Johnson Controls GH-5000 User manual

Electro- Hydraulic Actuator Gas Valves GH-5000
Electro-Hydraulic Actuator Gas Valve GH-5000-....
Function
Normally closed (NC). Single seat valve, fast closing, slow opening.
Sturdy and reliable electro-hydraulic actuator.
EC type-tested and certified as safety shut-off valve Class A (EN 161).
Models
• Threaded valve bodies Rp ¾ to Rp 3 and flanged valve bodies DN 40-150
• Actuator-Versions:
- On - Off * / **
- On - Low - Off *
- Ignition - On - Low - Off
* Closed Position Indicator (CPI) available
** with switch for Manual Restart available
Applications
Typical applications include commercial and industrial boilers, burners, ovens, rooftop units, make up
air heaters, hot water heaters, kilns, and paint booths.
Johnson Controls SA/NV - Leuvensesteenweg 248D - B-1800 Vilvoorde - [phone] - www.johnsoncontrols.be
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130 4280 010
Index
Specifications ...................................................................................................................................................3
Code Key ...........................................................................................................................................................4
Safety Instructions ...........................................................................................................................................7
Installation.........................................................................................................................................................8
Wiring.................................................................................................................................................................9
Checkout Procedure.......................................................................................................................................10
Adjustments ....................................................................................................................................................11
Switch M........................................................................................................................................................11
Switch S ........................................................................................................................................................11
Switch R ........................................................................................................................................................12
Switch MR .....................................................................................................................................................12
Repairs and Replacement..............................................................................................................................13
DN 40-80 Flanged Body and All Threaded Body Models .............................................................................13
DN100-150 Flanged Body Models................................................................................................................15
Terminal Box Replacement ...........................................................................................................................16
Actuator Replacement....................................................................................................................................17
Spare Parts, Replacement Actuators ...........................................................................................................18
Troubleshooting .............................................................................................................................................20
Declaration of conformity ..............................................................................................................................21
Flow Characteristic flanged valve bodies ....................................................................................................22
Flow Characteristic threaded valve bodies .................................................................................................24
Flow/Stroke Characteristic contour plug .....................................................................................................25
Dimensions and weight of flanged valve bodies DN40-150.......................................................................26
Dimensions of threaded valve bodies Rp ¾ to Rp 3...................................................................................27
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Specifications
Product GH-5000 Electro-Hydraulic Actuator Valve
Media Gas families to DVGW-Arbeitsblatt G 260/I. 1., 2. and 3. Gas family.
Max. operating pressure Rp ¾ - 2 ½ & DN 40-65 1000 mbar
Rp 3 & DN 80-100 800 mbar
DN 125 650 mbar
DN 150 350 mbar
Permissible ambient
temperature
-10 to +60°C (14 to 140°F)
Valve sizes Threaded connections Rp ¾, 1, 1 ½, 2, 2 ½, 3: ISO 7-1:1994
Flanges DN 40, 50, 65, 80, 100, 125, 150: ISO 7005 PN 16, DIN EN 1092-2
Valve torsion group Group 2
Valve class A
Pressure taps Valve body: Rp 1/4 (ISO 7-1:1994)
Materials
Valve body : die-cast aluminium EN AC-43400 or
EN AC-47100, DIN EN 1706
(Rp ¾ to 2 and DN 40-50)
cast iron EN-GJS-400-15, DIN EN 1563
(Rp 2½ to 3 and DN 65-80 and
valves GH-57.. DN100-150)
cast iron EN-GJL-250, DIN EN 1561
(valves GH-54.. DN100-150)
Seals, diaphragm: NBR
Filter Standard Strainer: 1 mm (0.04 in). mesh (steel)
Mounting position
Limited horizontal and vertical
90° max. from
verticaln
ATTENTION: See also Valve position label!
