A4021 Series

VALVE PROVING SYSTEM

PRODUCT HANDBOOK

APPLICATION
The A4021 is a self--checking microprocessor based Valve
Proving System (VPS). The A4021 checks the effective clo-
sure of automatic shut--off valves by measuring the pressure
differential between two valves during the test sequence.
Subbase and pressure switch are required to complete the
system.
When during the test sequence of the A4021 a failing valve is
detected, the A4021 will go into a non--volatile lock--out sta-
tus, generates an alarm and prevents a burner start--up.
The intended application is for gas fired power burners and
other large capacity gas firing installations, where according
to the European norm EN676 a valve proving system can be
used as an alternative for pre--purging the combustion cham-
ber. And for all combustion applications with or without pre--
purge with a capacity of more than 1200 kW a valve proofing
system is mandatory.
Subject to change without notice. Printed in the Netherlands.

EN2R--9023 1404R1--NE
CONTENTS
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Application (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Working principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Functional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Energizing valve 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Use of terminal 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fail--safe relay drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Anti--recycle--counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Calculation examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mounting Wiring Subbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Applications with EC/RM7850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Final checkout of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Standards and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ordering information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

L
GENERAL
Application (continued) there is a mounting bracket available (order separately)
The A4021A can be used for both single and combination According the European standard EN676 a valve proving
valves with or without pilot valve. system can be used under certain conditions, as an
For valves with large nominal sizes, valve proving is possible alternative for pre--purging the combustion chamber.
by use of auxiliary valves (pre--configuration only, see page 4). EN676 and EN746-2 prescribe a valve proving system for
For mounting the A4021 on a typical combination valve as the capacity rating over 1,200 kW, see Table 1.
VQ400 Series or on a large valve like the VE5000 Series
Table 1. Application valve proving systems according EN676

p
Heat--Input With Pre--Purge Without Pre--Purge
[kW] Main Gas Start Gas Main Gas Start Gas
≤ 10% ≥ 10% ≤ 10% ≥ 10%
≤ 70 2xB B*) 2xB 2 x A or A**) 2xA
2 x B +VPS
> 70, ≤ 1200 2xA 2xA 2xA 2 x A + VPS 2xA 2xA
> 1200 2 x A + VPS 2xA 2xA 2 x A + VPS 2xA 2xA

NOTE: A: Automatic shut--off valve approved on EN161, class A

B: Automatic shut--off valve approved on EN161, class B
Valve Proving System required
Valve Proving System as alternative for pre--purge of the combustion chamber
*) For third family gases: two class B valves are required
**) For third family gases: two class A valves are required

Fig. 1. VQ400 combination valve with A4021 valve proving System.

2 EN2R--9023 1404R1--NE
FEATURES
• Microprocessor technology • Automatic valve proving before heat demand, after
heat--demand or during pre--purge possible.
• Based on 7800 SERIES Burner Programmer safety
technology. • Different test--times (per valve) available by different
O.S. numbers.
− Dynamic relay test
− Safe start test • Clear visual indication of the test sequence and
− Self--diagnostic test faults--causes through 5 LEDs.
• Testing independent of type of gas at any inlet • Storage of fault code when line interruption occurs
pressure. • Can be applied in all common valve configurations
• Valve proving done by using the line pressure of the • 2--wire gas pressure switch.
gas. • Output for external alarm signal.
• Non--volatile lockout. • Optional external remote reset.

