Honeywell ESYS S4965A3025 Operating and installation instructions

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
Page 1/22
ESYS CONTROLLER
S4965A3025
FUNCTIONAL DESCRIPTION
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roductionFunctionalDescription/S4965A3025E20.doc $
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Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
Page 2/22
Table of Contents
1. Software revisions...........................................................................................................................3
2. Reference standards and Approvals .............................................................................................4
3. Quality assurance statement..........................................................................................................5
4. Identification.....................................................................................................................................6
5. Product description.........................................................................................................................7
6. Modes of operation........................................................................................................................15
7. Control Panel for ESYS.................................................................................................................17
8. History information........................................................................................................................18
9. Other documentation.....................................................................................................................19
10. Installation....................................................................................................................................20
2.1 - Standards ....................................................................................................................................................4
2.2 - Approvals .....................................................................................................................................................4
5.1 - General ........................................................................................................................................................7
5.2 - Layout ..........................................................................................................................................................8
5.3 - Technical features .......................................................................................................................................9
5.3.1 - Connector and connections ..................................................................................................................9
5.3.2 - High Voltage Connections ..................................................................................................................10
5.3.3 - Communication Connector .................................................................................................................10
5.3.4 - Low Voltage Connections ...................................................................................................................11
5.3.5 - Specification........................................................................................................................................11
5.4 - Timing diagram ..........................................................................................................................................13
5.5 - Recommended peripheral devices ............................................................................................................14
5.6 - Sensors and actuators...............................................................................................................................14
5.6.1 - Safety Cut-off Switch...........................................................................................................................14
5.6.2 - Alarm/Error Led...................................................................................................................................14
5.6.3 - Error Output to Esys 2.........................................................................................................................14
5.6.4 - Gas Valve............................................................................................................................................14
6.1 - Stand-by.....................................................................................................................................................15
6.2 - Heat Demand.............................................................................................................................................15
6.3 - Protection and error conditions..................................................................................................................15
6.4 - Ignition sequence.......................................................................................................................................16
10.1 - General remarks ......................................................................................................................................20
10.2 - Electrical connection................................................................................................................................20
10.3 - Cables and wirings ..................................................................................................................................21
10.4 - Ionization current check...........................................................................................................................21
10.5 - Adjustments and final checkout...............................................................................................................22
10.6 - EMC guidelines........................................................................................................................................22

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
Page 3/22
1. Software revisions
Software Description Date Description of amendments CRC
45007997-005
45007998-005
C0.05_P0.19
E0.05
03-Nov-2011 78FE
45007997-006
45007998-006
C0.06_P2.19
E0.06
03-Oct-2014 Platform update:
-repaired exceeded safety time + flame-off time
-repaired error E08
-repaired error E21 (band gap shift)
4931
45007997-009
45007998-009
C0.09_P2.19
E0.09
06-Mar-2015 Added custom:
-postpurge time class 5, 0x0CC1, default 0
Changed possibility postpurge break at HD.
Revised timing spark time, safety time, flame
failure response time.
E9BD

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
Page 4/22
2. Reference standards and Approvals
2.1 - Standards
ESYS boiler controller meets the requirements laid down in standards-documents:
EN 298:2012
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 ESYS can be used in appliances according to European Standards for household
electrical requirements EN 60335 series.
2.2 - Approvals
The boiler control conforms to the following EC - Directives:
Gas Appliance Directive 2009/142/EC;
Low Voltage Directive 2006/95/EC;
Electro Magnetic Compatibility Directive 2004/108/EC*.
* 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.

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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3. Quality assurance statement
Products are manufactured under an ISO 9001:2008 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 SAI GLOBAL against certificate number CERT-0077998.
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.