Operating voltages 120 V +6% / -10% 50/60 Hz
230 V +6% / -10% 50/60 Hz
Power consumption 200 W on opening action
15 W in opened state
Compression fitting EN 50262
Enclosure IP 54 (NEMA 1)
Operating time rating 100% ED
Duty cycles 3 min-1 (Rp ¾ - 1½, DN 40)
2 min-1 (Rp 2-3, DN 50-80)
1 min-1 (DN 100-150)
Opening time Rp ¾ - 1½, DN 40: < 6,5 s
Rp 2-3, DN 50-80: < 8 s
DN100-150: < 13 s
Closing time < 1 s
Agency Listing EC-Type Approval
Specification Standards Pressure Equipment (97/23/EC)
Appliances burning gaseous fuels (90/396/EC): EN 161
Electromagnetic compatibility (89/336/EC)
Low voltage equipment (73/23/EC)
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.
We reserve the right to make technical changes without warning.
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Code Key
Flange
Size
Product Code
Number
(Excluding
Voltage)*
Actuator
Configuration
Max.
Operating
Pressure
(mbar)
Opening
Time
(s)
Stroke
(mm)
GH-5120-11_0 On-Off
GH-5120-13_1 On-Low-Off
GH-5129-14_1 On-Low-Off + CPI
GH-5120-15_1 Ignition On-Low-Off
GH-5129-16_0 On-Off + CPI
DN 40
GH-5129-19_0 On-Off + CPI + MR
1,000 < 6.5 14
GH-5220-21_0 On-Off
GH-5220-23_1 On-Low-Off
GH-5229-24_1 On-Low-Off + CPI
GH-5220-25_1 Ignition On-Low-Off
GH-5229-26_0 On-Off + CPI
DN 50
GH-5229-29_0 On-Off + CPI + MR
1,000 < 8 22
GH-5620-31_1 On-Off
GH-5620-33_1 On-Low-Off
GH-5629-34_1 On-Low-Off + CPI
GH-5620-35_1 Ignition On-Low-Off
GH-5629-36_1 On-Off + CPI
DN 65
GH-5629-39_1 On-Off + CPI + MR
1,000 < 8 22
GH-5620-41_1 On-Off
GH-5620-43_1 On-Low-Off
GH-5629-44_1 On-Low-Off + CPI
GH-5620-45_1 Ignition On-Low-Off
GH-5629-46_1 On-Off + CPI
DN 80
GH-5629-49_1 On-Off + CPI + MR
800 < 8 22
GH-5720-51_0 On-Off
GH-5720-53_1 On-Low-Off
GH-5729-54_1 On-Low-Off + CPI
GH-5720-55_1 Ignition On-Low-Off
GH-5720-56_0 On-Off + CPI
DN 100
**
GH-5729-59_0 On-Off + CPI + MR
800 < 13 36
GH-5720-61_0 On-Off
GH-5720-63_1 On-Low-Off
GH-5729-64_1 On-Low-Off + CPI
GH-5720-65_1 Ignition On-Low-Off
GH-5729-66_0 On-Off + CPI
DN 125
**
GH-5729-69_0 On-Off + CPI + MR
650 < 13 36
GH-5720-71_0 On-Off
GH-5720-73_1 On-Low-Off
GH-5729-74_1 On-Low-Off + CPI
GH-5720-75_1 Ignition On-Low-Off
GH-5729-76_0 On-Off + CPI
DN 150
**
GH-5729-79_0 On-Off + CPI + MR
350 < 13 36
* Complete Product Code Number by inserting a 1 or 3 for the blank number.
1= 230 VAC (50/60 Hz) models and 3= 120 VAC (50/60 Hz) models.
** Material of valve body EN-GJS-400, DIN EN 1563
CPI = Closed Position Indicator
MR = with switch for manual restart
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Threaded
Size
Product Code
Number
(Excluding
Voltage)*
Actuator
Configuration
Max.
