S4562C 1085 COMBI BOARD APPLICATION PRODUCT HANDBOOK The S4562C 1085 combi board is an integration of an on/off temperature control and an electronic ignition control. The S4562C 1085 combi board is intended for use in a fan assisted combi boiler with direct burner ignition for non permanent operation. The S4562C 1085 combi board is intended for use with a VK4105 gas valve. The S4562C1085 combi board uses a sensor equivalent to the T7335 temperature sensor. The temperature setpoint can be set with a potmeter. The S4562C 1085 combi board can be used in appliances according European standards for household electrical requirements EN 60335. For glossary of terms, abbrevations and symbols, see document EN2R--9039 Subject to change without notice. Printed in the Netherlands. General Contents Description... 2 Features... 3 Technical Dimensional drawing... 4 Specifications... 5 Specifications logic control... 7 System operation... 8 Timing diagram... 9 Installation, adjustment and checkout... 10 Various Tolerances and product life... 11 EMC guidelines... 11 Quality assurance statement... 11 Approvals and standards... 11 Ordering information... 12
DESCRIPTION The S4562C 1085 combi board is a combination of an on/off temperature control with electronic ignition, pump control, mid position valve control, transformer, fuse(s) and a wiring centre at Printed Circuit Board (PCB) When the S4562C 1085 combiboard is energized by the central heating thermostat (CH--mode), the igniter is controlled depending on the temperature setting of the potmeter and the temperature sensor. If the flow switch detects a flow rate (DHW--mode), the igniter is also controlled depending on the temperature setting and temperature sensor. 2
FEATURES Logic control Potmeter for temperature control. Off position of potmeter. LED indication for power on. Suitable for both Y--plan and S--plan systems. Pump overrun. Ignition control Hybrid technology for high reliability. Flame supervision. Built in 25 Hz ignition. Internal reset. Accurate safety timer. Full operating sequence after flame loss. Non volatile lock--out according to EN 298. EMC filter. Protective impedance flame rod. Under voltage protection. 3
DIMENSIONAL DRAWING 179 Flame detection 43 15 X 7 X 9 X 8 8.5 4(5x) 10 Earth connection X 10 X 11 X 12 S 1 Reset switch L 1 P 1 1 2 3 1 2 3 4 1 2 3 4 5 128.5 10 Flow switch Mid valve S 101 Y pos S pos Timer Y plan S plan Temperature setting 35 79 X 1 X 2 1 3 1 2 3 5 6 L N Ls Lr N 7 Room thermostat Froststat X 3 4 X 4 3 2 1 2 1 X 5 X 6 2 1 1 2 3 4 18.5 20 Line voltage DBI gas valve High Limit Fan Pump APS Sensor T7335 Fig. 1. Dimensional drawing and connections 4
SPECIFICATIONS Model S4562C 1085 electronic interface system for fan assisted combi boilers with direct burner ignition. Dimensions See fig 1. page 4 Supply voltage 230 Vac, 50 Hz Power consumption PCB 6VA Electrical rating Mains input Supply voltage: 230 Vac (+10 %/--15 %), 50 Hz Max. power rating: 460 VA Fusing: 4 A Pump output Power rating: 120 VA Minimum cos :0.6 Gas valve Output voltage: 230 V rectified (+10 %/--15 %), 50 Hz Power rating: 10... 120 VA High limit control Output voltage: 230 V rectified (+10 %/--15 %), 50 Hz Power rating: 10... 120 VA Mid valve position Power rating: 120 VA Minimum cos :0.6 Timer control Power rating: 10... 120 VA Room thermostat Current rating: < 1mA Flow switch Current rating: < 1mA Frost stat Current rating: < 1mA Fan output Power rating: 120 VA Minimum cos :0.6 Air pressure switch Output voltage: 24 Vdc (+10 %/--15 %) Power rating: 0.5 VA Temperature sensor Output voltage: 6 Vdc (+10 %/--15 %) Electrical connection (see table 1. page 5 and fig. 1. page 4) The combi board accepts Molex connector 3069 series (ordernumber 09--91--XX00) with crimp terminals of the 2478 series. The combi board accomodates polarising key type 2560--1 Table 1. Connection Status Range Type Mains supply Input 230 Vac Srew connector Room thermostat Input 230 Vac Srew connector Flow switch Input 230 Vac Stelvio Frost switch Input 230 Vac Srew connector Temperature sensor Air pressure switch Input -- -- Molex Input 24 Vdc Molex Fan Output 230 Vac Molex Pump Output 230 Vac Molex Mid valve Output 230 Vac Stelvio Timer Output 230 Vac Stelvio Gas valve Output 230 V rectified High limit control Molex Input 230 Vac Molex Earth Input Tinned area on PCB that contacts a metal spring Flame sensing Input 230 Vac high source impedance Ignition Output > 12 kv at 12 pf load Timing Self check time (T c ): 2.2 s Safety time (T s ): 10 s Extended spark ignition time: 0 s Flame sensing Min flame current: 0.9 A Response time on: > 0.2 s Response time off (T FR ): < 1. s (at I FLAME <2 A) Maximum length of flame sensing cable: 1 m Ignition Spark voltage: >12 kv at 40 pf load Spark frequency: 25 Hz Spark energy: 3 As. Maximum spark gap: 3.5 mm Maximum length of ignition cable: 0.5 m 6.3 mm spade terminal 2.8 mm spade terminal 5