3 EN2R--9023 1404R1--NE
DESCRIPTION
The A4021 valve proving system checks the effective closure LGPS H.D
of the valves before burner start--up (pre--configuration) or at 14

the end of a heat demand (post--configuration). The 9 ignition

L A4021 controller
configuration can be set by means of wiring the A4021 in two
12
different ways, see Fig. 2. and 3.
The flow chart (Fig. 5. ) and sequence diagram (Fig. 6. )
Fig. 2. Valve proving pre--configuration.
explain the procedure during the valve proving.
An external pressure switch monitors the pressure between
both valves. The pressure switch must be set to half the inlet
H.D
pressure in order to test both valves with the same sensitivity. LGPS
After a short interruption of the mains supply during valve 14

proving or during RUN, the A4021 restarts automatically. 9 ignition

L A4021 controller
The A4021 valve proving system can be used with several
pilot--valve configurations, like intermittent and interrupted 12

pilot systems and 3--valve configurations as well. Fig. 3. Valve proving post--configuration.

heat Valve Proving System burner--controller

demand
A4021 Series 7800 SERIES

L.G.P.S. G.P.S.
Pinlet
Gas pressure switches
2
C6097A2 Series

gas V1 V2
Combi--valve VQ400 Series burner
Pinlet
Servo Motor MT4000 Series

air
Fig. 4. System set--up .

Working principle The section between the two valves is filled with gas
(high--pressure status) by opening valve--1 (upstream valve)
The A4021 valve proving system is based on the pressure and the pipe is emptied (low--pressure status) by closing
status--principle. This means that the valves are checked by valve--1 and opening valve--2 (down--stream). When one of
means of measuring (on/off) the pressure in the gas--pipe the valves is leaking this will mean that either the pressure
between the two safety--valves. This system will only work will not maintain the high--pressure status or the low--pressure
when there is sufficient gas--pressure (line--pressure). status at the end of the test period.
Therefore a Low Gas Pressure Switch (LGPS) is part of the For this method of testing, the test time is a function of three
installation. When the line--pressure (Pinlet) is too low the parameters.
LGPS will disable the valve proving system. − inlet pressure
− volume between the valves.
− maximum burner capacity.
The test time can be calculated as given on page11.

4 EN2R--9023 1404R1--NE
 Table 2. Sequence timings for normal operation
STANDBY
State Description Time1) (s)
0 STANBY infinite2)
start 0
1 self--test + memory test <2
manual reset
2 V2 powered 5
error + lock--out
no self test 3 waiting for pressure to get low 3
1
15 = OK ?
4 wait 22
yes
5 valve 1 powered 5
open valve 2
(5 sec.) 2 6 waiting for pressure to get high 3
7 wait 22
stabilization
time (3 sec.) 3 8 waiting for ignition controller to start indefinite3)
9 RUN period, every 4 hours self--test

no 10 alarm, “error during test valve 1” indefinite

pressure
10 = low ? 11 alarm, “valve 1 failing/leaking”5) indefinite
yes 12 alarm, “error during test valve 2” indefinite
test valve 1
wait 13 alarm, “valve 2 failing/leaking” 5) indefinite
(22 sec.) 4
14 alarm, “error heat demand” indefinite
15 alarm, “self--test error”4) indefinite
no
pressure
11 = low ?
1) Timings depending on O.S. numbers, shown
A4021A1002/1010
yes 2) STANDBY can be infinite time period
open valve 1 3) Depending on pre--purge and start--up time of the used
(5 sec.) 5 ignition controller
4) When during the test sequence a fault is discovered by the
stabilization A4021, the system will go into a non--volatile lock--out and
6 generate an alarm “self test error” (see also
time (3 sec.)
Troubleshooting section).The “self test error” also occurs
when the anti--recycle--counter reaches the value 10, see
no pressure also page 10 of the Product handbook.
12 = high ? 5) Leakage ≥ 0.1 % of maximum flow rate.
yes
test valve 2
wait
(22 sec.) 7
WARNING
No standard valve proving after lock--out of the
ignition controller.
no pressure
Valve proving after lockout maybe required, this can
13
= high ? be achieved by special wiring diagrams. E.g. when a
DTSP switch is used to reset the ignition controller
yes
and interrupting the heat--demand for the A4021A.
enable
ignition 8
controller

no pin 12
connected
14 ?
yes
enable
ignition
controller RUN

no self test
9
15 = OK ?

yes
each 4 hours
Fig. 5. General flow chart valve proving (given timings
for A4021A1002/1010

5 EN2R--9023 1404R1--NE
 Line voltage

Heat demand

Leak test

Valve V1

POST
Valve V2
CONFIG

Vent valve
(normally open)

GPS
6

Leak test

Valve V1

PRE
Valve V2
CONFIG

Vent valve
(normally open)

GPS

Lock--out
EN2R--9023 1404R1--NE

(Ignition controller)

Reset ign. control.

power--up start end start lock--out reset burner controller

heat--demand heat--demand heat--demand start whithout valve proving !

