Johnson Controls GS-20 Series Manuel utilisateur

Installation Sheets Manual 121

Gas Combustion Combination Controls and Systems Section G

Technical Bulletin GS

Issue Date 0297

Part No. 24-8711-5, Rev. —

Code No. LIT-121895

Figure 1: GS Series Single-Block Multi-Function

Gas Control Valves

The GS Series single-block multi-function gas control valves provide for

protection and control of atmospheric and forced draft gas burners in

industrial and commercial heating installations. Optional sizing of body

flanges offers greater application flexibility. Valves are approved to

European and North American standards.

Typical applications include commercial and industrial boilers,

commercial and industrial burners and ovens, rooftop units, make up air

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

These single-block multi-function gas control valves offer single unit

control, replacing multiple components in a gas-train assembly, such as

on-off gas valves, gas pressure regulators, and modulating gas valves.

Options include adjustable start gas and slow open function, spring and

servo regulators, and gas/air ratio control.

GS Series

Single-Block Multi-Function Gas Control Valves

Application

2 G Gas Combustion Combination Controls and SystemsGS Series Single-Block Gas Control Valves

Table 1: Specifications

Types of Gas Natural and Liquid Petroleum (LP) Gas

Maximum Operating Pressure 5 psi (350 mbar)

Maximum Inlet Pressure 5 psi (350 mbar) on shutoff valves

3 psi (200 mbar) with pressure regulator

Maximum Differential Pressure 8 inches W.C. (20 mbar) (GS-_03_)

20 inches W.C. (50 mbar) (GS-405_ and GS-406_)

Permissible Ambient

Temperature 5 to 140°F (-15 to 60°C)

Body Connections Detachable flanges with pipe thread 3/8 inches to

1-1/2 inches NPT

Pressure Taps Flanges: 1/8 inch threads with plastic tube

fitting

Body: Standard is 1/8 inch (multi-position)

Special is 1/4 inch (multi-position) on

GS-4 only

Filter Segment Dirt Strainer: 0.02 inch (0.5 mm) mesh

Filter: 0.002 inch (0.05 mm) gauze

Valve Timings Closing Time: ≤ 1 second

Opening Time: <1 to 15 seconds

Dead Time: < 1 second

Operating Time Rating 100% Continuous

Coil Insulation Class Class F

Electrical Connections Standard Plug DIN 43 650, screw terminals inside

DIN plug

(Set Number GO-9101-0000, see separate

accessories.)

Table 2: Electrical Ratings

Valve Model Operating Voltages Power Consumption

GS-20_ _ 230 VAC +10/-15%, 50/60 Hz

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

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

18 VA

25 VA

21 VA

GS-40_ _ 230 VAC +10/-15%, 50/60 Hz

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

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

25 VA

27 VA

26 VA

Electrical

Ratings

GGas Combustion Combination Controls and SystemsGS Series Single-Block Gas Control Valve 3

CAUTION: This instruction sheet is intended as a guide for

qualified service personnel installing or servicing

Johnson Controls products.

WARNING: The system must meet all applicable codes. Improper

installation may cause explosions, property damage,

and injuries.

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.

CAUTION: Isolate the gas supply at the main manual shutoff

valve before installing the GS Series valve.

The GS Series valve may be mounted on a horizontal manifold with the

magnetic operator 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

Figure 2: GS Series Valve Mounting Position

The ambient temperature maximum must not exceed the specified limits

(see Table 1).

Check the power supply voltage for compatibility with the required valve

voltage. For valves with 24 volt coils, use only NEC Class 2 transformers,

such as the Johnson Controls Y65 transformer.

Note: The Y65 transformer must be mounted to a grounded metal

enclosure.

When installing the valve on the manifold, ensure the gas flows 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.

When installing the valve, mount the flanges to the pipe separately, then

mount the valve between the two flanges.

Installation

4 G Gas Combustion Combination Controls and SystemsGS Series Single-Block Gas Control Valves

An optional thread lubricant may have been factory applied to the first

two or three threads of the inlet and outlet to avoid galling. Use an

approved pipe joint sealing compound on male threads before assembly.

Take care to see that excess compound is removed after mounting the

flanges to the pipe work. 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. For 24V applications,

the ground wire must not be connected to prevent

possible grounding of the 24V transformer secondary.

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

product identification label.

Route the electrical connection for the valve solenoid actuators from the

burner sequence control to the standard plug (DIN 43 650) and make the

wiring connections in accordance with Figure 3.

(

Ground

)

(

Common

)

3DIN Terminals

Line

Figure 3: Electrical Connection Diagram

Electrical

Connection

(from burner

sequence

control)

GGas Combustion Combination Controls and SystemsGS Series Single-Block Gas Control Valve 5

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

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

Figure 4). 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.

PFPA

Figure 4: Impulse Line Connections

Close the upstream shutoff cock. Connect the test pressure of a maximum

of 1 psi (70 mbar) to inlet pressure connection. Paint the pipe connection

to the valve with a rich soap and water solution. Open the upstream

shutoff cock and if bubbles occur this is an indication of a gas leak. To

stop a leak, tighten joints and pipe connections. Replace the part if the

leak cannot be stopped.

