Johnson Controls GM 20 Series Manuel utilisateur

Installation Sheets Manual 121

Gas Combustion Combination Controls and Systems Section G

Technical Bulletin GM-20/25

GM-40/45

Issue Date 1298

Part No. 24-8711-48, Rev. A www.johnsoncontrols.com

Code No. LIT-121892

Introduction Page 3

Application 3

Electrical Ratings 3

Specifications 4

Installation 5

Mounting 5

Standard Wiring (From Burner Sequence Control) 6

4-Pin Connector Plug Wiring (From Burner Sequence Control) 8

GM-4_6_ Connection of Impulse Lines 9

Checkout Procedure 10

Adjustments 11

GM-_ _1_ (Dual On/Off Fast Open with Flow Adjustment) 11

GM-_ _2_ (Dual On/Off Step-slow Opening with Flow Adjustment) 12

GM-_ _3_ (Dual On/Off with Pressure Regulator) 12

GM-_ _4_ (Dual On/Off with Step-slow Opening with Pressure Regulator) 13

GM-4_5_ (Dual On/Off with Servo Precision Regulator) 13

GM-4_6_ (Dual On/Off with Gas/Air Ratio Control) 15

Repairs and Replacement 19

GM-20/25 and GM-40/45 Series

Dual-block Multi-function Gas Control Valves

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2 G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin

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G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin 3

Introduction

Figure 1: GM Series Dual-block Multi-function

Gas Control Valves

The GM Series dual-block multi-function gas control valves are intended

for use on atmospheric and forced-draft gas burners in heating

installations. This multi-functional control on a dual-block valve body

provides a compact answer to gas train applications. The GM valve

replaces multiple gas train components, such as on/off gas valves, gas

pressure regulators, and modulating gas valves. Optional sizing of body

flanges offers greater adaptation to diversified burner designs and

applications. Valves are approved to European and North American gas

valve standards.

Typical applications include boilers, burners and ovens, rooftop units,

makeup air heaters, hot water heaters, kilns, and paint booths.

Table 1: Electrical Ratings

Valve Model Operating Voltages Power Consumption

GM-2_ _ _ 230 VAC +10/-15%, 50/60 Hz

120 VAC +10/-15%, 50/60 Hz

24 VAC +10/-15%, 50/60 Hz 46 VA

GM-4_ _ _ 230 VAC +10/-15%, 50/60 Hz

120 VAC +10/-15%, 50/60 Hz

24 VAC +10/-15%, 50/60 Hz 46 VA

Application

Electrical

Ratings

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4 G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin

Table 2: Specifications

Media 1st (Manufactured Gas), 2nd (Natural Gas), and 3rd (Liquefied

Petroleum [LP] Gas) Family Gases

Maximum Inlet

Pressure

Europe:

GM-_01 _ and GM-_02_: 360 mbar

GM-251_ and GM-252_: 200 mbar

All Other Models 100 mbar

North America:

GM-_01 _ and GM-_02_: 5 psi

GM-251_ and GM-252_: 2 psi

All Other Models 0.5 psi

Maximum

Regulating

Setting

20 mbar (8 in. W.C.) (GM-_ _3_ and GM-_ _4_)

50 mbar (20 in. W.C.) (GM-4_5_ and GM-4_6_)

Reverse

Pressure Rating 150 mbar (60 in. W.C.) minimum; Class A (EN 161)

Regulator

Classification Spring Regulator (GM-_ _3_ and GM-_ _4_): Class B (EN 88)

Servo Regulator (GM-4_5_): Class A (EN 88)

Permissible

Ambient

Temperature

-15 to 60°C (5 to 140°F)

Body

Connections Detachable flanges with pipe thread 3/8 to 1-1/2 in. NPT or Rp

Valve Torsion

Group Group 2 (EN 88 and EN 161)

Pressure Taps Flanges: 9.0 mm (0.35 in.) spigot for flexible tubing

Body: Rp 1/8 thread standard (multi-position)

Rp 1/4 thread special (multi-position) GM-4 only

Materials Body and Flanges: Die-cast aluminum

Diaphragms and Seals: Perbunan rubber

Solenoid Enclosure: IEC 529 (NEMA 1 and IP 54)