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
Page 6/22
4. Identification
To ensure product tracking and identification:
On housing label is:
Bar code (or 2D code) label with production data
CE-0063BR1922 printed on the label;
Customer code (if requested)
And each board shows:
Paper label with firmware version, type and model burner control, programming batch, production date.
Laser 2D code label with production data
Customer code (if requested)
Honeywell part number
Customer part number Notes
S4965A3025 – –

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
Page 7/22
5. Product description
5.1 - General
Controller S4965A3025 is intended to be used for ON/OFF applications. It is made for direct burner ignition applications. The
controller can drive a gas valve. High Limit switch ensures additional safety level. A Heat Demand (HD) can be generated by
the high voltage or low voltage switches. A special test mode heat demand can be controlled through the communication port
of the ESYS and the appropriate software or through the MMI.

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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5.2 - Layout
Component side view
Overall dimensions 113 x 100 mm
PCB thickness 1,6 mm
Fixing points n° 3 holes Ø 3 mm
Tolerances according to STP0015
C300
C301
C302
D302
D300
D301
R131
R134
J108
R135
J106
R133
R132
D303
C307C308
C309
C562
Q106
Q104
R108
R137
D105
C101
C102
R138
C55b
R16
D108
X603 X1
C369
R119
C105
C106
C114
R115
R141
C118
J109
C370
R313
R117
C115
R114
C107
C113
R147
R136
U105
U103
U104
Q108
J110
R104
R22
J105
Q103
R103
Q107
C313
D19
J111
L3
R2
Q2
C32
SI1
Q4
C305
U2
R303
D11
R5
F1R306
D7
C1
D16
R308
C310
R307
C365
C30
U302
R17
R15 C31
C368
Q10
D4
D24
R120
D318
Q9
R21
D305
D107 Q105
R109
C14
R41
U6
R60
R28 R67
C54
R324
C120
R40
C367
R63
C55a
R38 U102 D22
Y601
Q5
R55
R126
U4
R61
R140
S1 C372 C33C371 J115 J104 C34J103L8 L7 J112 J113 J114 R25
R19
R302 X2
R124 X3
R125
R127
R118
Q102
C104
R301
R123
J102
R139
C109
C116
C111
R142
C304
U300
C103
C303
J107
R300
R128
R146
R102
C112
R145 R144
R121
L5
R130
L6
R314
R113
K3
R101
R33
J300
R26
D104
K2
J301
D102
Q109
Q101
S2
C504
D2
R7
C3
J101
TR1
R58 Q7
R3
R4
R1
K1
Q8
Q3 D3
R62
R66
R8
C505
U303
R57
Q11
R6
R304
C56
C10
Q1
C306
C566
J7
R42
R23
TR3 J1
D20
R20
D317
X6
Q12
L1L2
C29
D1
C312
U301
C61
R12
R13
R18
R9
C8 R14
R37
D26
C28
R311
C311b C311a
R36
C117
R116
C12 C16
R312
D327
R11
D25
U7
C21
C358
D306
L4
U1
C9
U5
R10
R122
R323
R129
R112
R70 R69
R59
R107
R110
C108
R111
R39
D28
R321R322
D307
C13
C20 R24
R105
D23
C52
Q6
R143
C53
C51
C314
P1
C19
U101 D106 D101
Fig. 1 - Component side view.

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
Page 9/22
5.3 - Technical features
5.3.1 - Connector and connections
In the diagram below the connection diagram is shown. The Minifit connector contains the high voltage (230 VAC)
connections, and the Microfit connectors contain the safety extra low voltage connections.
Fig. 2 - Connection diagram.

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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5.3.2 - High Voltage Connections
Connector
name Pin Type of Connection Description
HIGH VOLTAGE (230 VAC) CONNECTIONS
X1 1 Molex Minifit High Voltage Heat Demand
X1 2 Molex Minifit Not used
X1 3 Molex Minifit Not used
X1 4 Molex Minifit LPG output – Phase
X1 5 Molex Minifit Main Power Line – Phase
X1 6 Molex Minifit Not used
X1 7 Molex Minifit Neutral
X1 8 Molex Minifit Neutral
X1 9 Molex Minifit LPG output – Neutral
X1 10 Molex Minifit Main Power Line – Neutral
SPARK IGNITION CONNECTION
TR1 2.8x0.5mm faston High voltage Transformer output
FLAME INPUT CONNECTION
X6 4.8x0.8mm faston Flame rod detection input
EARTH CONNECTION
5.3.3 - Communication Connector
Connector
name Pin Type of Connection Description
X2 1 Molex Microfit MicroCom connection – 24V
X2 2 Molex Microfit MicroCom connection – Rx
X2 3 Molex Microfit MicroCom connection – 6V
X2 4 Molex Microfit MicroCom connection – ground
X2 5 Molex Microfit MicroCom connection – Tx
X2 6 Molex Microfit MicroCom connection – input
NOTE: UART Connection 2400 or 19200 Baud, 8 bits, no parity, 1 stop bit