Fig. 6. System sequence of A4021A in post and pre--configuration.

SPECIFICATIONS
Mechanical Internal fuse: 5 A slow max.
Model Power consumption
A4021A Maximum 4.5 VA
Dimensions Electrical ratings
Refer to Fig. 7. Valve outputs: 4A, cos. ϕ 0.7
For mounting bracket dimensions refer to Fig. 8. Vent valve output: 1A, cos. ϕ 0.7
Ignition controller output: 4A, cos. ϕ 0.7
Weight Alarm output: 2A, cos. ϕ 0.7
Including subbase: 0.65 Kg
Electrical connection
Mounting
4 Wiring conduit according to PG11 are provided in the
ZL030001 subbase. subbase. M3.5 screw terminals, including earth connection.
The subbase can be assembled by 2 screws on a panel.The
cover can be removed by loosening one screw. For mounting Enclosure
hole dimensions see Fig. 7. installation drawing. IP40
Orientation Functional
There are no restrictions in the orientation.
Field adjustments (calibration)
Environmental ratings None
Ambient temperature range: Test--times
Operating :--10 ... 60 °C
Storage :--40 ... 80 °C Depending on O.S. number.
Humidity: :0 -- 95% RH at 40 °C (non--condensing) For A4021A1002 and A4021A1010 per valve: 25 s.
Vibration :0.5 G environment
Total test--time (depending on test time per valve)
Electrical
For model A4021002 and A4021A1010: approx. 65 seconds
Supply voltage Reset
Line voltage: 220 ... 240 Vac, 50 Hz NON--volatile lock--out
100 ... 120 Vac, 50 Hz
Manual, with push--button on controller or with remote reset
Refer to Table 3.
Other voltage ranges and frequencies are available on button.
request. Design life
Fusing > 10 years or 250.000 cycles.
The A4021A should be externally fused to prevent damage to
the valve proving system, wiring or peripherals Recommended pressure switch
External fuse: 16 A slow max. C6097A2 gas pressure switch

7 EN2R--9023 1404R1--NE
 Table 3. Connections for A4021A pre-- and post configuration with contact ratings
Terminal Abbreviations Direction Description Ratings
No
No. (220 ... 240Vac/100 ... 120Vac,
120Vac
pre post depending on O.S. number)
1 NO NO input Normally Open contact of the pressure n.a.
switch (high pressure)
2 RESET RESET input Input for external reset connect with n.a.
momentary switch to line
3 LINE LINE power--input Line voltage input for valve proving n.a.
system.
4 N N power--input Neutral input for valve proving system. n.a.
5 N N power Neutral for external devices. n.a.
6 N N power Neutral for external devices. n.a.
7 V1--IN V1--IN input Valve--2 voltage from ignition controller n.a.
8 V2--OUT V2--OUT output Output connect with Valve--2 4A
9 HD LGPS input Heat--demand input (pre--configuration) n.a.
or LGPS input (post--configuration)
10 ALARM ALARM input Alarm input n.a.
11 ALARM ALARM output Alarm output 2A
12 RB RB input Read back signal for: heat--demand n.a.
(post-- config.) ign. contr. (pre--config.)
13 VENT VENT output Normally open valve output 1A
14 IGNCTR HD output Heat call signal to ignition controller, 4A
when there is a heat call and the valve
proving has taken place
15 V2--IN V2--IN input Valve--1 voltage from ignition controller n.a.
16 V1--OUT V1--OUT output Output connect with Valve--1 4A
NOTE: cos. ϕ = 0.7 for all outputs

