Honeywell VQ400M Series User manual

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HONEYWELL
CLASS “A” COMBINATION VALVES
VQ400M-Series
EN2R9081-C
October 2009
1
VQ400M SERIES
CLASS “A” COMBINATION VALVES
PRODUCT HANDBOOK
APPLICATION
Figure 1 VQ420M & VQ425M
Figure 2 VQ440M & VQ450M
The VQ400M Series class “A” safety combination
valves are used for control and regulation of
gaseous fluids in gas power burners, atmospheric
gas boilers, melting furnaces, incinerators and
other gas consuming appliances.
The VQ400M offers flexibility to mount accessories
like valve-position indicator, pressure indication
switches, vent-valves or by-pass valves at several
positions at the gas valve, whenever, wherever.
These combination valves are available in two body
sizes:
•Small model
oVQ420
oVQ425
•Large model
oVQ440
oVQ450
All models are connected at suitable sized gas
pipes by flange kits which can be ordered
separately in several sizes.

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CLASS “A” COMBINATION VALVES
VQ400M-Series
EN2R9081-C
October 2009
2
CONTENTS
VQ400M SERIES ........................................................... 1
CLASS “A” COMBINATION VALVES ......................... 1
APPLICATION................................................................ 1
Contents......................................................................... 2
FEATURES .................................................................... 2
DESCRIPTION............................................................... 3
SPECIFICATION............................................................ 3
Models ........................................................................ 3
Dimensions................................................................. 3
Pipe sizes.................................................................... 4
Capacity...................................................................... 4
Connections................................................................ 4
Torsion and bending stress......................................... 4
Supply voltages........................................................... 4
Electrical equipment.................................................... 4
Electrical connections ................................................. 5
Ambient temperature range ........................................ 5
Coil insulation solenoid valves.................................... 5
Enclosure.................................................................... 5
Body material.............................................................. 5
Closing spring ............................................................. 5
Valve plunger.............................................................. 5
Seals and gaskets....................................................... 5
Power consumption .................................................... 5
PERFORMANCE CHARACTERISTICS......................... 6
Opening time............................................................... 6
Closing time................................................................ 6
Maximum working frequency ...................................... 6
Duty cycle ................................................................... 6
Operational voltage range........................................... 6
Designed life time ....................................................... 6
CAPACITY CURVES...................................................... 7
INSTALLATION.............................................................. 8
IMPORTANT............................................................... 8
WARNING................................................................... 8
Maintenance and service............................................ 8
Mounting position........................................................ 8
Mounting location........................................................ 8
Main gas connection flanged valves........................... 9
WARNING!.................................................................. 9
Electrical connection................................................... 9
WARNING................................................................... 9
Wiring.......................................................................... 9
ADJUSTMENTS AND FINAL CHECKOUT .................. 11
CAUTION.................................................................. 11
2nd main valve fast opening....................................... 11
2nd main valve slow opening..................................... 11
IMPORTANT............................................................. 11
Final checkout of the installation............................... 12
OPTION INSTALLATION ............................................. 13
WARNING................................................................. 13
CONSTRUCTION AND WORKING PRINCIPLES........ 13
ORDERING INFORMATION ........................................ 14
NOTE........................................................................ 14
Replacement of parts.................................................... 15
Warning..................................................................... 15
Recommended accessories ......................................... 15
APPROVALS................................................................ 17
Declaration of Conformity.......................................... 17
FEATURES
•Class “A” safety combination valve for
control of gaseous fluids in gas consuming
appliances in accordance with international
standards.
•Main body with two gas valves with single
seat.
•Possibility of installing internal by-pass
valve to achieve high-low flame control.
•Possibility of installing internal or external
pilot valve.
•Possibility of installing vent valve.
•Possibility of installing flanged minimum
and maximum pressure switches.
•Possibility of installing valve Proving
System (VPS).
•Possibility of mounting Closed Position
Indication switch (CPI) at bottom of safety
valve V1 and / or valve V2.
•Closing time: < 1 second.
•Coils field replaceable.
•Coils suitable for permanent energizing.
•Fine mesh screen between inlet flange and
main body (optional).
•Various pressure tap points at main body
available
•Second main valve, either with adjustable
flow regulator (fast), or characterized
opening mechanism (slow) with adjustable
maximum flow rate and step pressure.
•Rectifier boards field replaceable.
•PG11 cable strain relief standard at
VQ400M.
•Plug connector according to ISO 4400 /
DIN EN 175301-803 optional for VQ400M.