Mounting The printed circuit board offers a means for direct mounting as a bare board. The printed circuit board has five mounting holes with a diameter of 4 mm. The combi board has to be placed in a clean situation according to EN 60730. The air pressure switch, sensor, potmeter and flame sensing connection are safely accessible according to EN 60730. If the ignition frequency is 25 Hz, the ignition cable and its connections shall have a protection against electrical shock hazard. The reset switch and all other connections are inside the boiler and therefore not accessible. The printed circuit board should be mounted in an enclosure that provide the correct creepage and clearance distances. The combi board has to be mounted by means of insulated spacers. Environmental conditions Free air operating temperature range inside the housing: 0... 60 _C Ambient operating humidity: 95% at 40 _C (non condensing) Storage temperature: --20... + 60 _C 6
SPECIFICATIONS LOGIC CONTROL General Temperature sensor equivalent to T7335 type, R 25 = 10000 Ohm. All specified temperatures are based on the nominal temperature sensor characteristic. DHW--mode has priority above CH--mode. DHW- mode Temperature setting (P 1 ) Maximum switch off point: 86 _C (± 2.5 _C) Maximum switch on point: 63 _C (± 2.5 _C) Minimum switch off point: 60 _C (± 2.5 _C) Minimum switch on point: 36 _C (± 2.5 _C) Pump overrun During DHW--mode the pump is on. After DHW heat demand there is a pump overrun time. Pump overrun time: 180 s (± 25%). Temperature sensor break The combi board shall de--energize the igniter when the temperature sensor is in high resistance state. High resistance state is activated at temperature sensor resistance higher than >50 k. CH- mode Temperature setting (P 1 ) Maximum switch off point: 86 _C (± 2.5 _C) Maximum switch on point: 63 _C (± 2.5 _C) Minimum switch off point: 60 _C (± 2.5 _C) Minimum switch on point: 36 _C (± 2.5 _C) Pump overrun During CH--mode the pump is on. After CH heat demand there is a pump overrun time. Pump overrun time: 180 s (± 25%). Temperature sensor break The combi board shall de--energize the igniter when the temperature sensor is in high resistance state. High resistance state is activated at temperature sensor resistance higher than >50 k. 7
SYSTEM OPERATION Logic control general description Power indication There is a LED L1 (green) placed at the printed circuit board for power indication. If the mains supply is present, the LED L1 is on. S/Y plan With the slide switch mounted at the copperside of the printed circuit board it is possible to switch from Y plan to S plan. This is the Sundial plan system Disable function With potmeter P1 at minimum position it is possible to disable the combi board. It is not possible to get DHW--mode or CH--mode. During pump overrun time it is possible to disable the combi board, but the pump is still running during its overrun time. After this the combi board is disabled. RY101 Disable Enable Fig. 2. Logic control Domestic Hot Water (DHW) mode When DHW--mode id detected as a result of detecting flow rate, the pump is on and the gas valve is controlled, depending on the input signal of the temperature sensor. The S4562C 1085 has an on/off temperature control. The temperature is set by the potmeter P 1. After heat demand the pump stays on for a certain time (pomp overrun time). P 1 Logic control Central Heating (CH) mode When the room thermostat is energised (CH--position), the operation is identical to DHW--mode. The pump is on. The temperature can be adjusted by the potmeter P 1. The S4562C 1085 has an on/off temperature control. After heat demand the pump stays on for a certain time (pomp overrun time). Ignition control General The combi board provides closed loop sparking. Program run (see fig. 3.) When the logic control generates a call for heat, a self check period (T c ) elapses when the air proving switch (APS) is in the no air position. After the self check period (T c ) the fan starts running. When sufficient air flow is proven by the air proving switch (APS), the built in igniter and the gas valves are switched on. The ignition spark ignites the gas and the resulting flame is detected by the flame rod. If flame is not established within the safety time (T s ), the S4562C 1085 locks--out. If the flame is lost during normal run, the S4562C 1085 repeats the start sequence. If no air flow is proven by the air proving switch (APS), the ignition control stays in waiting mode. If the limiter opens during run, the gas valves close and the start sequence is repeated. The S4562C 1085 will lock--out since no flame will be detected. NOTE: If an automatic return high limit thermostat is used, it should have a return time that is longer than the safety time, otherwise the combi board will not lock--out. Reset from lock- out The combi board can be reset from the lock--out state by pressing the reset button S 1. NOTE: If during normal run the reset button is pressed, the gas valves close and the S4562C 1085 starts a new sequence after releasing the reset button. NOTE: When first starting, the combi board can be in the lock--out condition; reset the combi board. If a first reset is not successful, wait at least 15 seconds before attempting another try. NOTE: After a reset an extended waiting time will occur. 8
