Honeywell Compact Corona Series Operation manual

V5442N Compact
4-way Rotary Mixing Valves
APPLICATION
The “Corona” series of Compact Rotary valves and
Actuators provide integrated mixing of boiler supply, boiler
return, loop supply, and loop return water in hydronic
heating systems. The V5442 is very effective for low
temperature loops such as radiant floor heating.
The V5442 4-way valve can mix both loop supply water
and boiler return water simultaneously to control loop supply
temperature and boiler shock or flue gas condensation
protection. They may be plumbed in either a direct mixing
or injection configuration.
The effective Cv of the valves is increased when piped in
an injection configuration.
PRODUCT DATA
FEATURES:
• 4-way mixing action for closed hydronic heating systems.
• Mixes loop supply with boiler supply and loop return.
• Mixes boiler return with boiler supply and loop return.
• Optimized mixing characteristics for most accurate
control.
• Cast iron body; chrome plated plug.
• NPT threads.
• Suitable for manual or automatic control.
• “Universal” body orients either to the left or right to
match piping.
• Functional replacement for Centra ZRK-series of
compact 4-way mixing valves.
• Can be automated with M6063 actuator.
Contents
Application ............................................................................1
Features..................................................................................1
Specifications ........................................................................2
Ordering Information..............................................................2
Installation..............................................................................3
Settings ..................................................................................5
Operation................................................................................5
Checkout and Test ................................................................5
Troubleshooting......................................................................6
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V5442N “Corona” 4-way Compact Rotary Mixing Valves — SPECIFICATIONS • ORDERING INFORMATION
SPECIFICATIONS
Important
The specifications given in this publication do not
include normal manufacturing tolerances; therefore,
an individual unit may not exactly match the listed
specifications. Also, this product is tested and
calibrated under closely controlled conditions and
some minor differences in performance can be
expected if those conditions are changed.
Models:
The V5442N provides mixing of both loop supply and boiler
return water in hydronic heating systems. They can be automated
with an M6063A actuator and a tri-state (floating) controller.
V5442N
Mechanical Specifications:
Fittings: Female NPT threads, 3/4 to 1 1/4".
Dimensions: see Fig. 1, Table 1.
Materials: Cast iron body
Double O-rings
Chrome -plated interior cast iron parts
Water: maximum 50% glycol solution
Fig: 1 V5442N mounting dimensions in inches (mm).
C
SW
a
a i
Table. 1 V5442N specifications by valve size.
NOTE: Cannot be used in open systems such as Combo
heating where fresh water is present. Valve will corrode.
Static pressure rating: 90 psi (600 kPa)
Differential pressure rating: 15 psi (100 kPa)
Cv: see Table 1.
Leakage: less than 1% of Cv
Weight: see Table 1.
Temperature Ratings:
Water: 36°F to 230°F (2° to 110°C).
Shipping: -40°F to 140°F (-40° to 60°C)
Humidity Ratings:
Less than 90% RH, non-condensing.
Controller Compatibility:
Must be used with M6063 actuator.
Cross Reference:
V5442N functionally replaces Centra ZRK compact rotary
mixing valves and Centra ZR series rotary mixing valves if
piping reconfigured to injection mixing.
Replacement Parts:
P/N 071161035 replacement O-ring.
350 mm
14" minimum
Size [ i ] [a] [SW] [C] [C] with actuator Net Weight Cv
3/4"
1"
3 3/8"
(85 mm) 1 5/8" (41 mm) 13 3/8" (304 mm) 13 3/4"
(350 mm) 2.2 lb. (1.0 kg) 7.4
11.7
1 1/4" 4 1/8"
(105 mm) 1 13/16" (46 mm) 13 9/16" (345 mm) 3.3 lb. (1.5 kg) 18.7
ORDERING INFORMATION
When purchasing replacement or modernization products from your wholesaler or distributor, refer to the price sheets for
complete ordering number.
If you have additional questions, need further information, or would like to comment on our products or services, please write
or phone:
1. Your local Home and Building Control Sales Office (check white pages of your phone directory.)
2. Home and Building Control Customer Logistics
Honeywell Inc. 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386 [phone]
In Canada – Honeywell Limited-Honeywell Limitée, 155 Gordon Baker Road, North York, Ontario M2H 3N7.
International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France,
Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
95C-10888 2