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CLASS “A” COMBINATION VALVES
VQ400M-Series
EN2R9081-C
October 2009
3
DESCRIPTION
The VQ400M Series combination valves are
suitable for the control of gaseous fluids in gas
consuming appliances according to international
standards.
The VQ400M Series combination valves meet the
class “A” specification according EN161. The
VQ400M Series combination valves can be ordered
with straight flanged pipe connection from 1/2 " up
to 2". The VQ400M Series combination valves are
standard equipped with two safety valves V1 and
V2. The first valve (V1) is always fast opening. The
second valve (V2) can be either fast or slow
opening.
•Standard the second valve (V2) is supplied
with throttle screw (fast opening with flow
regulation).
•Optionally the second valve (V2) can be
ordered with slow opening device (with flow
regulation and adjustable opening).
•Optionally the second valve (V2) can be
ordered fast open, without any regulation
device.
SPECIFICATION
The specifications described in this chapter are
related to the main gas valves.
Models
Models can be ordered according order
specification numbering which is shown
in Figure .15
For an overview of all known combinations see
surveys:
•50040300
•50040301 (Accessories)
The VQ400M series combination valves are
available in two body sizes:
•Small model
oVQ420M
oVQ425M
•Large model
oVQ440M
oVQ450M
All models are connected at suitable sized gas
pipes by flange kits which have to be ordered
separately.
Dimensions
Main dimensions of the models are given at
installation drawings:
Table 1 Overview of installation drawings.
Model Installation drawing
VQ420M INST0171
VQ425M INST0172
VQ440M INST0169
VQ450M INST0170
Installation drawings are available in Honeywell
documentation centre “HotDocs” and can be
supplied digitally on request through Honeywell
sales representative.

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CLASS “A” COMBINATION VALVES
VQ400M-Series
EN2R9081-C
October 2009
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Pipe sizes
For connecting with several pipe sizes it is
recommended to mount Honeywell flange kits
which can be ordered separately as indicated
below.
Table 2 Overview of recommended pipe sizes.
Gas valve Recommended pipe size Option
VQ420M ½” 1
VQ420M ¾” 2
VQ425M 1”
VQ440M 1 ¼” 1
VQ440M 1 ½” 2
VQ450M 2”
Recommended flanges for each model to be
mounted are given in table 3 and table 4.
Capacity
Main body: see capacity curves at Figure .
Maximum operating pressure is 360 mbar for all
models
•360 mbar
oVQ420M
oVQ425M
oVQ440M
oVQ450M
Connections
As shown in the figure below, VQ400M is provided
with plugs and flanges giving flexibility to customize
this combination valve with Honeywell accessories.
Figure 3 Interfaces for possible accessories
Torsion and bending stress
Pipe connections meet group 2 according to EN161
requirements.
Supply voltages
VQ400 M series can be ordered for line voltage:
•230 Vac, 50/60 Hz
•115 Vac, 50/60 Hz
•120 Vac, 50/60 Hz
Electrical equipment
AC rectified coils with separated rectifier inside the
cover.
Plugs for mounting:
•pressure tap
•Val e pro ing
system
•Pressure switches
Plugs for connecting:
•By pass al e
•Internal or external
pilot al e
•Vent al e
Flange connection V2
In the bottom plate two
plugs are a ailable for
mounting Closed
Outlet flange
connection
Inlet flange
connection
Flange connection V1
Plug for mounting
pressure
tap