Filter Segment Standard Dirt Strainer: 0.5 mm (0.02 in.) metal mesh

Optional Filter Set: 0.05 mm (0.002 in.) nylon mesh and fleece filter

Operating Time

Rating 100% Continuous

Valve Timings Closing Time: < 1 second

Opening Time: < 1 to 15 seconds

Dead Time: < 1 second

Electrical

Connections Standard Wiring: PG 13.5 compression fitting with cage-type

terminal blocks inside the electrical box

Optional Wiring: 1/2 in. NPT conduit adapter compression fitting or

4-pin connector plug (ISO 4400 [DIN 43650])

Coil Insulation

Class Class F

Agency Listings IAS (AGA/CGA) Certificate Numbers: C0197002

C0197004

European Certificate Number: CE 0063AN3731

Specification

Standards EN 88, EN 126, and EN 161

Standards Complying with the EMC Directive

Standards Complying with the Low Voltage Directive

ANSI Standards, Z21.18, Z21.21, and Z21.78

Canadian Standards CAN1-6.3 and CAN1-6.5

The performance specifications are nominal and conform to acceptable industry standards. For

application at conditions beyond these specifications, consult the local Johnson Controls office.

Johnson Controls, Inc. shall not be liable for damage resulting from misapplication or misuse of its

products.

Refer to the GM-20/25 and GM-40/45 Series Product Bulletin (LIT-4350340) for necessary information on

operating and performance specifications of this product.

Specifications

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G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin 5

Installation

IMPORTANT: This technical bulletin is intended as a guide for

authorized service personnel installing or servicing

Johnson Controls products. Carefully follow all

instructions in this sheet and all instructions on the

appliance. Limit repairs, adjustments, and servicing to

the operations listed in this sheet or on the appliance.

WARNING: The system must meet all applicable codes. Improper

installation may cause fire, explosions, property

damage, and injuries or death.

Carefully follow all instructions in this sheet and all instructions on the

appliance. Limit repairs, adjustments, and servicing to the operations listed

in this sheet or on the appliance.

WARNING: Fire or explosion hazard. Shut off the gas supply at

the main manual shutoff valve before installing or

servicing the GM Series valve.

1. Ensure that the maximum ambient temperature is not exceeded

(see Table 2).

2. Check the power supply voltage for compatibility with the required

valve voltage. All wiring must conform to national and local electrical

codes and regulations.

3. When installing the valve on the manifold, the gas must flow through

the valve body in the direction indicated by the arrow on the body. If

the valve is installed with the gas flow opposite the arrow, leakage can

occur.

4. Shut off the gas at the main manual shutoff valve.

5. Mount the valve. It is recommended that the flanges be mounted to

the pipe separately with the valve then mounted between the

two flanges. The filter plate assembly should be installed (using the

longer bolts) between the inlet flange and the valve.

Mounting

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6 G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin

The GM Series valve may be mounted on a horizontal manifold with

the solenoid actuator pointed up (vertical) or in any position not

exceeding 90ofrom the vertical. The valve may also be mounted on a

vertical manifold in any position around its axis (see Figure 2). Do not

install the solenoid actuator upside down. Install vertically wherever

possible.

90° Maximum

from Vertical

90° Maximum

from Vertical

Limited Horizontal and Vertical

Figure 2: GM Series Valve Mounting Position

Use an approved pipe joint sealing compound on male threads before

assembly.

6. Remove excess compound after mounting the flanges to the pipe.

Threads of pipe and nipples must be smooth and free of tears and

burrs. Steam clean all piping to remove foreign substances such as

cutting oil or thread chips.

WARNING: Shock hazard. Avoid electrical shock and equipment

damage by disconnecting electrical power to the valve

before proceeding.

CAUTION: Equipment damage hazard. To prevent possible

grounding of the 24 VAC transformer secondary, do

not connect the ground wire on 24 VAC models.

Follow the procedure below to wire the valve when using the standard

PG 13.5 cable compression electrical connection.

1. Observe that the operating voltage is identical to the information on

the product identification label.

2. Route the electrical cable for the valve solenoid from the burner

sequence control to the valve.

