Azbil GV-A Series User manual

Thank you for purchasing the GV-A
High-Performance Gas Solenoid Valve
for Industrial Applications. This manual
contains information for ensuring the
correct use of the GV-A.
This manual should be read by those who
design and maintain equipment that uses
the GV-A.
Also, the manual provides necessary
information for installation, maintenance,
and troubleshooting. Be sure to keep this
manual nearby for handy reference.
No. CP-SP-1356E
High-Performance Gas
Solenoid Valve
for Industrial Applications
GV-A
User's Manual
for
"Installation and Configuration"
How this unit is delivered:
The unit is not provided with the threaded flanges.
Obtain the threaded flanges separately and mount
them for use at your site.
(Photo: Valve with threaded flange (sold separately))

NOTICE
Be sure that the user receives this manual before the product is used.
Copying or duplicating this user’s manual in part or in whole is forbidden.
The information and specifications in this manual are subject to change
without notice.
Considerable effort has been made to ensure that this manual is free from
inaccuracies and omissions. If you should find an error or omission, please
contact Azbil Corporation.
In no event is Azbil Corporation liable to anyone for any indirect, special or
consequential damages as a result of using this product.
© 2014-2020 Azbil Corporation. All Rights Reserved.
- This unit has functions that are extremely important for the safe operation of combustion
equipment. Read this user's manual carefully to use the unit correctly.
- To ensure the safety of equipment that incorporates this device, all work related to this
device should be conducted by specialists having sufficient knowledge, experience, and
skills related to combustion and industrial furnaces.
- Before starting to operate the unit, be sure to perform an external leak inspection and an
internal leak inspection on your own responsibility.
- Before wiring, installing, or removing the unit, be sure to turn off the power and gas supply.
Failure to do so could result in an electric shock or gas leak.
IMPORTANT

The following is the CE Declaration of Conformity issued by Elster GmbH.
Note:
1. Azbil's GV-A corresponds to Elster GmbH's model VAS.
VCS (double valve) is a product consisting of two VAS (single valve) units connected in series.
2. VAS is certified under EN 161 Class A Group 2 and has obtained the Product ID Number
CE-0063BO1580, which is printed on the Elster GmbH product label of the valve unit.
CE Declaration of Conformity
i

To prevent injury to the operator and others, and to prevent property damage, the following types of safety
precautions are indicated:
In describing the product, this manual uses the icons and conventions listed below.
: Use caution when handling the product.
: The indicated action is prohibited.
: Be sure to follow the indicated instructions.
Handling
Precautions
: Handling Precautions indicate items that the user should pay attention to
when handling this module.
Note : Notes indicate information that might benefit the user.
: This indicates the item or page that the user is requested to refer to.
(1)(2)(3) : Numbers within parentheses indicate steps in a sequence or parts of an
explanation.
[XXX], [XX] : Square brackets indicate a message or button shown on the PC screen.
[XXXX]Key
[X]Key
: Indicates keys on the keyboard.
[XXX]+[XX]Key : Refers to the operation of pressing the [xxx] key while holding down the
[xxxx] key.
>> : Indicates the result of an operation, details displayed on the personal
computer or other devices, or the state of the device after operation.
ii
WARNING Warnings are indicated when mishandling this product might result in
death or serious injury.
CAUTION Cautions are indicated when mishandling this product might result in
minor injury to the user, or only physical damage to the product.
Conventions Used in This Manual