8 EN2R--9023 1404R1--NE
DIMENSIONAL DRAWINGS
88 35

16 97

1 2 3 4 5 6 7 8

97

PG11
9 10 11 12 13 14 15 16

Fig. 7. Mounting dimensions of A4021A and subbase in millimeters

103

90°

3
∅ 4.5 (4x)
86.5

∅ 20
60.5

34.5

52
8.5

69
80

96

74.5

80

96

Fig. 8. Mounting bracket A4021A for VQ400 and VE5000 Series in millimeters.

9 EN2R--9023 1404R1--NE
SAFETY PROVISIONS
A4021A
external reset
13
2
vent--valve

LGPS H.D. N
pre--config. 12 burner controller
H.D.
9 post--config.
H.D.
internal fuse 14
L fuse 5 A slow input out
post--config
16A V1 V2
GPS
pre--config.

1 7

3 int. power supply

15

10

11

16
alarm

4
N 6

= input micro--processor
valve--1 valve--2
= external wiring

= optional

Fig. 9. Simplified internal schematic and wiring diagram pre-- and post--test configuration.

Energizing valve 1 and 2 Anti--recycle--counter

The hardware of the A4021A prevents that during the valve For reason that during each valve proving a small amount of
proving both valves can be opened at the same time. gas enters the combustion chamber, extra safety provisions
Use of terminal 12 are build in to prevent the A4021A from continuously
recycling, in case of failures of the complete burner control
With terminal 12 of the valve proving system the heat demand
system. This safety feature is provided by an anti--recycling
status is checked by the valve proving system in post
counter in the A4021A. When the heat--demand signal
configuration. For the pre--configuration it is necessary that
disappears during a valve proving or within 10 seconds, after
terminal 12 and14 are connected.
the valve--proving is finished. This leads to lockout (error
If terminal 12 is not connected, the A4021A will raise an alarm
self--test) of the A4021A when this behavior occurs 10 times
(error heat demand).
in a row. The counter will be reset by the first heat--demand
Fail--safe relay drivers which lasts longer than the A4021A total--test time + 10
The fail--safe relay drivers which are used to give the seconds. In this way the A4021A offers additional safety.
heat--demand to the burner controller are fail safe.