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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5.3.4 - Low Voltage Connections
Connector
name Pin Type of Connection Description
X3 1 Molex Microfit Heat Demand (LV) switch input
X3 2 Molex Microfit External Reset switch input
X3 3 Molex Microfit Error Output (to Esys 2)
X3 4 Molex Microfit High Limit switch input
X3 5 Molex Microfit NC
X3 6 Molex Microfit Alarm LED / GAS Error (to ELS*) [out]
X3 7 Molex Microfit Error Input (from Esys 2)
X3 8 Molex Microfit NC
X3 9 Molex Microfit NC
X3 10 Molex Microfit GAS Reset (from ELS*) [in]
X3 11 Molex Microfit GND – External Reset switch
X3 12 Molex Microfit High Limit switch – supply (24V)
X3 13 Molex Microfit NC
X3 14 Molex Microfit GND
X3 15 Molex Microfit GND
X3 16 Molex Microfit GND – (from Esys 2)
X3 17 Molex Microfit
GND – Heat Demand (LV) switch
X3 18 Molex Microfit
GND – (from ELS*)
NOTE: *ELS - External Lockout System / Switch
5.3.5 - Specification
Nominal data Value
Supply voltage 230 VAC +10%, -15%, 47 – 65 Hz
Power consumption 2,5 VA
Humidity 90% RH max at 40°C (no condensing)
Ambient temperature -20°C – +60°C
Communication Value
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

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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Electrical rating Value
Fusing Ext. fuse 2A slow sand filled
Relay output (LPG) 230 VAC, 0,8 A max, cos φ= 0,6
Gas valve output 230 Vrac, 50 mA
High limit switch input 24 VDC (22 kΩ)
Communication input logic “0” 0,8 VDC, logic “1” 2 – 24 VDC (10 kΩ)
Communication output open collector 24 VDC and 10 mA max
Length of wiring for external component 1,0 m max
Ignition Value
Spark voltage 20 kV
Spark frequency 10 Hz
Spark pulse energy 15 μAs
Spark to ground
Timings Value
Pre purge/waiting time 0 s
Pre ignition time 0,4 s
Safety time 10 s
Number of ignition trials 3
Flame failure response time 1 s
Stabilization time 0 s
Post purge time 0 s (adjustable)
Pump over run time -
Anti cycling time -
Flame sensing Value
Flame and sparking rod separate
Flame current (factory parameter setting) minimum 0,8 μA
Length flame sensing / spark cable 0,5 m max
Product life Value
For safety and main operator gas valve 500.000 cycles
At rated loads 250.000 cycles
Operations with rated loads 6.000 lock-out

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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5.4 - Timing diagram
Fig. 3 - Timing diagram.

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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5.5 - Recommended peripheral devices
Recommended valve: atmospheric VK41xxxxxx
Recommended display: N/A
5.6 - Sensors and actuators
5.6.1 - Safety Cut-off Switch
The safety cut-off switch (also called high limit switch) prevents the system from being damaged by overheat. This switch is
in fact the last stop to the ignition control if the appliance is overheating itself. Overheating can be caused for example by a
bad connected temperature sensor or a low water situation. This switch is normally closed and opens if the overheat
condition occurs. The controller reads continuously the status of the switch and immediately activates the lockout state if the
switch opens due to whatever reason. A manual action is required to release the controller from the lockout state. This can
be done by the integral reset button or by the external communication.
5.6.2 - Alarm/Error Led
When an error condition is reached, the Alarm/Error LED indication output will be used to remote the fault indication
externally (to ELS).
5.6.3 - Error Output to Esys 2
When the lockout error condition is reached (except error 40) the Error output indication will be low. It is used to indication
lockout state to the second Esys.
5.6.4 - Gas Valve
The gas valve which must be connected to the Basic ESYS controller is a CVI-m valve. An example of such a valve is the
VK4115G1005B. There are many other valves which can work together with this ESYS. For more information about gas
valves, please contact the appropriate department or your local Honeywell affiliate.