iii
Safety Precautions
WARNING
Before using the unit, be sure to read this manual in order to use the product correctly.
Incorrect installation, adjustment, modification, operation, or maintenance may result in an injury
or accident.
The unit should be installed, wired, adjusted, inspected, and maintained by specialists having
sufficient knowledge and skills related to combustion and industrial furnaces.
After piping and wiring the unit, be sure to perform gas leak inspections before supplying gas.
Failure to do so might cause fire or device failure.
Do not place your foot on the unit or climb on it.
Doing so is extremely dangerous, because the seal might be damaged, resulting in an external gas
leak from the valve unit or pipe flange.
Do not install the unit outdoors where it is exposed to wind, rain, or direct sunlight.
Doing so may cause device failure.
The valve unit is a heavy object. The edges at the bottom of the valve unit may cause injuries
during handling. Wear work gloves or other protective gear when handling this product. Also wear
work gloves or other protective gear when unpacking the product.
Do not touch the valve seat directly or push it up with a screw driver.
If the valve seat is damaged, the sealing ability cannot be maintained, resulting in gas leaks.
Before wiring, installing, or removing the unit, be sure to turn off the power and gas supply.
Failure to do so could result in an electric shock or gas leak.
Connect the unit to the low-voltage side (G). If it is connected to the high-voltage side (H), a
ground-fault current may flow into the unit, causing the valve to open and the gas to flow out,
regardless of the burner controller.
Be sure to check that the unit has been correctly wired before turning on the power.
Incorrect wiring of the unit can damage the unit and lead to other hazards.
While the equipment is operating do not touch the coil part of the solenoid valve directly.
It may reach a high temperature (80°C or more), causing burns.
Do not reuse any removed O-ring. Be sure to use new O-rings when replacing the unit, and when
removing or re-attaching the threaded flanges.
Reusing O-rings may cause gas leaks.
When replacing an O-ring, before assembling make sure that the threaded flange is not biting into
the O-ring. Biting may lead to external gas leaks.
Connect the ground wire to the ground terminal to prevent electric shock in case of an electrical
fault.
High-voltage side (H)
(Ground fault)
Burner
Burner
controller
Boiler
6600 V 100 V
Valve (closed)
Low-voltage
side (G)
Gas
LV1 (+)
N (–)
When the valve is wired to the low-voltage side correctly, as shown
in the gure, no ground-fault current ows into the solenoid valve,
even if an insulation failure causes a ground fault. Therefore, the valve
does not open and there is no risk of gas outow.
Correct connection method
High-voltage side (H)
(Ground fault)
6600 V 100 V
Gas
If the valve is wired to the high-voltage side, as shown in the gure,
a ground-fault current ows into the solenoid valve when the ground
fault shown in the gure occurs. Regardless of the burner controller,
therefore, the solenoid valve opens and the gas ows out.
Valve (open)Low-voltage
side (G)
LV1 (+) N (–)
Incorrect connection method
Burner
Burner
controller
Boiler

iv
CAUTION
Use this device within the operating environment ranges listed in the specifications.
Not doing so might cause fire or device failure.
Use this device only for natural gas, LPG (propane/butane) and air.
Using any other gas may corrode metal parts or deteriorate rubber parts, causing gas leaks or other
problems.
Do not allow wire clippings, metal shavings, water, etc. to enter the unit.
Foreign objects, etc., can cause fire or faulty operation.
Use cables with heat resistance of 80°C or more.
Failure to do so might increase the temperature of the terminal block and damage the cable
insulation.
When using a gas that contains a large amount of dust (such as non-liquefied natural gas), install a
gas filter upstream to reduce the risk of dust entering the valve.
When using LPG, attach a mist trap, if necessary, to reduce the risk of any re-liquefied component
(viscous substance) entering the unit.
Do not disassemble this device.
Doing so may result in an electric shock or gas leak.
Do not grip the unit with a vise or other equipment.
Use a compatible wrench to grip only the octagonal part of the threaded flange for the valve unit.
Improperly gripping this product can cause gas leaks or other problems.
This unit has a limited lifespan. Do not use it if it has exceeded the lifespan. ( See "Chapter 8.
Specifications" on page 27.) Operation after the lifespan is exceeded might result in a gas leak,
fire, or electric shock.
Precautions on facility design
Facilities that use combustion safety equipment should be designed with careful
consideration of safety guidelines such as the following.
• Technical policy on safety standards for combustion equipment in industrial
furnaces, by the Ministry of Health, Labour and Welfare [Japan]
• General safety code for industrial combustion furnaces (JIS B 8415:2008)
• Forced draught burners - Part 1: Gas burners (JIS B 8407-1:2012)
• Forced draught burners - Part 2: Oil burners (JIS B 8407-2:2012)
• Index of safety technology of industrial gas combustion equipment, by the Japan
Gas Association
• Index of safety technology of gas boiler combustion facilities, by the Japan Gas
Association
• Standard for ovens and furnaces (NFPA 86), by the National Fire Protection
Association [U.S.]
• Industrial thermoprocessing equipment (EN 746) [Europe] Appliances burning
gaseous fuels (Directive 93/68/EEC ) [Europe]
If the system is to be used overseas, refer to the laws and standards of the relevant
country when designing the system.