10 EN2R--9023 1404R1--NE
CALCULATIONS
General Calculate the maximum pipe length between two 1 1/2” safety
valves when an A4021A valve proving system is used with a
The maximum allowable leak--rate (according the EN676 and test period (per valve) of 25 seconds.
EN746--2) is 0,1 % of the maximum burner capacity. The test Given: Pi = 75 mbar
time necessary to detect a falling valve is a function of: Qm = 30 dm3/h
− inlet pressure valve: 1 1/2”→DN40
− test volume To be calculated: L(max.) [m]
− burner capacity. Calculation:
When the volume between two safety--valves is bigger it
takes more time (in case of a leaking valve) to change the 2 x Pi x Vp Tp x Qm
status of the gas pressure switch. The correct OS--number Tp ≡ [ s ] → Vp ≡ [dm3]
Qm 2 x Pi
for the A4021A can be selected after calculating the
appropriate test--times for the intended application.
25 x 30
The switching point of the pressure--switch is set to 50 % of Vp ≡ = 5 [dm3]
the maximum inlet pressure. 2 x 75
The test period Tp is calculated from the inlet pressure Pi, the From Table 4. :
test volume Vp ( see Table 4.) and maximum burner capacity DN40T, Vp= 5 dm3 → length L = 2 + (5--3.3)/1.3 = 3.3 m.
Qm, in formula:
2 x Pi x Vp Example 2
Tp ≡ [s]
Qm
Pi = inlet pressure [mbar]
Vp = test volume [ dm3], see also Table 4.
Qm = burner capacity [dm3/h]
Calculate the test period (per valve) in a given situation.
Table 4. Volumes in dm3 for UGV valves Vp with length of Given: Pi = 150 mbar
pipe L (including V1 and V2) Qm = 60 dm3/h
valve: VE4065A with 0.5 meter pipe
DN Length between valves (m) To be calculated: Tp [s]
Calculation:
0 0,5 1 1,5 2 per
From Table 4. :
extra
DN65T, L=0.5m → Vp = V0.5m = 4.4 dm3.
meter
10T 0.06 0.10 0.14 0.18 0.22 0.08 2 x Pi x Vp 2 x 150 x 4.4
Tp ≡ [ s ] → Tp ≡ = 22[ s ]
15T 0.06 0.15 0.24 0.33 0.42 0.18 Qm 60
20T 0.12 0.28 0.43 0.59 0.74 0.31 Choose always a A40121 with a test time (per valve) higher
25T 0.19 0.44 0.68 0.93 1.2 0.49 than the (minimum) calculated test time Tp.
32T 0.69 1.1 1.5 1.9 2.3 0.80 Example 3
40T 0.71 1.4 2.0 2.7 3.3 1.3
50T 1.3 2.3 3.3 4.2 5.2 2.0
65T 2.7 4.4 6.0 7.7 9.3 3.3
80T 2.9 5.4 7.9 10 13 5
65F 3.2 4.9 7.5 8.2 9.8 3.3
80F 4.4 6.9 9.4 12 14 5.0
100F 6.5 10.5 14.4 18 22 7.9
Calculate the test period (per valve) in given situation.
NOTE: T = Thread Given: Pi = 150 mbar
F = Flange Qm = 100 dm3/h
V0m = volume of 2 valves with L= 0 m valve: VE4080A with 1 meter pipe (L1)
pilot valve: VE4025 with 0.5 meter pipe (L2)
IMPORTANT
To be calculated: Tp [s]
The total volume Vp has to be calculated with all Calculation:
volumes between the tested valves: internal From Table 4. :
volumes of valves and all pipes DN80T, L1=1m
Calculation examples DN25T, L2=0.5
Vp = V1m + (V0.5m -- V 0m = 7.9 + (0.44 -- 0.19/2) = 8.25 dm3.
Example 1
2 x Pi x Vp 2 x 150 x 8.25
Tp ≡ [ s ] → Tp ≡ = 25 [ s ]
Qm 100
Choose always a A40121 with a test time (per valve) higher
than the (minimum) calculated test time Tp.

