Distribuitor: CALOR SRL

Str. Progresului nr. 30-40, sector 5, Bucuresti

tel: 021.411.44.44, fax: 021.411.36.14
www.calorserv.ro - www.calor.ro

S4965 SERIES
COMBINED VALVE AND BOILER CONTROL SYSTEMS

PRODUCT HANDBOOK
APPLICATION
The S4965 boiler controls have been developed for application
in gas fired domestic appliances.
The S4965 boiler controls are used in conjuction with the
VK41.. series modulating or non modulating gas controls. (see
Product Handbook EN2R-9025 and EN2R-9004) They provide
both an optimised safety sub-system for programmed safe
light-up and flame supervision of the main burner of the
appliance and a boiler comfort control sub system for
temperature, pump, and 3-way valve control
Bi-directional communication with a MMI enables
comprehensive diagnostics and operation.
For glossary of terms, abbrevations and symbols see
document EN2R-9039

Contents
General
Description ......................................................................... 2
Features ............................................................................ 3
Dimensional drawing S4965 boiler control ........................ 4

Technical
Subject to change without notice. All rights reserved.

Specifications .................................................................... 5
Connection diagram .......................................................... 7
Timing diagram ................................................................ 8
Description of LOCON ...................................................... 9
Description of SQUARE ................................................... 10
General considerations ................................................... 11
Electrical connections and wiring .................................... 12
Adjustments and final checkout ...................................... 13

Various
EMC guidelines ............................................................... 14
Quality assurance statement ........................................... 15
Standards and approvals ................................................ 15
Ordering information ....................................................... 16

1 EN2R-9053 0408R11-NE
DESCRIPTION
The Combined Valve Boiler Control (CVBC) is the
combination of a VK41.. modulating or non-modulating gas
control with an electronic boiler control.
The boiler control consists of an automatic ignition control and
a comfort boiler control.
Most of the standard control functions of a gas fired boiler can
be performed within one single control box which can easily be
clicked on the gas control.
Possible applications are:
• Instantaneous water heaters. SE
T
AL
AR
M

• Floor standing boilers. RE

• Combi boilers.
• Low Nox boilers.
• Condensing boilers.
• See chapter Features for the standard features which can
be implemented in this control box.

EN2R-9053 0408R11-NE 2
FEATURES
• Multi trial full sequence ignition control.
• Permanent operation in accordance with EN 298 (2003).
• Non volatile lock-out.
• Self learning ignition sequence; no minimum adjustment,
using LOCON.
• Direct Burner- or Intermittent Pilot operation.
• Integral ignition including emission filter.
• Combined ignition and flame sensing option.
• Phase insensitive flame detection.
• Lock-out at flame simulation.
• Restart after flame loss.
• AC or DC fan control (24 VDC fan needs external trafo).
• Dynamic airflow check.
• Lock-out on no air.
• Automatic fan assisted/atmospheric recognition.
• Integral gas pressure modulation circuitry.
• Pump control.
• 3-way valve control.
• Multi temperature CH and DHW control with DHW priority
setting.
• ∆T control in CH mode
• Flow sensor input for DHW detection and control
• Sensor- or contact switch high limit at control.
• Communication to MMI enabling comprehensive
diagnostics and operation.
• Factory safety parameter settings.
• Installer and OEM comfort boiler control parameter
settings.
• On board transformer and wiring center.
• Integral and/or remote reset and alarm indicator.
• Electrical safety in accordance with EN 60730-1 (2000).
• Replacable fuse
• OpenTherm communication

3 EN2R-9053 0408R11-NE
DIMENSIONAL DRAWING S4965 BOILER CONTROL

X1 X12 X11 14
Material : ABS - V0
18
10 16 6
Tolerances ± 1 mm
11 3 1 61
5 1 98 unless noted

17
115
110
24

16

120 117

82
64
46

12
33

FOR CONNECTORS, USE FEMALE PARTS Molex Minifit (for X1) and Microfit (for X11 and X12) can be
Plastic part Pins Terminal
used as alternatives
X1 TYCO 1-106527-0 10 TYCO 106528-2 (reel)
(for AWG 22-26, insulation
diameter 1,20 - 1,75 mm)
X11 TYCO 794617-6 6
TYCO 794607 (reel)
X12 TYCO 1-794617-6 16 TYCO 794611
(for AWG 26-30)
X12 TYCO 1-794617-8 18