v
zImportant points for ensuring combustion safety
• Both the main valve and pilot valve must have a redundant shutoff configuration.
• Connect this device directly to the load terminals (for main and pilot valves) of
the burner controller.
• Do not provide any mechanical or electrical bypass of this device.

vi
This manual is organized as follows:
Chapter 1. Overview
Provides a list of features and model numbers and gives the name of each part.
Chapter 2. Restrictions on Installation
Describes restrictions on the installation.
Chapter 3. Piping and Wiring
Describes piping and wiring methods.
Chapter 4. Adjustments
Describes how to adjust the gas flow rate.
Chapter 5. Inspection, Maintenance and Disposal
Describes how to maintain, inspect and dispose of the unit.
Chapter 6. Troubleshooting
If some problem arises during the operation of the device, this chapter tells how to
determine the cause and take countermeasures.
Chapter 7. Joining Two Valves Together
Describes the double-valve configuration.
Chapter 8. Specifications
Describes the specifications, external dimensions, etc.
Appendix
Provides reference materials such as European standards (extracts) and Supply
Pressure of Town Gas (extracted from the Index of safety technology of industrial
gas combustion equipment) and explains the terms used in this document.
Organization of This User's Manual

vii
Contents
CE Declaration of Conformity
Conventions Used in This Manual
Safety Precautions
Organization of This User's Manual
Chapter 1. Overview
1 - 1 Overview and Features ……………………………………………………………………… 1
1 - 2 Model Number List …………………………………………………………………………… 2
1 - 3 Part Names …………………………………………………………………………………… 4
1 - 4 Exploded View………………………………………………………………………………… 6
Chapter 2. Restrictions on Installation
Installation space ………………………………………………………………………… 7
Mounted orientation ……………………………………………………………………… 7
Ambient temperature …………………………………………………………………… 8
Filter installation ………………………………………………………………………… 8
Chapter 3. Piping and Wiring
3 - 1 Piping Method…………………………………………………………………………………10
Before piping ………………………………………………………………………………10
Piping work …………………………………………………………………………………10
3 - 2 Wiring Method ………………………………………………………………………………12
Valve without a POC switch ……………………………………………………………… 12
Valve with POC switch …………………………………………………………………… 13
Chapter 4. Adjustments
Maximum flow rate adjustment and initial flow rate adjustment ……………………15
Adjusting the maximum flow rate ………………………………………………………15
Adjusting the initial flow rate (slow opening type only) ………………………………16
Chapter 5. Inspection, Maintenance and Disposal
5 - 1 Inspection ……………………………………………………………………………………17
Gas leak inspections performed after piping and wiring …………………………… 17
External and internal gas leak inspections (regular inspection cycle: Once a month)
………………………………………………………………………………………………18
5 - 2 Maintenance …………………………………………………………………………………19
Replacing the valve unit …………………………………………………………………19
5 - 3 Disposal ………………………………………………………………………………………20

Chapter 6. Troubleshooting
The valve does not open. …………………………………………………………………21
The flow rate is low (a large pressure loss). ……………………………………………21
The slow opening operation is disabled. ………………………………………………21
Chapter 7. Joining Two Valves Together
Method for joining two valves together…………………………………………………23
Method for connecting the terminal boxes ……………………………………………24
Chapter 8. Specifications
Specifications ………………………………………………………………………………27
Flow rate characteristics (flow rate at 15°C, 101.325 kPa) ……………………………29
External Dimensions ………………………………………………………………………31
Appendix
About European Standards …………………………………………………………………… App-1
Supply Pressure of Town Gas…………………………………………………………………… App-2
Explanation of Terminology …………………………………………………………………… App-3
viii