Operating
Pressure
(mbar)
Opening
Time
(s)
Stroke
(mm)
GH-5110-21_0 On-Off
GH-5110-23_1 On-Low-Off
GH-5119-24_1 On-Low-Off + CPI
GH-5110-25_1 Ignition On-Low-Off
GH-5119-26_0 On-Off + CPI
Rp ¾
GH-5119-29_0 On-Off + CPI + MR
1,000 < 6.5 14
GH-5110-31_0 On-Off
GH-5110-33_1 On-Low-Off
GH-5119-34_1 On-Low-Off + CPI
GH-5110-35_1 Ignition On-Low-Off
GH-5119-36_0 On-Off + CPI
Rp 1
GH-5119-39_0 On-Off + CPI + MR
1,000 < 6.5 14
GH-5110-51_0 On-Off
GH-5110-53_1 On-Low-Off
GH-5119-54_1 On-Low-Off + CPI
GH-5110-55_1 Ignition On-Low-Off
GH-5119-56_0 On-Off + CPI
Rp 1 ½
GH-5119-59_0 On-Off + CPI + MR
1,000 < 6.5 14
GH-5210-61_0 On-Off
GH-5210-63_1 On-Low-Off
GH-5219-64_1 On-Low-Off + CPI
GH-5210-65_1 Ignition On-Low-Off
GH-5219-66_0 On-Off + CPI
Rp 2
GH-5219-69_0 On-Off + CPI + MR
1,000 < 8 22
GH-5610-71_1 On-Off
GH-5610-73_1 On-Low-Off
GH-5619-74_1 On-Low-Off + CPI
GH-5610-75_1 Ignition On-Low-Off
GH-5619-76_1 On-Off + CPI
Rp 2 ½
GH-5619-79_1 On-Off + CPI + MR
1,000 < 8 22
GH-5610-81_1 On-Off
GH-5610-83_1 On-Low-Off
GH-5619-84_1 On-Low-Off + CPI
GH-5610-85_1 Ignition On-Low-Off
GH-5619-86_1 On-Off + CPI
Rp 3
GH-5619-89_1 On-Off + CPI + MR
800 < 8 22
* Complete Product Code Number by inserting a 1 or 3 for the blank number.
1= 230 VAC (50/60 Hz) models and 3= 120 VAC (50/60 Hz) models.
CPI = Closed Position Indicator
MR = with switch for manual restart
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130 4280 010 E
Safety Instructions
Definition of symbols
This symbol indicates cautionary information. The statements WARNING, ATTENTION, CAUTION
indicate a potentially hazardous situation with the risk of property damage, injuries or death.
WARNING: Carefully read and follow all instructions in this sheet and all instructions on the
appliance. This unit must be installed by authorised service personnel in accordance with the
regulations in force. Incorrect installation, adjustment, modification, operation or maintenance may
cause fire, explosions, property damage, and injuries or death. All repairs, adjustments and servicing
must be made in conjunction with the gas appliance and in accordance with the appliance
manufacturer’s instructions.
Keep operating instructions in a safe place.
CAUTION: It is possible to use fluids other than stated in the chapter Specifications but, this must first
be confirmed by the manufacturer.
In places where it is necessary to withstand high temperatures, the gas valves must be preceded for
instance, by a thermally activated shutting-off device for gas. It may be necessary to discuss these measures
with the manufacturer.
Storage and transport temperature -20°C to 65°C, dry and free of dirt. Protect the valve from adverse
weather conditions e.g. rain, splash water (otherwise use drying agent).
•
•
•
•
•
•
•
Protect against external forces (shock, Vibration etc.). Do not damage the surface
Ensure that valve body and piping are free of impurities, see also chapter Troubleshooting.
Ensure installation without tension and torque.
Do not use the valve as a step or fixation point. Only piping supports it.
Protect valve from dust or dirt on construction sites. Provide strainer or filter upstream of valve.
Use compensators to balance thermal expansion of piping.
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Installation
WARNING: Explosion hazard. To prevent leakage of upstream gas, shut off the gas supply at the
main manual shutoff valve before installing or servicing the GH-5000 valve.
CAUTION: Equipment damage. To prevent damage to the valve when mounting to pipework, do not
use a wrench on any surface other than the casting flats provided at the inlet and outlet ends of the valve
body.
IMPORTANT: Ensure that the drilled holes in the actuator cover are not covered. These holes are
necessary for ventilation and must not be covered by paint or other materials.
Perform the following procedure to install the GH-5000 valve.
• Ensure that the specified maximum ambient temperature is not exceeded (see Table 1).
• Ensure that the power supply voltage is compatible with the required control valve voltage.