68,1 ±0,3
Material : ABS - V0

Tolerances ± 1 mm
unless noted
3,3 ± 0,3

6,6 ± 0,4

33,4

48,2

74,65
Dimension cover

EN2R-9053 0408R11-NE 4
SPECIFICATIONS
Models
Basically there is one PCB for a number of applications.
Depending on which components are mounted different
applications can be covered.
Atmospheric combustion Premix combustion
Normal Combustion feedback Normal SQUARE
Application (LoCon) (Pneumatic (Electronic gas/air
gas/air) or Gas addaptive)
Open flue Fan assistant Open flue Fan assistant
Electronics S4965A S4965C ------------- ------------- S4965V -------------
On /Off
Gasvalve VK4105A2/C2 VK4105A2/C2 ------------- ------------- VK4115V2 -------------
Electronics S4965AM S4965CM S4965AL S4965CL S4965V S4965S
Modulation
Gasvalve VK4105G1 VK4105G1 VK4105G2 VK4105G2 VK4115V2 VK4105G3

Supply voltage Sensors inputs (total maximum 6):

230 Vac -15% +10% Standard NTC T7335 10k-A material
50Hz ± 2%
(see survey S-T7335)
Power consumption High limit dual sensor 10 kOhm NTC *
5 VA (Sensor type : T7336B 1001)
Humidity * this sensor needs special input
90% RH max. at 40°C (non condensing) MicroCom Communication input and output:
input: logic “0” < 0.8 Vdc
Ambient temperature logic “1” > 2 , < 24 Vdc (10 kOhm)
-20 ... 60°C output: open collector 24 V and 10 mA max
Electrical rating DC output: depending on OS number:
fusing: external: 2 A slow, sand filled 9Vrac, 5mA max
optional integral: 2A slow, sand filled or 24Vdc, 50mA and 7V, 250mA
230V output 1 (ac fan or lpg valve): Electrical PCB connectors
230 Vac, 0.8 A max, cos ϕ ≤ 0.6 High voltage spark: 2.8 x 0.5 mm faston
230V output 2 (pump or aux): or 4 mm round.
230 Vac, 0.8 A max, cos ϕ ≤ 0.6 Flame sensing: 4.8 x 0.8 mm faston
230V output 3 (3 way or aux): Mains connector: 10 pole TYCO, AMP-duac
230 Vac, 0.8 A max, cos ϕ ≤ 0.6 Low voltage connectors: 16 or 18 and 6 pole TYCO,
MATE-N-LOCK
230V output 4 (3 way or aux):
230 Vac, 0.8 A max, cos ϕ ≤ 0.6 Flame sensing
Total output (1..4) : 2A Factory parameter setting:
Room thermostat input: minimum flame current settable between 0.5 and 5 µA
230 Vac, 1 mA or by communication Response time ON: < 0.2 s
Response time OFF: <1s
Gas valve output: :
230Vrac, 50mA Ignition
Auxilary input: Spark voltage: 15 or 20 kV @ 30pF
12 Vdc, 100 kOhm Spark frequency: 15 Hz
Spark pulse energy: 4 or 15 µAs
Air pressure switch input:
12 Vdc, 100 kOhm Timing
DC fan control output: Pre purge time: 0 ... 51 s
5 V 10 mA Waiting time (Tw): 0 ... 51 s
High limit switch input: Pre ignition time: 0 ... 51 s
5 Vdc, 100 kOhm Safety time (Ts): 0 ... 51 s
Number of retrials: 0 ... 255
Water pressure switch input:
Flame failure response time: 1s
12 Vdc, 100 kOhm
Stabilisation time: 0 ... 51 s
Flow sensor input and output: Post ignition/stabilisation time: 0 ... 51 s
12 ± 4Vdc, 10 mA max supply open collector input Post purge time: 0 ... 51 s
Alarm output: Pump over run time: 0 ... 600 s
12 Vdc, 5 mA or by communication Anti cycling time: 0 ... 255 s
OpenTherm output and communication: Timing tolerance ± 5%
In accordance with OpenTherm standard

5 EN2R-9053 0408R11-NE
Communication
Bit rate: 2400 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
RS232 with additional PC cable (nr. 45.900.419-038).
(see document EN2R-9066)
Cable and wiring length
flame sensing cable and spark cable 0.5 m max.
for external components 0.5 m max., except heat demand
Remote reset
Maximum of 5 resets in 15 minutes
Tolerances and product life
Spark frequency at 230 V line voltage
0.7 fspark ≤ fspark ≤ 1.4 fspark
Spark energy
>0.6 * specified spark energy
Product life
500.000 cycles for safety and main valve operator of gas valve
250.000 cycles at rated loads
6.000 lock out operations with rated loads

EN2R-9053 0408R11-NE 6
CONNECTION DIAGRAM

COM / GND Tx COM / GND

out out in / out in / out

18* 10*
6 16* 9 6 4
10
8* 1* 3 1
5 1 9* 1*

in / out in / out in / out in / out in / out in / out Vdc (output)

in / N in / out in / out in / out in / out
out out out Rx
N L * : depending on OS number

230Vac Safety Extra Low Voltage (SELV)

Fig. 1. General connection diagram CVBC

Due to software parameters and hardware jumpers,

specific configurations can be made.
See OS# specific connection diagram !
Connection diagram is mounted on the back of the
housing

IN/OUT can only be configured as input or output.