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CLASS “A” COMBINATION VALVES
VQ400M-Series
EN2R9081-C
October 2009
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Electrical connections
VQ400M: standard plug connection according
PG11 on main gas valves and additional valves.
Optional: three pin plug connector („DIN plug“) on
main gas valves and additional valves.
Ambient temperature range
VQ400M is designed to operate in ambient
temperature levels between: -15 ... 60 °C
Coil insulation solenoid valves
Insulation material is specified according class F.
Enclosure
IP54 in combination with PG11 connection.
IP65 in combination with DIN-plug connection.
Body material
Aluminum alloy die cast body.
Closing spring
AISI 302 steel
Valve plunger
Chrome plated Fe 360B steel sliding on anti-friction
bearing.
Seals and gaskets
Hydrocarbon resistant NBR rubber type
Power consumption
Honeywell provides VQ400M with coils that suit
demands of specified inlet pressure levels. An
overview of power consumption for different
applications is given in the table below.
Table 3 Power consumption of each VQ400M main valve for
360 mbar applications.
115V 120V 230V
VQ420M 16,5 18 15
VQ425M 23,9 26,1 21,1
VQ440M 52 56,7 46,5
VQ450M - - 61

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CLASS “A” COMBINATION VALVES
VQ400M-Series
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PERFORMANCE
CHARACTERISTICS
Opening time
The first valve (V1) opens in less than 1 second.
The second valve (V2) can be either a fast opening
valve which opens in less than 1 second or a
characterized opening valve which is adjustable
from 1 up to 30 seconds, at rated capacity.
The opening characteristic is factory set at
approximately 6 seconds at the following
conditions:
•measured at 80 % of rated capacity
•30 mbar supply pressure
•nominal voltage
•20 °C
•2,5 mbar pressure drop
•no step pressure
Due to the influence of ambient temperature (-15 ...
60 °C) the adjusted opening time of 6 seconds
measured at 80% of adjusted flow rate can vary +/-
4 seconds.
Closing time
Less than 1 second for both valves.
Maximum working frequency
VQ400M is equipped for maximal working
frequency of one cycle per minute.
Duty cycle
Coils are suitable for permanent energizing.
Operational voltage range
The combination gas valve will function satisfactory
between 85% and 110% of the rated voltage.
Designed life time
Overview of designed life time is given in the table
below.
Table 4 Number of cycles per model.
Model Number of cycles
VQ420MA 500.000
VQ425MA 500.000
VQ440MA 300.000
VQ450MA
300.000

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CLASS “A” COMBINATION VALVES
VQ400M-Series
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CAPACITY CURVES
For comparison an overview of specified capacity of VQ400M is shown in table 5.
Table 5 Overview of reference capacity in m3/h air at ∆p = 2.5 mbar.
Gas valve Flange size Pipe size Flow capacity
VQ420MA DN15 ½” -
VQ420MA DN20 ¾” 8
VQ425MA
DN25 1” 11
VQ440MA DN32 1 ¼” 25
VQ440MA DN40 1 ½” 31
VQ450MA
DN50 2” 40
In figure 4 a broader range of specified capacity for VQ400M is shown in curves.
Figure 4 Capacity curve for VQ400M Series class „A” combination valves.

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CLASS “A” COMBINATION VALVES
VQ400M-Series
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INSTALLATION
IMPORTANT
1. Read these instructions carefully. Failure to
follow the instructions could damage the
product or cause a hazardous condition.
2. Check the ratings given in the instructions
and on the product to make sure the
product is suitable for your application.
3. The installation has to be carried out by
qualified personnel only.
4. Carry out a thorough checkout when
installation is completed.
WARNING
•Turn off gas supply before installation.
•Disconnect power supply to the valve
actuator before beginning the installation to
prevent electrical shock and damage to the
equipment.
•Do not remove the seal over valve inlet and
outlet until ready to connect piping.
•The valve must be installed so that the
arrow on the valve points in the direction of
the gas flow (gas pressure helps to close
the valve).
Maintenance and service
The designed lifetime* of this product is 10 years,
based on date code, according to:
a) the standard EN 126
b) the table on designed lifetime as stated on
the Afecor website http://www.afecor.org/
We cannot assume that the product can be safely
used beyond the mentioned designed lifetime. This
lifetime is based on use of the control according
manufacturer’s instructions.
Regular inspection of the control by authorized
personnel in accordance with guidelines of the
appliance manufacturer is required.
After reaching the designed lifetime the product has
to be replaced by authorized personnel.
Note: * Warranty as opposed to designed lifetime is
described in the delivery terms.
Mounting position
The gas valve can be mounted in vertical position
with the coils at top side. The gas valve can be
mounted plus or minus 90 degrees from the
vertical.
Mounting location
The distance between the gas valve and the
wall/ground must be at least 30 mm.

