Johnson Controls UL Listed GS-20 Series Manuel utilisateur

Installation Sheets Manual 121

Gas Combustion Combination Controls and Systems Section G

Technical Bulletin GS-20/25

GS-40/45

Issue Date 1298

Part No. 24-8711-374, Rev. — www.johnsoncontrols.com

Code No. LIT-121905

Introduction Page 3

Application 3

Electrical Ratings 3

Specifications 4

Installation 5

Mounting 5

Standard Wiring (From Burner Sequence Control) 6

GS-406_ Connection of the Impulse Lines 7

Checkout Procedure 8

Adjustments 9

GS-_ _1_ (On/Off with Flow Adjustment) 9

GS-_ _2_ (On/Off Step-slow Opening with Flow Adjustment) 10

GS-_03_ (On/Off with Pressure Regulator) 10

GS-405_ (On/Off with Servo Precision Regulator) 10

GS-406_ (On/Off with Gas/Air Ratio Control) 12

Repairs and Replacement 15

UL Listed GS-20/25 and GS-40/45 Series

Single-block Multi-function Gas Control Valves

2 G—UL Listed GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin

G—UL Listed GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin 3

Introduction

Figure 1: UL Listed GS Series Single-block

Multi-function Control Valves

The UL Listed GS Series single-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 single-block valve body

provides a compact answer to gas train applications. The GS 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 North American and European gas

valve standards, including UL 429.

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

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

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

24 VAC +10/-15%, 50/60 Hz 23 VA

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

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

24 VAC +10/-15%, 50/60 Hz 23 VA

Application

Electrical

Ratings

4 G—UL Listed GS-20/25 and GS-40/45 Series Single-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:

GS-_01 _ and GS-_02_: 360 mbar

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

All Other Models: 100 mbar

North America:

GS-_01 _ and GS-_02_: 5 psi

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

All Other Models: 0.5 psi

Maximum

Regulating

Setting

20 mbar (8 in. W.C.) (GS-_ 03_)

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

Reverse

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

Regulator

Classification Spring Regulator (GS-_03_): Class B (EN 88)

Servo Regulator (GS-405_): 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

Valve Torsion

Group Group 2 (EN 88 and EN 161)

Pressure Taps Flanges: Rp 1/8 blank plug

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

Rp 1/4 thread special (multi-position) GS-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: 0.05mm (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 1/2 in. NPT conduit adapter compression fitting with cage-type terminal

blocks inside the terminal box

Coil Insulation

Class Class F

Agency

Listings IAS (AGA/CGA) Certificate Numbers: C0197002

C0197004

European Certificate Number: CE 0063AN3731

UL Listed File Number MH25441 (Guide YIOZ)

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

UL Standard 429

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 GS-20/25 and GS-40/45 Series Product Bulletin (LIT-4350240) for necessary information on

operating and performance specifications of this product.

Specifications

G—UL Listed GS-20/25 and GS-40/45 Series Single-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 GS 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. For valves supplied with a filter set and filter plate as

standard, the assembly should be installed (using the longer bolts)

between the inlet flange and the valve.

Mounting

6 G—UL Listed GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin

The GS 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: GS 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.

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

the product identification label.

2. Connect conduit from the burner sequence control to the valve

solenoid electrical box 1/2 in. NPT conduit adapter.

3. Remove the cover 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)

G—UL Listed GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin 7

NL1

GND

Electrical Box

Connection

1/2 in. NPT Conduit

Thread Adapter

(

Factor

Installed

)

N = Common

L1 = Line

GND = Earth Ground*

(* Do not connect earth ground for 24 VAC models.)

Wirin

Connections

Figure 3: Standard Wiring Electrical Connections

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 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.

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

damage to the tubing and allow for an accurate pressure

reading.

Figure 4: Impulse Line Connections

GS-406_

Connection of

the Impulse

Lines

8 G—UL Listed GS-20/25 and GS-40/45 Series Single-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 GS

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

G—UL Listed GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin 9

Adjustments

IMPORTANT: All adjustments must be made in conjunction with the

gas appliance and in accordance with the appliance

manufacturer’s instructions. Only authorized

personnel should make adjustments. See each valve

model version for specific adjustments.

WARNING: Explosion hazard. The minimum flow rate of the

valve must not be adjusted below the minimum safe

working rate of the appliance.

It is recommended that pressure connections be used to monitor the inlet

and outlet valve pressure while performing each of the specific adjustment

procedures.

This valve provides manual flow adjustment throughout the full range of

zero to maximum flow. For flow rate adjustment, loosen the unsealed

mounting screw on the plastic adjustment knob at the top of the solenoid

coil. Hand turn the adjustment knob clockwise to decrease or

counterclockwise to increase the flow rate through the valve

(see Figure 5). Tighten the mounting screw to secure the adjustment knob

at the desired flow rate.

Figure 5: Manual Flow Adjustment Knob

GS-_ _1_

(On/Off

with Flow

Adjustment)

10 G—UL Listed GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin

This valve provides adjustable step/slow opening for smooth ignition in a

burner application. The valve is factory set to maximum start gas position

and maximum flow position. Adjust the hydraulic damper at the top of the

solenoid coil to set the desired flow rate through the valve as well as the

desired start gas flow rate.

To adjust the maximum flow rate, loosen the unsealed mounting screw on

the aluminum hydraulic damper housing. Hand turn the housing clockwise

until the desired setting is obtained. Tighten the mounting screw to secure

the adjustment knob at the desired flow rate.

To adjust the start gas position, remove the plastic cap from the hydraulic

damper housing and turn the brass screw clockwise until the desired

setting is obtained (see Figure 6). Replace the plastic cap.

Figure 6: Hydraulic Damper Housing

This valve provides spring regulation to maintain the gas pressure at the

valve outlet. For outlet pressure adjustment, loosen the unsealed mounting

screw on the plastic regulator knob at the top of the solenoid coil. Hand

turn the regulator knob clockwise to increase or counterclockwise to

decrease the outlet pressure of the valve (see Figure 7). Tighten the

mounting screw to secure the adjustment knob at the desired outlet

pressure.

Figure 7: Spring Pressure Regulator Adjustment Knob

This valve provides servo regulation for precision control of the valve

outlet pressure. Before setting the valve for the desired outlet pressure,

adjust the start gas pressure.

GS-_ _2_

(On/Off Step-

slow Opening

with Flow

Adjustment)

GS-_03_

(On/Off with

Pressure

Regulator)

GS-405_

(On/Off with

Servo Precision

Regulator)

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