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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6. Modes of operation
The controller has a number of basic modes of operation:
STAND-BY, when there is no heat demand or error present;
HEAT DEMAND;
ERROR/FAULT conditions like over temperature conditions, sensor faults etc.
The priority of operating modes is fixed as following:
1. Error / Fault mode;
3. Heat Demand;
5. Stand-by mode (Idle).
6.1 - Stand-by
In STAND-BY mode igniter is off and gas valve is off.
6.2 - Heat Demand
When the high or low voltage Heat Demand input is closed, the boiler switch on if no error are present.
The DHW demand is ended when the high or low voltage HD input will be open.
6.3 - Protection and error conditions
Several checks are included to protect the boiler and its environment. Double High Limit sensor 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 codes can be divided in 2 groups:
1. Lockout condition codes;
2. Blocking condition codes.
Error Code Description
LOCKOUT
1 Flame lockout after five ignition trials
2 False flame lockout
3 High Limit error
8 Flame circuit error
9 Gas valve driver circuit error
13 Remote reset lockout
21 ADC error
25 CRC error
40 Lockout on the second Esys
BLOCKING
22 Low Main voltage
26 Internal reset knob blockage

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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Lockout condition codes
Lockout condition codes are all codes from 1 till 30. The meaning of the error numbers is as following:
FAULT 1 = Lockout 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. All resets are limited to 5 resets per 15 min.
FAULT 2 = False flame indication. If flame signal is measured with no heat demand currently present, error 2 is created. This
error condition also requires manual reset action.
FAULT 3 = High Limit error. If one of the two High Limit sensors detects a temperature of more than 85°C, High Limit error
will be generated.
FAULT 8 = Flame circuit error - during normal operation of the ignition controller, flame circuit is regularly checked. This
check has predictable behavior 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 behavior and several steps. If check fails, error 9 will be set.
FAULT 13 = All remote resets (communication) are limited to 5 resets per 15 min. If the limit is exceeded, error will be
generated and to reset it. Power Off/On and reset is necessary.
FAULT 21 = ADC error.
FAULT 25 = Matching error between Hup and Lup CRC codes (different software versions).
FAULT 40 = When Error input from Esys 2 signal is low. This error condition is stopping the boiler and to get to the normal
operation again, manual/remote reset is required. All resets are limited to 5 resets per 15 min.
Blocking condition codes
The boiler controller recognizes 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. The meaning of the code is as follow:
FAULT 22 = Low Mains voltage (less than 150 +/- 10 VAC) will trigger this error. When Mains brought back (164-176 VAC),
error is resolved in 10 seconds.
FAULT 26 = If the Reset knob is switched on for more than 2s, error 26 is set till the reset knob will be released.
6.4 - 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.

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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7. Control Panel for ESYS
A Control Panel for ESYS has been developed for monitoring. In the following picture the default screen is shown:

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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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 MicroCom communication protocol.

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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9. Other documentation
This chapter contains references for further documentation of the ESYS and the CVI-m valves which can be used in
combination with the ESYS.
Title Reference
Product Handbook ESYS EN2R9071
Product Handbook Modulating Valves EN2R9025
External Communication ERE2038
Terms used in Honeywell product handbooks EN2R9039

Honeywell
Heating & Cooling Appliance Controls
Title: Functional description S4965A3025
Doc.: S4965A3025E20
Description Sign. E.C.N. Date Rev.
First issue M.Matiasko 01-Sep-2015 A
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10. Installation
10.1 - 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 miss-wiring.
After installation boiler control can become wet due to condensation. Do not connect wet device to mains.
10.2 - 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.