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V5442N “Corona” 4-way Compact Rotary Mixing Valves — INSTALLATION
2. Check the ratings given in the instructions and on the
INSTALLATION
product to make sure the product is suitable for your
application.
When Installing this Product . . .
3. Installer must be a trained, experienced service technician.
4. After installation is complete, check out product operation
1. Read these instructions carefully. Failure to follow as provided in these instructions.
them could damage the product or cause a hazardous 5. Follow local codes for installation and application.
condition.
Fig: 2 V5442 installation and orientation (Boiler supply from left).
Mixed Supply
to Loop Loop
Return
Mixed
Loop
Loop
Return
Supply
boss
Supply Water
Boiler
Supply
Position
Indicator
32" min.
(≥0.8 m)
Manual
handle
Boiler
Boiler Return
Supply
Water
Mounting
Mixed
Boiler
Return
Supply boss
(actuator
mounting hub)
Valve
If you intend to control the valve with an outdoor temperature com- Fig: 3 V5442 handle assembly (Boiler supply from left;
pensator, we recommend installing the valve body within 20" (0.5 m) mixed output from top).
of the OTC panel to simplify the wiring.
The valve must be oriented correctly towards the boiler
supply water in order to work correctly. Boiler supply water may
enter vertically from below, or horizontally from the left, or right of
the valve. Mixed loop supply exits the valve horizontally (left or
right) with bottom boiler supply, or from the top with left-handed
or right-handed boiler supply. The position indication scale must
not point to the floor.
A. Mount the valve at least 32" (0.8 m) above the return line to
prevent thermal siphoning. See Fig. 2.
Position the valve body so that boiler water enters the port
Mixed
Output
Position
Indicator
9
Handle stop pin
marked by the boss.
Loop
See Fig.4 for possible mounting orientations for the V5442,
Supply
and select the appropriate configuration.
B. Install the valve body in the pipes. Use NPT-to-sweat
adapters if installing on copper pipe. Unions are not required
Alignment
mark
for serviceability, but may speed installation.
Note: Threaded fittings must have pipe dope or Teflon™ tape
to prevent leakage.
C.Identify the mixed output port, and select the corresponding
range on the valve position indicator scale. See Fig. 3.
D. If using the valve manually, clip the stop pin from the molding
sprue on the handle and insert the pin in the hole, according to
Fig.3. Assemble the handle onto the valve.
E. For other valve orientations, use the manual handle to align the
position indicator on the valve’s square drive socket with the
mixed output port. The mixed output will be either be 90°
counterclockwise or clockwise relative to the boiler supply
input port. Insert the stop pin into the appropriate hole on the
handle and assemble the handle to the valve body.
Refer to Fig.5 to 8 for piping options in various hydronic
systems. 3 95C-10888

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V5442N “Corona” 4-way Compact Rotary Mixing Valves — INSTALLATION
Fig. 4 Valve and handle installation for other piping configurations
A. Boiler supply enters
from left, mixed output
exits from top.
B. Boiler supply enters
from right, mixed output
exits from top.
C. Boiler supply enters
from bottom, mixed
output exits from left.
D. Boiler supply enters
from bottom, mixed
output exits from right.
Fig. 5 Single mixing valve installation
9
ºC
ºC
9 9
Fig. 6. Multiple loop installation
2
1
1 1
3
2
3
1
V5442 valve always has flow from and to boiler.
Install expansion tank at point of lowest pressure.
Recommended location of boiler circulator,
if installed, to prevent serial pumping.
1 V5442 valve always has flow from and to boiler.
4 95C-10888