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CLASS “A” COMBINATION VALVES
VQ400M-Series
EN2R9081-C
October 2009
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Main gas connection flanged
valves
1. Take care that dirt does not enter the gas
valve during handling.
2. Remove the flanges from the valve.
3. Use a sound taper fitting with thread
according to ISO 7-1 or new, properly
reamed pipe, free from swarf.
4. Apply a moderate amount of good quality
thread compound to the pipe for fitting only;
leaving the two end threads bare, PTFE
tape may be used as an alternative.
5. Screw the flanges onto the pipes.
6. Ensure that inlet and outlet flanges are in
line and separated from each other enough
to allow the valve to be mounted between
them without damaging the gasket.
7. Place gasket. If necessary grease it slightly
to keep it in place.
8. Mount gas valve between flanges using the
bolts for each flange.
9. Complete the electrical connections as
instructed in the electrical connection
section.
WARNING!
Tightness test after installation
•Spray all pipe connections and gaskets
with a good quality gas leak detection
spray.
•Start the appliance and check for bubbles.
If a leak is found in a pipe connection,
remake the joint. A gasket leak can usually
be stopped by tightening the mounting
screws, otherwise, replace the gas valve.
Electrical connection
WARNING
•Switch off power supply before making
electrical connections.
•All wiring must comply with local codes,
ordinances and regulations.
Use lead wire which can withstand 105 °C ambient.
The electric ON/OFF operator is provided with a
terminal block for electrical connections.
Wiring PG11
Small models VQ420M-VQ425M
Remove screws (A).
Take off protective cover lids and gaskets (B).
Take off plugs Pg11 from holes (Figure 5):
(K) and (N) – for connecting separately.
(K), (L) and (M) – for connecting by
common supply from inlet side.
(N), (L) and (M) – for connecting by
common supply from outlet side.
Figure 5 IP54 version closed by plugs
Prepare cables
•Remove plastic outside insulation for about
50-75 mm.
•Strip wires from plastic insulation for about
5-7mm.
Place cable support screw (C), steel ring(D), rubber
ring (E) and guide wires through the hole in the
cover to the connection block (F).
Connect wires between plates by tightening the
particular screws (F1, F2, F3)
•Left: Phase
•Middle: Earth connection
•Right: Neutral

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If common supply:
Loose screw (P) and cap (S). Turn coils and insert
adaptor (G).
Turn back coils and tight screw (P) and cap (S) by
tightening torque 2,5 Nm.
Connect corresponding contact by wires through
adaptor.
Tight cable support screws (C)
Place gaskets and cover lids in position (B)
Place screws (A) and tight.
Figure 6 Small model connected by common supply from outlet
side
Large models VQ440M-VQ450M
Each coil have to be supply separately.
Remove screws (A)
Take off protective cover lids and gasket (B)
Take off one from two plugs Pg11.
Prepare cables
•Remove plastic outside insulation for about
50-75 mm.
•Strip wires from plastic insulation for about
5-7mm.
Place cable support screw (C), steel ring(D), rubber
ring (E) and guide wires through the hole in the
cover to the connection block (F).
Connect wires between plates by tightening the
particular screws (F1, F2, F3)
•Left: Phase
•Middle: Earth connection
•Right: Neutral
Tight cable support screws (C)
Place gaskets and cover lids in position (B)
Place screws (A) and tight.
Figure 7 Large model – V2 coil connected from outlet side
Wiring DIN plug
Follow the instructions supplied by the appliance
manufacturer as shown in the figures below. Coils
supply separate
Figure 8 Three pin electrical plug connector (according to
ISO 4400 / DIN EN 175301-803).