Fig. 3. Side connection CVBC for sparking to ground

Fig. 2. Side connection CVBC for closed loop sparking

Fig. 4. Side connection CVBC for combined ignition and

flame sensing

7 EN2R-9053 0408R11-NE
TIMING DIAGRAM

DBI +
IP pilot

IP
main valve

Alarm

Tpre purge Tpre ignition Tstab Tpre purge Tpre ignition Ts Tpost purge

Fig. 5. General timing diagram CVBC

EN2R-9053 0408R11-NE 8
DESCRIPTION OF LOCON
LOCON means Load Control. LOCON is based on the phenomena that the ionisation flame
LOCON is able to measure and control the load of a gas fired current in an atmospheric boiler is almost linear with burner
heating appliance. load. (see fig. 7)
LOCON is suitable for atmospheric (with or without fan) Using this property the critical minimum pressure and ignition
modulating boilers. pressure adjustment can be avoided.
Features are: If a throttle is used for maximum pressure regulation no
No or minimum adjustments of VK4105G2000 valve at the adjustment is needed.
production of the combiboiler. Only injectors have to be changed if LPG is needed.
Improvement of the DHW temperature control performance.
Easy swap from LPG to natural gas ( see fig. 6.for the control flow diagram )

LOCON loop

temp.
setpoint temp.
control PI control Valve current control Burner Heat exchanger
+ +
- -

ionisation current

NTC temperature sensor information

Fig. 6. LOCON control flow diagram

I flame (P0)

throttle-adjustment
at Pi-nom

I flame-max
P0 max

I flame (P0) ign

I flame (P0) max

B min B ign B max

Boilerload
Fig. 7. Ionisation flame current versus the boiler load
REMARK: Electrode postition and choice is important.
In cooperation with Polidoro, Honeywell has made
a standard solution.
New applications require Honeywell approval.

9 EN2R-9053 0408R11-NE
DESCRIPTION OF SQUARE TECHNOLOGY
SQUARE is the abbreviation of Self adaptive, Quality, User SQUARE is based on the phenomena that the ionisation
friendly, Adjustment free, Reliable, Environmental friendly. current is a measure of the gas quality at a specific range of
the burner load in a fully premix burner.
SQUARE is able to control the load and burning process of a
fully premix heating appliance under varying gas quality After calibration based on this phenomena, the burner can be
conditions. See fig. 8. influenced by means of a micro bridge flow sensor. see fig. 8.

Features are : If the gasvalve is closed, the micro bridge acts as an airflow
• Gas adaptive control over the full natural gas band, with a meter in order to measure the chimney resistance.
modulation range of 1:5
• Electronic gas-air at a constant gas quality with a
modulation range of 1:10
• Automatic chimney lenth compensation

AIR
Pmix

Pair=1013hPa FAN

u-bridge
GAS

CVI-M Pgas

Fig. 8. schematic SQUARE system

EN2R-9053 0408R11-NE 10
GENERAL CONSIDERATIONS
To ensure reliable long term operation, mount the boiler NOTE 8.: Exhaust temperature protection may only be used
control at a position in the appliance with a low ambient in non safety critical applications.
temperature and a low radiation. NOTE 9.: Remote reset function may only be used in
The boiler control should be externally fused. applications where a maximum of five resets per
High temperatures will affect product life. 15 minutes is allowed.
NOTE 1.: When first starting the boiler control has a self
check time of about 10 seconds. WARNING
NOTE 2.: Electrical rating of connected controls should be Honeywell is not responsible for damage and/or injury
appropriate for the load that is switched by the due to mis wiring.
boiler control. After installation boiler control can become wet due to
NOTE 3.: Disconnect the boiler control from mains before condensation. Do not connect wet device to mains.
performing a dielectric strength test.
NOTE 4.: When first starting, the control can be in the lock-
out 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.: The modulation function of the S4965 boiler
control units is checked during the start up safety
check. As a result the gas technical safety of the
appliance provided with a S4965 boiler control
unit can rely on the proper functioning of the
adjustable gas outlet pressure during ignition of
this boiler control unit.
This means that due to a safe ignition pressure
level, the safety time of the boiler can be
extended.