V5442N “Corona” 4-way Compact Rotary Mixing Valves — SETTINGS • OPERATION • CHECKOUT
Fig. 7 Primary-secondary loop installation Fig. 8 Injection configuration.
1 2
1
1 V5442 must be sized to secondary LOOP flow; acts
as balancing valve.
. SETTINGS
The indicator scale on the V5442 ranges from 1 to 9,
where 1 (minimum) corresponds to no flow from boiler to
loop and full return of boiler supply to boiler return. This
scale is approximately proportional to radiation heat out-
put, and inversely proportional to boiler return water tem-
perature, but is not calibrated and intended for reference
only.
OPERATION
The rotary control plug of the V5442 diverts boiler supply
water to both the loop supply and boiler return. At the
same time, the control plug also diverts loop return water
to the boiler return and back to the loop supply. When the
loop does not use much boiler water, most of it is returned
to the boiler. The loop supply water temperature is the
result of mixing boiler supply and loop return water, and
boiler return water temperature is the result of mixing loop
return water with boiler supply water.
The control plug has a modified equal percentage mixing
characteristic on the mixed loop output to give linear
heat output in the space. The plug uses a linear mixing
characteristic on the mixed boiler return to give linear
temperature control of boiler return water.
The V5442 may be used to control space temperature for
comfort, boiler return water temperature to prevent boiler
shock and condensation, or both simultaneously, depend-
ing on the sophistication of the control system.
In low temperature systems such as radiant floor heating,
the V5442 may be used for mixing in an injection configura-
tion (See Fig. 8). In these configurations, the V5442 has an
effective Cv of a much larger valve.
1 V5442 valve always has flow from and to boiler.
2 V5442 must be sized to INJECTION flow; acts
as balancing valve.
CHECKOUT AND TEST
Checkout
1. Turn on loop (and main) circulators. Set the boiler
Aquastat control to its operating setpoint at design
conditions.
2. Rotate valve handle to 9. Verify that all boiler supply
water is being sent to the loop, that is, that the loop sup-
ply pipe is the same temperature as the boiler supply,
and the boiler return pipe is the same temperature as the
loop return pipe.
3. Rotate valve handle to 1. Verify that all boiler supply
water is being sent to the boiler return, that is, that the
loop supply pipe is the same temperature as the loop
return pipe, and the boiler return pipe is the same tem-
perature as the boiler supply pipe.
4. Rotate the handle to set desired mixed loop tempera-
ture. Verify that the boiler return water temperature
meets the boiler manufacturer’s or industry recommen-
dations. Make
a prominent note of the setting for future reference.
Note: If the boiler is fitted with a reset control such as the
AQ475 Aquatrol Outdoor Temperature Compensator, loop
temperature will vary proportionately with the boiler supply
temperature.
95C-10888 5

V5442N “Corona” 4-way Compact Rotary Mixing Valves — TROUBLESHOOTING • SERVICING
TROUBLESHOOTING
Table 2. Troubleshooting
Symptom Possible Causes Action
Space temperature too low. 1. Thermostat set too low.
2. Mixed supply water not hot enough. 1. Turn up thermostat. 2. Set V5442 to higher number
Boiler return temperature
too low. 1. Boiler Aqustat control set too low. 2. Mixed return water not hot enough.
3. Aquatrol minimum temperature too low.
1. Turn up Aquastat.
2. Set V5442 to lower number
3. Increase Aquatrol minimum temperature
setting
Space gets colder as higher
valve settings selected Loop supply and boiler return pipes are reversed. Switch control handle to opposite scale.
Fig. 9 O-Ring replacement
SERVICING
The V5442 is designed to give years of trouble-free operation,
provided it is used in an oxygen-depleted hydronic heating
system. The V5442 may be used in a combo heating system
only with heat exchangers between the potable and hydronic
heating systems.
Since the V5442 is a gate-type valve, we recommend that
the hydronic system be flushed before putting the valve into
operation to minimize potential damage to the seals by
debris in the system. We also recommend adding Y-strainers
and a 10% side-stream filter to the system after flushing to
capture debris that may be added in future through the boiler
feed water valve.
In automatic control systems where the V5442 has been
motorized with an M6063 actuator, the V5442 should be
operated every 3 days or so during the off season to ensure
the valve does not seize up.
If the valve stem starts to leak, replace the O-ring as shown
in Fig.9.
07116 1035
Home and Building Control
Honeywell Inc. Honeywell Limited-Honeywell Limitée
1885 Douglas Drive North 155 Gordon Baker Road
Minneapolis, MN North York, ON
55422-4386 M2H 3N7
95C-10888 RJ 10/99 Printed in U.S.A. www.honeywell.com