TIMING DIAGRAM P t 0 t 1 t 2 t 3 t 4 t 5 t 6 t 7 t 8 t 9 t 10 T c T ext T FR T c T s Legend t 0 -- Heat demand t 1 -- Fan starts running t 2 -- Air flow is proven, ignition trial t 3 -- Flame established t 4 -- Ignition stops t 5 -- Flame failure t 6 -- Flame failure response t 7 -- Air flow stopped, new start t 8 -- Fan starts running t 9 -- Air flow is proven, ignition trial t 10 -- End of safety time: lock--out Fig. 3. Timing diagram ignition part 9
INSTALLATION, ADJUSTMENT AND CHECKOUT WARNING Take care that installer is a trained experienced service person. Disconnect power supply to prevent electrical shock and/or equipment damage. Turn off gas supply before starting installation. After installation wait at least one hour before connecting the mains supply, because the device can become wet due to condensation. Do not connect wet device to mains IMPORTANT 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 combi board can be in lock -out; push the reset button to free control. CAUTION Do not connect the combi board to the mains when it is not connected to the gas control. Wiring IMPORTANT Wiring must be in accordance with local regulations. The appliance manufacturer s instructions should always be followed. If such instructions are not provided see fig.1. page 4 Use cable which can withstand 105 _C ambient. Use cable which is proven against moisture. Wiring between combi board and spark probe must be suitable for the temperatures encountered. Wiring between combi board and spark probe must have a minimum isolation resistance to earth of 500M under all working conditions. Wiring between combi board and flame sensing probe must be one piece without means for interrupting. CAUTION The ignition cable and its connections shall have a protection against electrical shock hazard. Fuses The combi board is internally fused with a2aslowfuse. NOTE: The ignition control has integrated fuse tracks that may not be replaced by any means. Spark gap Maximum allowable spark gap is 3.5 mm High voltage Make sure that the clearance and creepage distance from any metal parts of the high voltage connection to earth metal is more than 12 mm. Supply voltage polarity If the combi board seems to operate normally but does not detect flame, check for right polarity of the power supply line and neutral connections. Checkout 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. 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. If flame current is insufficient check that flame sensing rod is fully enveloped by the flame and that burner is reliable grounded to ignition control. If there is no sufficient flame current due to phase--phase mains it is recommended to use an AT7030A or AT7030B flame detection transformer. See also instruction sheet EN1R--9136 of the AT7030 transformer. Final checkout of the installation Set appliance in operation after any adjustment and observe several complete cycles to ensure that all components function correctly. WARNING Honeywell is not responsible for damage and/or injury due to miswiring. 10
TOLERANCES AND PRODUCT LIFE Ignition Under voltage disabling limit: 173 V ± 10 Vac No flame current: < 0.45 A Reliability The combi board must withstand at least 250000 cycles In order to ensure long term operation, mount the combi board at a position in the appliance where ambient temperature and heat radiation is low. High temperature will affect product life. EMC GUIDELINES The electronic ignition is a source of mains interference and radio frequency interference (RFI). In order to minimise RFI, do not lead the ignition wires close to mains wires. Twist the wires and position them close to earth metal. 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 Programme and its related operational procedures and instructions. The quality system is approved by Gastec against 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, using their own authorised equipment. All inspections (incoming and assembly) are performed by trained personel and according inspection procedures. STANDARDS AND APPROVALS Standards The combi board meets the european standards: EN 60730--1:Automatic electrical controls for household and simular use. EN 55014: Emission requirement for household appliances and portable tools. EN 55104: Immunity requirements for household appliances, tools and similar apparatus. The ignition control meets the european standard: EN 298: Automatic gas burner control systems. Regarding electrical safety, the combi board can be used in appliances according to european standard for household electrical requirements EN 60335 series. The S4562C 1082 combi board functions in accordance with EN 298 clause 4 code F/M/C/L/X/N. Approvals The combi board conforms with the following EC -- Directives: Gas Appliance Directive (90/396/EEC) Low Voltage Directive (73/23/EEC) Electro Magnetic Compatability Directive (89/336/EEC) 11
ORDERING INFORMATION Identification of device The identification of the device is by Honeywell Ordering Specification (O.S.) number and date code. Packing The combi boards shall be packed in a carton box according to the Honeywell standards. When ordering specify: Model number of combiboard. Order numbers of replacement parts and accessories required. 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 12