3. Remove the cover of one of the electrical box and make wiring

connections in accordance with Figure 3.

4. Reattach the electrical box cover.

Standard Wiring

(From Burner

Sequence

Control)

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G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin 7

Note: Figure 3 shows wiring connections for individual valve opening.

For simultaneous valve opening, wire a jumper between

Terminals V1 and V2 of either the electrical box on the first or

second valve.

5. Use a wrench to tighten the PG 13.5 cable compression plug to secure

wires and prevent moisture from entering the terminal box.

Note: If an optional 1/2 in. NPT thread electrical connector or 4-pin

DIN 43650 (ISO 4400) electrical connector (each ordered

separately) is used for wiring, refer to the documentation supplied

with the electrical connector for specific wiring instructions.

V1 V2

NV2V1 NV1V2

Addtional Connection

(

be used to connect pilot

or b

pass valves. Break awa

plastic to open.

)

GND GND

GND

Electrical Box

Connection

PG 13.5 Cable

Compression Plu

(

Factor

Installed

)

Wirin

Connections

N = Common

V1 = Line Valve 1

V2 = Line Valve 2

GND = Earth Ground*

(

* Do not connect earth

round

for 24 VAC models.

)

Figure 3: Standard Wiring Electrical Connections

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8 G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin

WARNING: Shock hazard. Avoid electrical shock and equipment

damage by disconnecting electrical power to the valve

before proceeding.

CAUTION: Equipment damage hazard. To prevent possible

grounding of the 24 VAC transformer secondary, do

not connect the ground wire on 24 VAC models.

Use the following procedure to wire the valve when using a factory-

installed 4-pin DIN 43650 (ISO 4400) electrical plug connection.

1. Observe that the operating voltage is identical to the information on

the product identification label.

2. Route the electrical cable for the valve solenoid from the burner

sequence control to the valve.

3. Make wiring connections in accordance with Figure 4.

Note: Figure 4 shows wiring connections for individual valve opening.

For simultaneous valve opening, wire a jumper between terminals

V1 and V2 of either the electrical box on the first or second valve.

(

Ground

)

(

Common

)

Line

(

Valve 1

)

Line

(

Valve 2

)

Terminal Desi

nations

V1 V2

Figure 4: 4-Pin Wiring Electrical Connections

4-Pin Connector

Plug Wiring

(From Burner

Sequence

Control)

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G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin 9

The internal diameter of the impulse tubes for the combustion air (PA) and

the combustion chamber pressure (PF) should be 4.0 mm (5/32 in.), see

Figure 5. Make the connections as short as possible and route to prevent

the entry of condensate into the controller. The installation of a

condensation trap in the connection line from the combustion chamber is

highly recommended. Do not close the connection for PFif not used.

IMPORTANT: Avoid sharp bends or kinks in the tubing to avoid

damage to the tubing and allow for an accurate pressure

reading.

Figure 5: Impulse Line Connections

GM-4_6_

Connection of

Impulse Lines

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10 G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin

WARNING: Fire or explosion hazard. Verify that the valve

functions properly and there are no gas leaks. Follow

this checkout procedure before leaving the installation.

Failure to verify proper valve installation, equipment

operation, and gas tight connections may result in fire,

explosion, property damage, and injuries or death.

1. Shut off the gas at the main manual shutoff valve and open the

pressure connection between the manual shutoff valve and the GM

valve.

2. Connect air tubing with a maximum pressure of 1-1/2 times the

valve’s maximum operating pressure (as indicated on the valve) to the

opened pressure connection.

3. Paint the pipe connections and flanges of the valve with a rich soap

and water solution to check for leakage.

If bubbles occur, this is an indication of a leak. To stop a leak, tighten

joints and pipe connections. Replace the part if the leak cannot be

stopped.

If bubbles do not occur, remove the air tubing and close the upstream

pressure connection.

4. Open the main manual shutoff valve.

5. Refer to the Adjustments section to make any necessary valve setting

adjustments.

WARNING: Fire or explosion hazard. Valve settings must be in

accordance with the appliance or equipment

manufacturer’s specifications.

6. Before leaving the installation, observe at least three complete

operating cycles to ensure that all components are functioning

correctly.

Checkout

Procedure

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