solution.Bubbles indicate between flame sensing wire and flame sensing rod.
a gas leak. • If flame current is insufficient check that flame sensing
• If a gas leak is detected, tighten the pipe connection. rod is fully enveloped by the flame and that burner is
reliable grounded to ignition control.
• Stand clear while lighting the main burner to prevent
injury caused from hidden gas leaks, which could cause • If there is no sufficient flame current due to phase-phase
flasback in the appliance vestibule. Light the main burner. mains it is recommandable to use a AT7030A or AT7030B
flame detection transformer. See also EN1R-9136
• With the main burner in operation, paint all pipe joints
instruction sheet AT7030.
(including adapters) and gas control inlet and outlet with
with a rich soap and water solutionan approved leak
detection fluid. WARNING
• If another gas leak is detected, tighten adapter screws, Short µA meter during ignition to prevent damage of
joints and pipe connections. the µA meter in single rod application.
• Replace the part if gas leak can not be stopped.

EN1R-9134 0503R20-NE 6
ADJUSTMENTS CHECKOUT
• After any adjustment check pressure taps and gas
WARNING connections with an approved leak detection fluid for gas
leakage.
Adjustments must be made by qualified persons only.
• After any adjustment set appliance in operation and
If the appliance manufacturer supplies checkout and/
observe a complete cycle to ensure that all burner
or service and maintenance instructions carefully
components function correctly.
follow them.
If such instructions are not provided then use the
procedure outlined below. MAINTENANCE AND SERVICE
Adjustment can only be made with a special tool.
Under normal circumstances no maintenance or service is
Pressure tap
required.
The gas control is provided with a pressure tap of 9 mm O.D.
at inlet and outlet side. WARNING
When checking the pressure undo the screw a half turn and Do not disassemble the gas control; it contains no
slip tube over nipple. replaceable components.
Ensure that screw is retightened after making test. Attempted disassembly or repair may damage the
gas control
CAUTION Screws on the valve that have been sealed must
never be removed.
To ensure a safe closing of the valves, it is essential
that voltage over the terminals of electric operators is
reduced to 0 Volt.
Offset adjustment (see fig. 1.)
• Remove cap screw with a Torx T-40 screw driver or 5 mm
hex key to expose offset adjustment screw.
• Check gas supply pressure to the appliance using a
pressure gauge connected to the inlet pressure tap.
• Start fan and check air flow.
• Energize both electric operators in order to have gas input
to burner and ignite boiler.
• Adjust CO2 % at the desired value at low output with
offset adjustment screw. Turn offset adjustment screw
clockwise to increase CO2 %.
• Operate boiler on high output. (Only modulating
applications).
• Replace cap screw and tighten pressure taps.

7 EN1R-9134 0503R20NE
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

EN1R-9134 0503R20-NE 8