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ADJUSTMENTS AND FINAL
CHECKOUT
The procedures described in this chapter are
related to the adjustments on the main gas valve,
pilot valve and by-pass valve. For adjustments on
the other additional functionalities (e.g. pressure
switch), refer to the included instruction sheet of the
product in question in the package.
CAUTION
•Adjustments must be made by qualified
personnel only.
•To ensure a safe closing of the valves, it is
essential that voltage over the terminals of
operators is reduced to 0 Volts.
2nd main valve fast opening
Figure 9 Adjusting flow rate.
Flow rate adjustment (see Fig. 9.)
1. Remove the cap screw from top of the coil.
2. Place a socket head wrench into the
adjustment nut.
3. Turn wrench counter-clockwise to increase
or clockwise to decrease flow rate.
4. Replace cap screw.
2nd main valve slow opening
The following characteristics can be adjusted:
•flow rate
•step pressure
•opening speed
Figure 10 Characterized opening.
IMPORTANT
To ensure a satisfactory setting of the valve the
pressure drop over the valve should be at least
10% of the supply pressure or 2.5 mbar which ever
is the greatest.
Flow rate adjustment
1. Remove the cap from top of the coil by
loosening both screws.
2. Place a wrench on the adjustment hexagon
nut.
3. Turn wrench counter-clockwise to increase
or clockwise to decrease the flow rate.
4. Replace cap on top of the coil.
Figure 11 Adjusting flow rate.

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Step pressure adjustment (see fig. 12.)
1. Remove the cap from top of the coil by
loosening both screws.
2. Place a screw driver in the slot of
adjustment screw which is situated in
center of the valve.
3. Turn screw driver counter-clockwise to
increase or clockwise to decrease step
pressure.
4. Replace cap on top of the coil.
Figure 12 Adjusting step pressure.
Opening speed adjustment
1. Remove the cap from top of the coil by
loosening both screws.
2. Place screw driver in the slot of adjustment
screw which is of center line.
3. Turn screw driver counter-clockwise to
increase the opening speed and therefore
the time till full opening will decrease.
4. Turn screw driver clockwise to decrease
the opening speed and therefore the time
till full opening will increase.
5. Replace cap on top of the coil.
Figure 13 Adjusting opening speed.
Final checkout of the installation
Set the appliance in operation after any adjustment
and observe several complete cycles to ensure that
all burner components function correctly.

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OPTION INSTALLATION
Installation can be done by the OEM or by qualified
personnel in field.
WARNING
If additional hardware needs to be installed on field,
then installation personnel should take care, that
the main gas flow to the appliance has been
completely stopped by an upstream manual shut-
off valve prior to the installation.
Installation
1. Open the required gas flow channels by
removing the suitable plugs from the valve
body.
2. Take care that dirt can not enter the gas
valve during handling
3. Install the screw-in additional hardware as
required (vent, by-pass, external pilot
valve)
4. Please refer to the relevant instruction
sheet
CONSTRUCTION AND WORKING
PRINCIPLES
The VQ400M combination gas valves are 2 x class
“A” fail safe shut-off valves. The valve is opened by
energizing the direct ON / OFF operator. The direct
ON / OFF operator consists of a coil and stop
sleeve assembly. Inside the top sleeve assembly a
plunger is placed which is able to move up and
down and thus opening or closing the valve. The
plunger is gliding on two anti-friction bearings. Flow
regulation is done by adjustable plunger stroke. A
strainer made out of steel AISI 303 is incorporated
between inlet flange and main body. Valve closing
springs are made out of steel AISI 302. Seals and
gaskets are manufactured out of hydrocarbon
resistant NBR according to DIN 3535 and EN291.
SECTION A-A
Figure 14 Schematic drawing of VQ400M.
Moveable valve to
open / close flow
channel
Automatic closing mechanism
when power is
switched off
Slow opening
device
Electro-magnetic
actuator
Flow direction

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ORDERING INFORMATION
Ordering specification number
VQ4xxMAxxxx
Valve size and flange connection
20: DN20 (3/4")
25: DN25 (1")
40: DN40 (1 1/2")
50: DN50 (2")
Characteristic second valve
A: Fast opening, no throttle
B: Fast opening, throttle
C: Slow opening
Specification number
Figure 15 Ordering information VQ400M Series combination valves.
NOTE
Accessories as flanges need to be ordered separately.