• Ensure the gas flows through the valve body in the direction indicated by the arrow on the valve body.
Leakage can occur if the valve is installed with the gas flow in the opposite direction of the arrow.
IMPORTANT: Do not install the actuator upside down. Install vertically wherever possible.
• The GH-5000 valve contains hydraulic fluid that the pump needs to operate the valve. Therefore, the
valve may be mounted horizontally with the actuator pointed up (vertical) or in one plane in positions that
do not exceed 90° from vertical. See Figure 1 and the valve position label.
• The valve may also be mounted vertically in any position around its axis, provided that the actuator is
mounted to the valve within the range indicated on the valve label. To provide application flexibility in
mounting, the actuator of the valve may be removed and rotated. However, the mounting of the valve
must still be within the range indicated on the valve label.
90° Maximum
from Vertical
Limited Horizontal and Vertical
IMPORTANT: Refer to valve
label for mounting
positions.
Figure 1: Mounting position
• If installing a valve with threaded connections, use an approved pipe joint sealing compound on male
threads before assembly. An optional thread lubricant may have been factory applied to the first
two or three threads of the inlet and outlet to avoid galling. Ensure that excess compound is removed.
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.
• If installing a valve with flanged connections, ensure that all mating surfaces are free from burrs and
loose particles. Ensure that gaskets and O-ring seats are correctly positioned in mating flanges. Ensure
that approved jointing compounds are not excessively applied.
• Check for leakage before making any valve adjustments. Close the upstream shutoff cock. Connect air
tubing with a maximum of 70 mbar(1 psi) pressure to the inlet pressure connection. Paint the pipe
connection to the valve with a rich soap and water solution (or use acceptable gas leak detection
equipment). Open the upstream shutoff cock. 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.
• Make wiring connections. Refer to the Wiring section for specific wiring instructions.
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130 4280 010 E
Wiring
WARNING: Shock hazard. Disconnect the power supply before making electrical connections to avoid
electrical shock or equipment damage. Ensure that the operating voltage is identical to the information on the
product identification label.
Make wiring connections in accordance with Table 1.
Actuator
Configuration
Terminal
Markings
Terminal
Connections
Wiring Diagram
On-Off 6
3
4
N
None
None
On-Off
System Neutral
6
on
LN
(
M
p)
(1)
(5)
3
4
N
On-Low-Off 6
3
4
N
None
On-Off
Low-Position
System Neutral
6
low
LN
(
M
p)
(2)
(5)
3
4
N
on
(1)
On-Low-Off + CPI 7
8
9
6
3
4
N
Opening Contact
Closing Contact
Common
None
On-Off
Low-Position
System Neutral
6
low
LN
(
M
p)
(2)
(5)
3
4
N
on
7
8
9
(1)
CPI
Ign. On-Low-Off 6
3
4
N
Ignition Position
On-Off
Low-Position
System Neutral
6
low
LN
(
M
p)
(3)
(5)
3
4
N
on
(4)
(6)
ign.
Continued on next page ...
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130 4280 010 E
Actuator
Configuration
Terminal
Markings
Terminal
Connections
Wiring Diagram
On-Off + CPI 7
8
9
6
3
4
N
Opening Contact
Closing Contact
Common
None
None
On-Off
System Neutral
6
on
LN
(
M
p)
(1)
(5)
3
4
N
7
8
9
CPI
On-Off + CPI + MR 7
8
9
6
3
4
N
Opening Contact
Closing Contact
Common
On-Off
None
None
System Neutral
6on
L
N
(
M
p)
(1)
(5)
3
4
N
7
8
9
CPI
Table 1: Electrical connections
With the gas line closed, apply power to the actuator and move the valve at least three times through the complete
stroke range to ensure faultless operation.
Checkout Procedure
WARNING: Fire or explosion hazard. Avoid personal injury or property damage by ensuring that the valve
functions properly and there are no gas leaks. Follow this checkout procedure before leaving the installation.
• Close the upstream shutoff cock and connect air tubing with a maximum of 1 psi (70 mbar) pressure to the
inlet pressure connection.