11 EN2R--9023 1404R1--NE
INSTALLATION AND WIRING
Installation Wiring
IMPORTANT 1. For proper subbase wiring, refer to Table 3.
1. Read these instructions carefully. Failure to follow 2. Disconnect the power supply from the main disconnect
the intructions could damage the product or cause a before beginning the installation to prevent electrical
hazardous condition. shock and equipment damage. More than one
2. Before installing or replacing any control check that disconnect may be involved.
the test time is correct for the application. Never use 3. All wiring must comply with all applicable electrical
a type with a smaller test time than the calculated codes, ordnances and regulations.
test time for the application. 4. Use the COM and NO contacts on both pressure
3. Check the ratings given in the instructions and on switches (LGPS and GPS).
the product to make sure the product is suitable for
your application. 5. Make sure loads do not exceed the terminal ratings.
refer to the label on the valve proving system, or to the
4. . The installation has to be carried out by qualified ratings in the Specifications, see Table 3.
personel only.
5. . Carry out a thorough checkout when installation is 6. Check the power supply circuit. the voltage and
completed. frequency tolerance must match those of the valve
proving system. Add the required disconnect means
Mounting Wiring Subbase and overload protection.
NOTE: For installation dimensions, see Fig. 7. 7. Check all wiring circuits before installing the valve
1. The subbase can be mounted in any position. Make proving system on the subbase
sure that the LEDs indicating the test sequence and 8. Install all electrical connectors.
faults--causes are clearly visible.
9. Restore power to the panel.
2. Select a location within an electrical panel. Be sure to
allow adequate clearance for servicing, installation and Pressure switch
electrical field connections. The pressure switch can be a normal normally open gas
3. For surface mounting, use the back of the subbase as a pressure switch which is suitable for the appropriate pressure
template to mark the two screw locations. Drill the pilot levels and a voltage of 220 ... 240 Vac. Refer to the enclosed
holes. instructions of the pressure switch. The switching point of the
4. Securely mount the subbase using two M3.5 x 0.6 GPS must be at 50 % of the nominal line--pressure.
screws. Recommended gas pressure switch: C6097A2xxx
Wiring
CAUTION
1. Disconnect power supply before beginning the
installation to prevent electrical shock, equipment
and control damage. More than one power supply
disconnect may be involved.
2. Wiring connections are for the A4021A are
unique, therefore, refer to Table 3. and Fig. 7. for
proper subbase wiring.
3. The A4021A must be installed with fixed wiring for
phase and neutral connections.
4. Wiring must comply with all applicable codes,
ordiances and regualtions.
5. After moving the A4021A valve proving system
from outdoor to indoor conditions, condensation
may occur. Do not connect condensated valve
proving system to mains.
6. The A4021A is not suitable for phase--phase
mains., can only be used with phase -- neutral
mains.
7. For each application diagram, local approval may
be needed
General considerations
There are two basic wiring diagrams:
• valve proving before burner start--up: pre--configuration.
• valve proving at end of heat demand: post--configuration.

12 EN2R--9023 1404R1--NE
 GENERAL WIRING DIAGRAMS
Ignition controller Ignition controller intermittent
pilot main
heat--demand main--valve heat--demand valve valve
N L input output N L input output output

reset (ext.) reset (ext.)

N N
ALARM
L 4(N) 3 2 14 12 7 15 10 L 4(N) 3 2 14 12 7 15 10 ALARM
fuse Valve Proving System 11 fuse Valve Proving System 11
16A 16A
A4021A A4021A
6(N) 6(N)
9 16 1 5(N) 8 13 9 16 1 5(N) 8 13

T T
V1 V2 vent--valve V1 V2 vent--valve

LGPS GPS LGPS GPS

Vp

Fig. 10. Wiring diagram for 2--valve configuration Fig. 12. wiring diagram 3--valve configuration
pre--configuration (pre--configuration)
Ignition controller intermittent
Ignition controller
pilot main
heat--demand main--valve heat--demand valve valve
N L input output N L input output output

reset (ext.) T reset T

N N (ext.)

L ALARM L ALARM
4(N) 3 2 14 12 7 15 10 4(N) 3 2 14 12 7 15 10
fuse Valve Proving System 11 fuse Valve Proving System 11
16A 16A
A4021A A4021A
6(N) 6(N)
9 16 1 5(N) 8 13 9 16 1 5(N) 8 13

V1 V2 vent--valve V1 V2 vent--valve

LGPS GPS LGPS GPS

Vp

Fig. 11. Wiring diagram 2--valve configuration for Fig. 13. Wiring diagram 3--valve configuration
post--configuration (post--configuration)

WARNING
These are general wiring diagram and have not been
approved yet by an official approval body. Depending
on the application and used ignition controller special
wiring diagrams maybe required.

13 EN2R--9023 1404R1--NE
APPLICATIONS WITH EC7850

(interrupted)
EC7850 (intermittent)
flame--
ground AL L1 FAN RT LD2 PV1 MV IGN signal HI COM MOD LOW C.V. ES2 ES1 ES3 LOS PV2 SHTR
G N 3 4 5 6 7 8 9 10 F 12 13 14 15 16 17 18 19 20 21 22

ALARM P.S. lock--out switch

FAN
flame--rod
ign.
LINE

NEUTRAL

EARTH open atmosphere

H.D.

vent--
EXTERNAL valve
RESET L.G.P.S.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 gas supply V1 V2 burner

NO ext. LINE N N N V1IN V2OUT LGPS / HDIN OUT RBHD VENTHD--OUT V1OUT
GPS RESET ALARM V2IN
A4021A
L.G.P.S.