1
Chapter 1. Overview
1 - 1 Overview and Features
The GV-A High-Performance Gas Solenoid Valve for Industrial Applications is used as a safety shutoff valve for gas
supplied to gas burners and other gas combustion equipment.
This is an imported product from Germany's Elst er GmbH .
• This product consists of a valve unit and threaded flange, and includes a solenoid
coil with a compact design.
• The maximum operating pressure is 50 kPa.
• This product is available in both quick opening and slow opening types. The
quick opening type has a maximum flow rate adjustment (variable) mechanism.
The slow opening type has an initial flow rate adjustment mechanism and a max-
imum flow rate adjustment mechanism.
• The valve close confirmation switch has an indicator that allows visual confir-
mation of operation. The valve is also available with a proof-of-closure (POC)
switch.
• This device is compliant with EN 161. Also, size 1 of the valve has obtained SIL 3
and PL e certification.
• As standard equipment, a blue LED is provided to allow the operator to check the
status of the power supplied to the device.
• Blue LED shows turning on electricity to this product.
SIL 3 (Safety Integrity Level 3)
Safety systems must receive safety certication (SIL) by a third party.
SIL 3 is a level at which risk is reduced to between 1/1000 and 1/10,000
of the risk at a plant where safety measures are not adopted. SIL 1
indicates the risk is reduced down to the 1/10–1/100 range.
PL (Performance Level)
The performance level indicates the ability of safety-related parts to
perform a safety function. Hardware failure rates and software safety
requirements were added to the qualitative requirements described
in category B, items 1 to 4 in EN 954-1 and ISO 13849-1:1999 (JIS B
9705-1:2000) to provide quantitative safety levels designated from PL
a to PL e.
Blue LED which shows
turning on electricity

2
Chapter 1. Overview
1 - 2 Model Number List
Base
model
number
Valve size Operation
type
Rated
supply
voltage
POC
switch
POC
switch
orientation
Inspection
report
Additional
process Description
GV-A High-Performance Gas Solenoid Valve for Industrial
Applications
100 Valve size 1 (for port sizes 10A, 15A, 20A, 25A)
200 Valve size 2 (for port sizes 25A, 32A, 40A, 50A)
300 Valve size 3 (for port sizes 40A, 50A, 65A)
NQuick opening type
LSlow opening type
P100 Vac
Y200 Vac
*1 GWith POC switch
*2 0Without POC switch
*1 RPOC switch on right side as viewed from upstream
*2 0None
DWith inspection report
0Without inspection report
0None
Note: Choose the threaded ange that is correct for your pipe size.
*1 If "G" is selected for POC switch, only "R" can be selected for POC switch orientation.
*2 If "0" is selected for POC switch, only "0" can be selected for POC switch orientation.
zParts Sold Separately
• Threaded flange
One threaded flange is included. Two pipe flanges are required for each valve.
For details, refer to "Method for joining two valves together" (page 23).
Model number Product name Product code*
74921504 Port size 10A for valve size 1 FLV110 R / B
74921505 Port size 15A for valve size 1 FLV115R / B
74922229 Port size 20A for valve size 1 FLV120R/B
74922230 Port size 25A for valve size 1 FLV125R/B
74922231 Port size 25A for valve size 2 FLV225R/B
74922232 Port size 32A for valve size 2 FLV232R/B
74922233 Port size 40A for valve size 2 FLV240R/B
74922234 Port size 50A for valve size 2 FLV250R/B
74922235 Port size 40A for valve size 3 FLV340R/B
74922236 Port size 50A for valve size 3 FLV350R/B
74922237 Port size 65A for valve size 3 FLV365R/B
* The product code is a product identication code that is printed on the product package, and it is
separate from the model number.
The valve size and pipe diameter are indicated by this code.
• Seal set
This set includes O-rings used for joining two valves together.
For details, refer to "Method for joining two valves together" (page 23).
Model number Product name
74921988 For valve size 1
74921989 For valve size 2
74921990 For valve size 3