Connection of the

Impulse Lines on

the GS-406_

Checking for

Leakage

6 G Gas Combustion Combination Controls and SystemsGS Series Single-Block Gas Control Valves

Pressure regulator adjustment must be made in conjunction with the gas

appliance. See each version for specific adjustments.

This valve provides manual flow adjustment throughout the full range

from zero to maximum flow.

Flow adjustment is accessible below the metal plate on top of the valve

cover. To adjust this device, loosen the screw nearest to the +/- scale and

swing out the metal plate. Flow adjustment can now be accomplished by

selective positioning of the adjustment screw.

Several hand turns of the setting screw, without undue force, will cover

flow adjustment from almost zero to 100% of the maximum flow for most

specific applications.

The slow opening device is factory adjusted to maximum start gas

position. The valve is factory adjusted to maximum flow.

The adjustment ring is provided with an unsealed locking screw. Loosen

this screw and turn the entire damper assembly. Flow can now be adjusted

from maximum flow down to the desired rate.

CAUTION: The minimum flow rate of the valve must not be

adjusted beyond the minimum safety working rate of

the appliance.

For fast open/step adjustment, remove the cap then turn the adjustment

screw counterclockwise until the required step level has been attained.

Loosen the screws of the metal plate on top of the cover to access pressure

adjustment screw, using a screwdriver to adjust to the required value.

To ensure proper control function, the pressure regulator must operate

within its control range. With a selected pressure drop, the flow must

remain within the given limits.

With valve in the open position, the plug screw (see Figure 5) below the

gas outlet can be removed to check the start gas pressure. The scale (PST)

will show the setting (see Figure 6). As these are approximations, a

subsequent fine adjustment may be necessary.

Adjustments

Version GS-_01_

Version GS-_02_

Version GS-_03_

Version GS-405_

GGas Combustion Combination Controls and SystemsGS Series Single-Block Gas Control Valve 7

Figure 5: Plug Screw Position

PST

5-50

610

Figure 6: PST Setting

The start gas pressure (PST) remains at the set level until the plug screw is

replaced and tightened. The pressure then rises to the setpoint (PG).

Requirement: PG>PST

Now PGcan be adjusted.

The repeated switching of cycles will permit the observation of the

pressure regulator timing and control performance (see Figure 7). The PG

setting can also be revised.

PST

3 - 12 seconds

Time (s)

Figure 7: Pressure Regulator Timing vs. Control Performance

8 G Gas Combustion Combination Controls and SystemsGS Series Single-Block Gas Control Valves

Start repetitions require an interim pause of approximately 20 seconds for

the evacuation of the pressure chamber.

With test pressure for external leakage applied, adjust pointer on scale (PG)

to white dot within curved ramp (see Figure 6).

For a typical installation, see Figure 8.

Gas/Air

Controller

Gas

Line

Manual

Shutoff

Valve

Boiler

Air Line

PGPA

PG= Internal Gas Pressure Feedback Line

PA= Air Pressure Feedback Line

PF= Combustion Chamber Pressure Feedback Line

GS Series Combination Control

Pressure

Switch

Filter/

Strainer

Solenoid

Valve Working

With Controller

Figure 8: Typical Application Installation

The ratio (R) of gas outlet pressure (PG) to combustion air pressure (PA) is

adjustable within a range of 0.6:1 to 6:1 (see Figures 9 and 10).

Zero set (Z) can be accomplished by parallel shift of the characteristic

curve from -0.8 to +0.8 inches W.C. (-2 to +2 mbar) (see Figure 9).

When operating the burner in low fire position, the gas/air ratio is adjusted

on scale (Z).

Version GS-406_

GGas Combustion Combination Controls and SystemsGS Series Single-Block Gas Control Valve 9

0,6

Figure 9: Zero Setpoint and Gas/Air Ratio Adjustment

Z0.6:1

0.7:1

1:1

2:1

3:1

5:1

6:1

004812 16 20

PG- PF(Inches W.C.)

PG(Inches W.C.)

(

Inches W.C.

)

PA- PF

(

Inches W.C.

)

Figure 10: Analysis Chart

With burner in maximum load position, the gas/air ratio must be adjusted

on the scale (R) to meet the desired flue gas analysis readings. Then check

the flue gas analyses on low and high settings without manipulating the

adjustments, and thereafter, revise the settings if necessary.

Adjustment of the zero set (Z) and the gas/air ratio (R) can be made

against the marked scales on both sides of the controller module. Scale

divisions are approximate.

The factory settings are:

•zero set: (Z) = 0

•gas/air ratio: (R) = 1:2

Make adjustments in accordance with burner manufacturers’ instructions

and check the outlet pressure at the pressure tap.

Otherwise set the burner to the low fire position, perform a flue gas

analysis, and vary outlet pressure with adjustment on the scale (Z) until the

desired flue gas analysis readings are obtained.

10 G Gas Combustion Combination Controls and SystemsGS Series Single-Block Gas Control Valves

Set the burner to the maximum load and make flue gas analysis. Then

adjust the outlet pressure against the scale (R) until the desired flue gas

analysis readings are obtained.

Check the flue gas analysis readings on the low and high settings without

manipulating adjustments. Thereafter revise settings if necessary.

The outlet pressure PG:

•without combustion chamber pressure PF: PG= R •PA+ Z

•with combustion chamber pressure PF: PG- PF= R •( PA- PF) + Z

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