• Paint the pipe connections of the valve with a rich soap and water solution (or use acceptable gas leak
detection equipment) to check for leakage. Open the upstream shutoff cock. 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.
• 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 manufacturer’s
specifications.
• Before leaving the installation, observe at least three complete operating cycles to ensure that all components
are functioning correctly.
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130 4280 010 E
Adjustments
WARNING: All repairs, adjustments and servicing must be made in conjunction with the gas
appliance and in accordance with the appliance manufacturer’s instructions. Only authorized
personnel should make adjustments in accordance with the regulations in force.
WARNING: Explosion hazard. The minimum flow rate of the valve must not be adjusted below the
minimum safe working rate of the appliance.
The GH-5000 valve can be adjusted through the use of three adjustable switches located inside the terminal
box of the actuator. The screws of these switches adjust the stroke, which affect the flow rate, depending on
the version of the actuator. (See Figure 2). Loosen the four screws of the terminal box cover and remove it to
access the adjustable switches.
MMaximum Flow
Factory set: full flow
Do not make any adjustments on the
sealed grub screw!
SFeed back position / CPI
Factory set is approx. 0.5 mm
OR
Ignition Stage
Factory set is approx. 3 mm
RReduced Stage
Factory set is approx. 3 mm
or 5.5 mm at models with ignition stage
MR Manual Restart
(switch is not illustrated)
Factory set is approx. 3 sec. running time
Do not make any adjustments on the
sealed screw!
MR MSR
Figure 2: Switches
Do not adjust the switches S and R below 3 mm stroke to obtain safe working of the appliance.
Do not make any adjustments on the sealed grub screw (M)!
Do not make any adjustments on the sealed screw (MR)!
Switch M
The valve is factory set to full flow. To adjust the maximum flow rate, turn the ‘M’ (Maximum Flow) screw.
Turn the screw clockwise to reduce and counterclockwise to increase the flow rate.
Switch S
For CPI versions the ‘S’ screw head is factory set and sealed.
If new adjustment is required, first make sure that the actuator is mounted on the valve and switched off.
Connect a suitable test circuit between terminals 8 and 9:
• Terminal contacts 8 and 9 opened: turn the adjustment screw clockwise until the contacts just are
closed. Now turn the adjustment screw one full turn counterclockwise.
• Terminal contacts 8 and 9 closed: turn the adjustment screw counterclockwise until the contacts are
opened. Turn the adjustment screw clockwise until the contacts just are closed. Now turn the adjustment
screw one full turn counterclockwise.
Energise the actuator and cycle on/off. The terminal contacts 8 and 9 have to be opened in the off position of
the actuator. Otherwise repeat the adjustments and cycle on/off. Finally seal the screw head and remove the
test circuit.
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130 4280 010 E
In a similar way, the ‘S’ switch can be used as an auxiliary signal switch for any actuator stroke position.
Turn the ‘S’ screw clockwise for a signal at a higher stroke or flow. Turning counterclockwise reduces stroke
or flow level to activate the switch.
To adjust the ignition flow, turn the ‘S’ screw. Turn the screw clockwise to reduce and counterclockwise to
increase the flow required for proper ignition.
Switch R
To adjust the reduced flow rate or low fire position, turn the ‘R’ (‘Reduced’) screw. Turn the screw clockwise
to reduce and counterclockwise to increase the flow for stage one.
Switch MR
The switch MR for Manual Restart stops gas from being automatically released again after a power cut.
For Manual Restart operate the red button on the terminal box cover for at least 3 seconds to drive the gas
valve to the open position, see Figure 3.
Should the button not be held long enough the gas valve will automatically return to the closed position.
switch MR
Figure 3: switch MR for Manual Restart
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130 4280 010 E
Repairs and Replacement
WARNING: All repairs, adjustments and servicing must be made in conjunction with the gas
appliance and in accordance with the appliance manufacturer’s instructions. Only authorized
personnel should make adjustments in accordance with the regulations in force.
Field repairs must not be made, except to replace the filter, valve seat plug, gasket, terminal box, or actuator.
For a replacement part, contact the nearest Johnson Controls representative or the original equipment
manufacturer.