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REPLACEMENT OF PARTS
Warning
•Take care that only qualified persons carry
out the installation of parts, accessories,
and add on components.
•Follow the installation instructions included
in the package.
•Check that the selected part, accessory or
add-on component is the correct one for
the application in question.
•Replace old gaskets with the new ones
supplied in the package and check for
leakage when the supply is switched on
again.
•After installation and/or replacement has
been completed, a gas leak test must be
carried out.
•Also check the gas valve for satisfactory
operation after fitting accessories.
Table 6 Rectifier boards for VQ400M series.
Gas valve Rectifier board
115V/120V
Rectifier board
230V
VQ420MA CS020020 CS020070
VQ425MA CS020020 CS020070
VQ440MA CS020020 CS020071
VQ450MA
CS020020 CS020071
RECOMMENDED ACCESSORIES
There are two different series of flange kits
available. The first series of flange kits consist of: 1
flange with sealing plug, 1 O-rings and 4 screws.
Table 7 Flange kits without strainer.
Gas valve Recommended flange kit
VQ420M KTCOMB15
VQ420M KTCOMB20
VQ425M KTCOMB25
VQ440M KTCOMB32
VQ440M KTCOMB40
VQ450M KTCOMB50
The second series of flange kits consist of: 1 flange
with sealing plug or cast pressure tap, 1 strainer, 1
O-rings and 4 screws
Table 8 Flange kits with strainer.
Gas valve Recommended flange kit
VQ420M KTCOMS15
VQ420M KTCOMS20
VQ425M KTCOMS25
VQ440M KTCOMS32
VQ440M KTCOMS40
VQ450M KTCOMS50

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Table 9 Overview of recommended internal by-pass valves.
Gas valve Internal by pass valve
VQ400M VB420Xxxxx
See Honeywell documentation VB420Xxxxx KIT for
further instructions on internal by-pass valves.
Table 10 Overview of recommended external pilot valves.
Gas valve External pilot valve
VQ400M VP420Xxxxx
See Honeywell documentation VP420Xxxxx KIT for
further instructions on external pilot valves.
Table 11 Overview of recommended vent valves.
Gas valve Vent valve
VQ400M VV420Xxxxx
See Honeywell documentation VV420Xxxx KIT for
further instructions on vent valves.
Table 12 Overview of recommended closed position
indication switches (CPI).
Gas valve Closed position indicator
VQ420M MS062001
VQ425M MS062501
VQ440M MS064001
VQ450M MS065001
Table 13 Honeywell fine particle filter.
Gasvalve Honeywell Filter
VQ420M
VQ425M
HFVR050 / HFVR150
This filter is used to filter fine (50 or 150 µm)
particles of dirt out of gas flow.

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Honeywell
HoneywellHoneywell
Honeywell
Manufactured for and on behalf of the Environmental and Combustion Controls Division of Honeywell Sàrl, Z.A. La Pièce 16, 1180 Rolle, Switzerland by its Authorized Representative:
Automation and Control Solutions
Combustion Controls Europe
Honeywell BV
Phileas Foggstraat 7
7821 AJ Emmen
The Netherlands
Tel.: +31 (-)591 695911
Fax: +31 (-) 591 695200
http://europe.hbc.honeywell.com
APPROVALS
The gas valve series VQ400M have been designed to
meet the European standards:
•EN 161 Automatic shut-off valves
•EN 126 Multifunctional controls
Declaration of Conformity
Honeywell Technologies Sàrl.
Rolle,
Switzerland,
declares under it’s sole responsibility that the VQ
Modular Valve product family, to which this statement
relates, is:
•in conformity with the essential requirements of
the Gas Appliance Directive 90/396/EEC
based on EN 126:2004
•in conformity with the essential requirements of
the Low Voltage Directive 2006/95/EC
based on EN 60730-1:2000
•in conformity with the essential requirements of
the EMC Directive2004/108/EC
for immunity based on the standard: EN55014-2: 1997
(Immunity, Product Family Standard)
for emission based on the standard: EN55014-1: 2006
(Emission , Product family standard
Emmen, February 2009.
On behalf of Honeywell Technologies Sarl,
B.Veld, Manager Standards & Approvals