Fig. 14. Wiring diagram A4021A-- EC7850 pre--configuration: intermittent pilot and vent--valve to open atmosphere

(interrupted)
EC7850 (intermittent)
flame--
ground AL L1 FAN RT LD2 PV1 MV IGN signal HI COM MOD LOW C.V. ES2 ES1 ES3 LOS PV2 SHTR
G N 3 4 5 6 7 8 9 10 F 12 13 14 15 16 17 18 19 20 21 22

FAN P.S.
flame--rod lock--out switch
ALARM ign.
LINE

NEUTRAL

EARTH

H.D.
EXTERNAL L.G.P.S.
RESET gas supply

V1 V2

PV1(*) PV2(*)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
NO ext. LINE N N N V1IN V2OUT LGPS / HD IN OUT RBHD VENT HD--OUT V1OUT
GPS RESET ALARM V21IN
A4021A

(*) Note: pilot burner is less than

1200kW, so testing the pilot
L.G.P.S.
valve train is not needed
LO

HI

Fig. 15. Wiring diagram A4021A -- EC7850: pre--configuration, intermittent pilot, 4--valve configuration

WARNING
These are general wiring diagram and have not been
approved yet by an official approval body. Depending
on the application and used ignition controller special
wiring diagrams maybe required.

14 EN2R--9023 1404R1--NE
Fig. 16. Wiring diagram A4021A -- EC7850, post--configuration: intermittent system with 3--valve configuration

Fig. 17. Wiring diagram A4021A-- EC7850 with by--pass valve, post configuration

WARNING
These are general wiring diagram and have not been
submitted for approved by an official approval body.
Depending on the application and used ignition
controller special wiring diagrams maybe required.

15 EN2R--9023 1404R1--NE
 STANDBY

Sequence of operation

OPERATION
Modes TEST MODE RUN MODE ALARM MODE

Timings (sec.) 25 * 25 *
*= depends on OS # 5* 3* 5* 3*

States 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Line voltage

Heat demand
Pressure
(between V1 and V2

Valve 1

Valve 2

Operate burner
16

Alarm output

Power

Run OK

Alarm

Valve 1

Valve 2
EN2R--9023 1404R1--NE

FAILING/
ERROR FAILING/ ERROR ERROR ERROR
STANDBY START OPEN TEST TEST OPEN TEST TEST WAIT OPERATE V2 LEAKING V1 LEAKING HEAT SELF--
SELF V2 GPS V1 V1 GPS V2 FOR BURNER
TEST LOW V1 V2 DEMAND TEST
HIGH START--UP (valves operated by
ignition controller)

WARNING = LED is off = blinking LED = LED on

No standard valve proving after lock--out of the ignition controller

CHECKOUT
The procedures described in this chapter are related to Final checkout of the installation
A4021A. For adjustments on the other additional Set the appliance in operation after any adjustment and
functionalities (e.g. pressure switch), refer to the included observe several complete cycles to ensure that all burner
instruction sheet of the product in question in the package. components function correctly.
Make sure that phase and neutral are connected as
WARNING instructed in the Wiring section.
Phase -- neutral dependency
As the EARTH is not connected to the actual A4021A
(earth only connected to the sub--base), it is not
possible to detect whether the line and neutral are
correct connected on the A4021A.
Exchanged connection of the phase and neutral can
lead to hazardous situations, when a short--circuit in
one of the valve connections occurs. Therefore the
A4021A can only be used with fixed wiring for the
line--voltage connections. Make sure that phase and
neutral are connected as instructed in the Wiring
section.