WARNING: Fire or explosion hazard. Shut off the gas supply at the main manual shutoff valve before
servicing the valve.
Only a trained service professional should perform these repair or replacement procedures.
Valve Servicing
Follow the model-specific procedure to service the valve. Perform this procedure with each recommended
inspection or at a minimum each annual functional inspection.
DN 40-80 Flanged Body and All Threaded Body Models
• Close the upstream shutoff cock and disconnect power to the actuator.
CAUTION: Personal injury hazard. The valve cover contains a compressed spring. Improper
disassembly could cause the valve cover and spring to fly off resulting in personal injury or equipment
damage.
• Remove two diagonally opposed mounting screws from the bottom valve cover and replace them with
two long bolts with screwed-on nuts. See Table 5 for bolt dimensions. Screw the nuts down against the
valve cover.
Valve Model Bolt Distance to relax spring(s)
DN 40 flanged body M 6 x 60 approx. 55 mm
DN 50 flanged body M 8 x 80 approx. 70 mm
DN 65 & DN 80 flanged body M 8 x 70 approx. 50 mm
Rp ¾ to 1 ½ threaded body M 6 x 60 approx. 55 mm
Rp 2 threaded body M 8 x 80 approx. 70 mm
Rp 2 ½ to 3 threaded body M 8 x 70 approx. 50 mm
Table 2: Bolt dimensions
• With the two bolts in place, remove the other two mounting screws.
• Uniformly back off the nuts of the two bolts to lower the valve cover and relax the spring. See Table 2 for
approximate distance required to fully relax the spring.
• With the spring relaxed, remove the two bolts, valve cover, valve spring, valve seat plug, and filter. Refer to
model-specific figures (Figure 4) for part identification.
• Clean or replace valve seat plug, filter, and gasket. (Figure 4)
• Check the surface of the valve seat plug. If the seat plug or seal is damaged in anyway, replace it. Contact
Johnson Controls for replacement part numbers.
• Ensure that the valve seat plug bore is free of foreign matter before installing it on the valve stem. Re-insert
valve seat plug, filter, and gasket.
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130 4280 010 E
• Place the valve spring inside the valve body and secure it with the valve cover and two opposing bolts. Ensure
that the valve seat plug is not tilted.
• Uniformly tighten the nuts of the two bolts to raise the valve cover and compress the spring.
• With the valve cover in position against the valve body, insert two of the mounting screws into the available
cover holes.
• Remove the two bolts and replace them with the other two mounting screws. Ensure that the valve body and
cover are sealed.
• Open the upstream shutoff cock and check for leakage along the valve cover. (Refer to the Checkout
Procedure section).
• Observe at least three complete operating cycles to ensure that all components are functioning correctly.
Valve Model Valve Cover Locking screw Flanged ring actuator
Rp ¾ - 1½ und DN 40 10 Nm - 5 Nm
Rp 2- 3 und DN 50 - 80 25 Nm - 5 Nm
DN100 -150 25 Nm 8 Nm 5 Nm
Table 3: Torques
Cover mounting
screws
Grub screw
Locking
screw
Valve
seat
plug
Distance piece
Valve
spring(s)
Valve cover
Strainer,
filter
Flanged bodies DN40-80 and all Flanged valve bodies DN100-150
threaded valve bodies
Figure 4: Detailed drawing
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130 4280 010 E
DN100-150 Flanged Body Models
• Close the upstream shutoff cock and disconnect power to the actuator.
CAUTION: Personal injury hazard. The valve cover contains a compressed spring. Improper
disassembly could cause the valve cover and spring to fly off resulting in personal injury or equipment
damage.
• Unscrew the sealed locking screw from the bottom valve cover and replace it with a centering disk
(disk to DIN 9021- 8,4 or JCI part number 130 2069 010) and screw M 6, see Table 4 and Figure 4.
Valve Model Bolt
DN100 Flanschventil GH-54.. M6 x 55
DN125 Flanschventil GH-54..
DN100-150 Flanschventile GH-57.. M6 x 60
DN150 Flanschventil GH-54.. M6 x 70
Table 4: Bolt dimensions
• Tighten the screw three turns past the stop so that the valve seat plug lifts off the valve seat, securing
the valve spring.