3
Chapter 1. Overview
• Cable gland set
To join two valves with POC together, connect their terminal boxes.
“Valve with POC switch”(page 13)
Model number Product name
74921985 Bushings for valve size 1
74921986 Bushings for valve size 2
74921987 Bushings for valve size 3
• Bolt set and strainer set
Use them for maintenance purposes, if necessary.
The required number of all items below is included with the initial purchase of the
valve.
Model number Product name
74921992 Bolt set for valve size 1
74921993 Bolt set for valve size 2
74921994 Bolt set for valve size 3
74921997 Strainer set for valve size 1
74921998 Strainer set for valve size 2
74921999 Strainer set for valve size 3
• Bolt set • Strainer set
Bolt × 2
Strainer × 1
Nut × 2
Strainer × 1
O-ring* × 2
* O-ring used to mount the
threaded ange
How this unit is delivered:
The unit is not provided with the threaded flanges. Obtain the threaded flanges separately and mount them
for use at your site.

4
Chapter 1. Overview
1 - 3 Part Names
zValve without a POC switch
Handling Precautions
• Function inspection screw
This screw is used for function inspections. Do not turn it, as it is not supposed
to be adjusted at the site. Turning it may cause an internal oil leak or make the
valve unable to open.
Maximum ow rate adjustment screw
Quick opening Slow opening
Cap Scale
Solenoid
coil
Strainer
Armature
Solenoid
coil
Strainer
Armature
Scale
Cap
Internal structure
Maximum ow rate adjustment screw
Note: In the above diagrams, the upper parts above the – – – lines are turned
anti-clockwise by 90° for a better understanding of the internal structure.
Blue LED viewing window
Pressure measurement ports
(4 locations)
Terminal box cover xing screw
Maximum ow rate adjustment screw
Damper unit
(Slow opening type only)
Cap
Terminal
box cover
Terminal box
Solenoid coil
*Function inspection screw
O-ring A
(2 locations)
Punch-out
for wiring
(2 locations)
Strainer
(Upstream side only) : Flow direction mark

5
Chapter 1. Overview
zValve with a POC switch
Solenoid
coil
Strainer
Scale
Cap
Maximum ow rate adjustment screw
Cap Scale
Solenoid
coil
Strainer
Armature
POC switch POC switch
Armature
Maximum ow rate adjustment screw
Note 1: In the above diagrams, the upper parts above the – – – lines are turned anti-clockwise
by 90° for a better understanding of the internal structure.
Note 2: In the case of the POC switch type, the terminal box and POC switch cannot be turned.
Maximum ow rate adjustment screw
Blue LED viewing window
POC switch
(POC switch
type only)
Pressure measurement ports
(4 locations)
Terminal box cover
xing screw
Damper unit
(Slow opening type only)
Cap
Terminal
box cover
Terminal box
Solenoid coil
O-ring A
(2 locations)
Punch-out
for wiring
(2 locations)
Strainer
(Upstream side only)
: Flow direction mark
* Function inspection screw
Quick opening type Slow opening type
Internal structure
Handling Precautions
• Function inspection screw
This screw is used for function inspections. Do not turn it, as it is not supposed
to be adjusted at the site. Turning it may cause an internal oil leak or make the
valve unable to open.

6
Chapter 1. Overview
1 - 4 Exploded View
Parts are shown in exploded view below.
The threaded flanges are sold separately.
refer to "Parts Sold Separately" (page 2)
O-ring A
(already attached)
O-ring A
(already attached)
Strainer
(already attached)
Bolt set
(accessory)
Bolt set
(accessory)
Flow direction mark
Threaded ange
(Sold separately)
Threaded ange
(Sold separately)