17 EN2R--9023 1404R1--NE
TROUBLESHOOTING
General
CAUTION If you encounter a error or fail on V1 or V2, refer to the
1. Use utmost care while troubleshooting the instruction sheet of the valve.
A4021A, line voltage is present on some of the If you encounter other problems in the system, refer to the
terminals when power is on. Troubleshooting section in the instruction sheet for the
2. Line voltage is present on the terminals when the appropriate flame safeguard control.
cover is removed. Make sure that the main power Upon completion of troubleshooting, be sure to perform the
supply is switched off before removing the cover. Checkout procedures previously specified for the A4021A.
3. The A4021A contains no serviceable parts. Any NOTE: Instructions for replacing the cover and fuse are
attempt or replacement of parts ( except from given in the Service section.
internal fuse) will affect the safety of this Before making a replacement, make sure you have the
deviceand is therefor not allowed. correct part (check its part number and voltage rating)

Table 5. Troubleshooting A4021A Series valve proving System

States Alarm mode Cause Action

PWR RUN ALARM V1 V2

OK

10 Error V2 V2 is damaged or V2 is Check connections V2 and

wrong/not connected if necessary replace V2

11 Failing/leaking V1 Allowed leak--rate (V1) Check the gas pressure

higher than 0.1% of the switch (GPS) and if
maximum flow--rate needed replace V1
12 Error V1 V1 is damaged or V1 is Check connections V1 and
wrong/not connected if necessary replace V1

13 Failing/leaking V2 Allowed leak--rate (V2) Check gas pressure switch

higher than 0.1% of the (GPS) and if needed
maximum flow--rate replace V2
14 Error heat demand Heat demand read--back Check if pin 12 on A4021A
error . is connected

15 Error self--test Internal Reset main supply, reset

Hardware/Software error A4021A; if error still
occurs: replace A4021A

= LED is off = blinking LED = LED on

18 EN2R--9023 1404R1--NE
STANDARDS AND APPROVALS
The product is designed according to the following standards: − IEC 1000--4--2 (electrostatic discharges)
− EN1643 − IEC 1000--4--5 (surges)
− ENV 1954 − IEC 1000--4--11 (voltage interruptions and decreases
− EN 60730 − IEC 1000--4--4 (fast transient bursts)
− EN 60742 Standards and Approvals (summarized)
− EN 60529 (IP40) The A4021A Series Valve Proving System is conform with the
Radio interference protection conform the standards: following EC directives:
− IEC 1000--4--3 (ENV 50140) (immunity to radiation
• Gas Appliance Directive (90/396/EEC)
emission)
− IEC 1000--4--6 (ENV 50141) (immunity to injected PIN: CE--0063AS1822
currents) • Low Voltage Directive (73/23/EEC)
− EN 50081--2 (emission industrial level) • Electro Magnetic Compatibility Directive (89/336/EEC)

19 EN2R--9023 1404R1--NE
ORDERING INFORMATION
When ordering specify: • C6097A pressure switch.
• Model number • 1030002020 Mounting bracket for VQ400/VE5000
• Voltage • Replacement parts, if desired.
Order separately:
• ZL030001 Subbase.
Table 6. Ordering information A4021A Series Valve Proving System.
O.S. Number Rated Test time** Power Enclosure* Functional description Remarks
V lt
Voltage l
per valve C
Consump.
gas 3--valve remote alarm
(Vac) (s) (W) pressure config. reset output
switch
A4021A1002 220 ... 240 25 5 IP40 2--wire yes yes voltage New !
free (without subbase)
A4021A1010 100 ... 120 25 5 IP40 2--wire yes yes voltage New !
free (without subbase)
ZL030001 100 ... 240 n.a. n.a. n.a. n.a. n.a. n.a. n.a. Subbase for
A4020/A4021A Series

* with ZL030001 subbase

** other test times on request

Honeywell Industrial Combustion

Luchthavenlaan 16
1800 Vilvoorde
belgium
Phone: +32 2 255 09 09

http://hic.emea.honeywell.com

20 EN2R--9023 1404R1--NE