11 EN2R-9053 0408R11-NE
ELECTRICAL CONNECTIONS AND WIRING

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 leadwire which can withstand at least 105°C ambient.
• Use leadwire which is proven against moisture.
• Wiring between boiler control and spark sensing probe
should have good quality insulation, suitable for the
temperatures encountered.
• Keep high voltage spark wire at least 10 cm. away from
other wires.
• Conduct spark wire as close as possible along shield metal
or metal pipes.
Fusing
The boiler control has to be externally fused at maximum 2A
slow sand filled.
This can be done externally or optional integrated.
The integrated fuse has to be mounted and demounted as
follows:
Demount: Press with screw driver the fuse cover
against spring inside fuse holder and
turn 90° to left. Release screw driver.
Fuse holder including fuse can be taken
out.

Mount: Mount new fuse in fuse cover and place

total in fuse holder. Press cover carefully
against spring in fuse holder, and turn
90° to right.
Spark gap
Max. allowable spark gap 3.5 mm (recommended 3 mm.)

EN2R-9053 0408R11-NE 12
ADJUSTMENTS AND FINAL CHECKOUT
Final checkout
WARNING After installation and any adjustment start the appliance and
observe a complete cycle to ensure that all burner
Adjustments must be made by qualified persons only.
components function correctly.
If the appliance manufacturer supplies checkout and/ or
service and maintenance instructions carefully follow Maintenance and service
them. If these instructions are not provided then use the Under normal circumstances no maintenance or service is
procedure outlined below.
required.

Checking flame current Adjustment of gas pressure.

• The minimum value should be in accordance with specified • The gas pressure can be adjusted after the S4965
value. automatic ignition control has been mounted on the
• To check flame current connect a DC micro-Ampèremeter VK4100/VK4105 gas valve.
between flame sensing wire and flame sensing rod. • Depending on the O.S. number the different values of the
Short micro-Ampèremeter during ignition to prevent gas pressure must be adjusted.
damage of the micro-Ampèremeter in single rod • Adjustments can be executed with the help of a PC tool and
applications. a communication link between the S4965 and the PC tool.
• Meter connections polluted with e.g. alkaline substances • Adjustment is described in an O.S. number specific
lying close to earth can cause flame current simulation. instruction sheet.
Make sure no false flame current can flow from meter
connections to earth.
• 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.

13 EN2R-9053 0408R11-NE
EMC GUIDELINES
The position of the ignition cable has to be determined for low-
est emission.
Do not lead ignition cable close to other cabling.
To suppress Radio Frequency Interference (RFI) the boiler
control including spark ignition cable should be mounted in
sufficient shielded environment.

EN2R-9053 0408R11-NE 14
QUALITY ASSURANCE STATEMENT
Products are manufactured under an ISO 9001 (1994) based The quality organisation is responsible for defining,
and certified Quality System. maintaining, improving and verification of the quality systems
The quality system is described in the Honeywell Combustion in the field of design, production process and field quality
Controls Center Quality Assurance Programme and its related service.
operational procedures and instructions. Assembly processes are guided by work instructions.
The quality system is approved by Gastec against certificate Patrol inspections form part of the assembly processes.
number 9.302/2. 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 Approvals
The S4965 has been designed to meet the European The boiler control conforms with the following EC - Directives:
Standards: • Gas Appliance Directive (90/396/EEC)
• EN 298 (2003): Automatic gas burner control systems. • Low Voltage Directive (73/23/EEC)
• EN 60730-1: Automatic electric controls for household and • Electro Magnetic Compatability Directive (89/336/EEC)*
simular use.
* Conformity with Electro Magnetic Compatibility Directive
Regarding electric safety, the S4965 can be used in regarding emission for non industrial appliances can be
appliances according to European Standard for household assumed for all selected Ordering .Specification (O.S.).
electrical requirements EN 60335 series numbers. However conformity can only be declared as part
S4965 systems function in accordance with EN 298. of the appliance.
S4965A, AM, AL .......................................... code A/M/C/L/X/K Regarding immunity, all controls comply with the levels for non
S4965C, CM, CL, V ..................................... code F/M/C/L/X/K industrial appliances.

15 EN2R-9053 0408R11-NE
 Ordering Specification number

S 4 9 6 5 X 9999

S: Residential market Specification number

4: line voltage

9: family code
See page 5

6: direct spark ignition or intermittent

pilot with safety time

5: CVI system boiler control