7
Chapter 2. Restrictions on Installation
Installation space
Leave a space of at least 20 mm around the device for heat dissipation.
For installation near a furnace wall or other location where high temperatures are
expected, leave sufficient distance to ensure that the allowable ambient temperature
is not exceeded.
Leave a space of 200 mm or more for maintenance inspections.
Mounted orientation
Install vertically with the maximum flow rate adjustment screw facing up, or install
horizontally.
• Correct installation
• Incorrect installation
20 mm min.
20 mm min.
20 mm min.
20 mm min.
Maximum ow rate adjustment screw

8
Chapter 2. Restrictions on Installation
Ambient temperature
Install where the ambient temperature is between -20 and +60°C.
Direction of gas flow
Align the flow direction mark on the valve with the actual direction of gas flow.
Filter installation
Be sure to install an appropriate filter upstream.
Gas ow
Filter
Gas ow

9
Chapter 3. Piping and Wiring
WARNING
After piping and wiring the unit, be sure to perform gas leak inspections before supplying gas.
Not doing so might cause fire or device failure.
Before wiring, installing, or removing the unit, be sure to disconnect the power and gas supply.
Failure to do so could result in an electric shock or gas leak.
Do not install the unit outdoors, where it may be exposed to wind, rain or direct sunlight.
Doing so may cause device failure.
Do not touch the valve seat directly or push it up with a screw driver.
If the valve seat is damaged, the sealing ability cannot be maintained, resulting in gas leaks.
While the equipment is operating do not touch the coil part of the solenoid valve directly.
It may reach a high temperature (80 °C or more), causing burns.
Connect the ground wire to the ground terminal to prevent electric shock in case of current
leakage.
Connect the unit to the low-voltage side (G). If it is connected to the high-voltage side (H), a
ground-fault current may flow into the unit, causing the valve to open and the gas to flow out,
regardless of the burner controller.
CAUTION
Use the unit within the operating ranges listed in the specifications.
Not doing so might cause fire or device failure.
Use cables with heat resistance of 80 °C or more.
Failure to do so might increase the temperature of the terminal block and damage the cable
insulation.
Do not allow wire clippings, metal shavings, water, etc. to enter the unit.
Foreign objects, etc., can cause fire or faulty operation.
Do not grip the unit with a vise or other equipment. Use a compatible wrench to grip only the
octagonal part of the threaded flange for the valve unit.
Improperly gripping this product can cause gas leaks or other problems.
High-voltage side (H)
(Ground fault)
Burner
Burner
controller
Boiler
6600 V 100 V
Valve (closed)
Low-voltage
side (G)
Gas
LV1 (+)
N (–)
When the valve is wired to the low-voltage side correctly, as shown
in the gure, no ground-fault current ows into the solenoid valve,
even if an insulation failure causes a ground fault. Therefore, the valve
does not open and there is no risk of gas outow.
Correct connection method
High-voltage side (H)
(Ground fault)
6600 V 100 V
Gas
If the valve is wired to the high-voltage side, as shown in the gure,
a ground-fault current ows into the solenoid valve when the ground
fault shown in the gure occurs. Regardless of the burner controller,
therefore, the solenoid valve opens and the gas ows out.
Valve (open)Low-voltage
side (G)
LV1 (+) N (–)
Incorrect connection method
Burner
Burner
controller
Boiler

10
Chapter 3. Piping and Wiring
3 - 1 Piping Method
Handling Precautions
• Do not apply too much force to the valve unit when screwing the pipe. Doing
so might damage the unit or cause a gas leak.
Before piping
zStrainer check
Check to make sure that the strainer in the inlet on the upstream side of the valve
unit is in its proper place.
zAir flushing
Before attaching the valve to the pipe, flush with air to remove metal shavings,
burrs, and other foreign objects from the inside of the pipe.
Piping work
(1) Wrap sealing tape around the male threads of the pipe. (Or apply sealing
compound.)
If using a sealing compound, apply the proper amount and do not apply to the area
from the end of the thread to the second ridge.
Handling Precautions
• An excessive amount of sealing compound, contaminants, burrs, etc., may
block the strainer or reduce the flow rate.
(2) To tighten, grip the octagonal part of the pipe flange with a wrench.
An excessive amount of
a sealing agent is applied.
There are contaminants
and burrs in the pipe