• Remove the valve cover mounting screws.
• Remove the valve cover, valve spring, valve seat plug, and filter. Refer to Figure 4 for part identification.
• Clean or replace valve seat plug and seal, filter, and gasket.
• Check the surface of the valve seat plug. If the seat plug is damaged in anyway, replace it. Contact
Johnson Controls for replacement part numbers.
• Ensure that the valve seat plug bore is free of foreign matter before installing it on the valve stem. Re-
insert valve seat plug, filter, and gasket.
• Place the valve spring inside the valve body and secure it with the valve cover and two opposing
mounting screws. Ensure that the valve seat plug is not tilted.
• Insert the other two mounting screws. Ensure that the valve body and cover are sealed. For torque refer
to Table 3.
• Remove the screw and centering disk inserted and replace it with the locking screw. For torque refer to
Table 3. The locking screw has to be sealed.
• Open the upstream shutoff cock and check for leakage along the valve cover. (Refer to the Checkout
Procedure section).
• Observe at least three complete operating cycles to ensure that all components are functioning correctly.
Page:14
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130 4280 010 E
Terminal Box Replacement
CAUTION: Equipment damage hazard. Ensure that the replacement terminal box matches the
existing one in every respect.
CAUTION: Equipment damage hazard. Label all wires prior to disconnection when servicing valves.
Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
Follow the procedure below to replace the terminal box.
• Close the upstream shutoff cock, disconnect power to the actuator.
• Remove the terminal box cover by loosen the four cover screws.
• Disconnect field wiring. Disconnect the flat plugs from the plug connector. See Figure 5.
• Loosen the four terminal box mounting screws. Lift the key lever and pull out the terminal box.
• Connect the flat plugs of the new terminal box to the plug connector in accordance with Figure 6. Please note
that the Th and 2 pins are towards the front and the 1 and N pins are towards the back of the terminal box.
Flat Plu
g
s
Mounting Screws
Ke
y
Lever
Lever
Figure 5: Terminal box
black
brown
blue
blue
brown
N
2
1
Th
2
1 N
Th
On-Off Version On-Low-Off Version
Ignition On-Low-Off Version
Figure 6: Flat plug connector
• Lift the key lever and insert the replacement terminal box into the housing. Ensure that the back of the
key lever is inserted into the opening in the back of the housing.
• Attach the terminal box to the housing using the four mounting screws. Tighten the screws in the
numbered order shown in to ensure that the terminal box is flat.
• Connect field wiring to the terminal box.
• If necessary, make switch adjustments. Refer to the Adjustments section for details.
• Reattach the terminal box cover by tightening the four cover screws.
• Apply power to the actuator and open the upstream shutoff cock.
• Observe at least three complete operating cycles to ensure that all components are functioning correctly.
Page:15
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130 4280 010 E
Actuator Replacement
CAUTION: Equipment damage hazard. Label all wires prior to disconnection when servicing valves.
Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
Follow the procedure below to replace the actuator.
• Close the upstream shutoff cock and disconnect power to the actuator.
• Remove the terminal box cover by loosening four cover screws.
• Disconnect field wiring. As you disconnect each wire, label it with the correct terminal designation.
• Remove the four fixing screws from the flanged ring and lift off the actuator and flanged ring.
• If the actuator is equipped with an extension piece: loosen the grub screw from the extension piece and
remove the extension piece from the actuator stem. See Figure 4.
CAUTION: Equipment damage hazard. The extension piece must be retained when replacing the
actuator. The stem length is critical to proper closing of the valve. There must be a minimum clearance
of 1 mm between the valve stem and valve seat plug.
• Push the extension piece onto the stem of the replacement actuator and tighten the grub screw.
• Place the actuator, without seal, onto the valve body. It must rest firmly on the valve body. If the actuator
does not rest firmly, clean the bore of the valve body.
• Clean the seal and place it on the valve body.
• Place the flanged ring and actuator on the valve body and loosely tighten the fixing screws (torque see
Table 3).
• Turn the actuator to the preferred position and evenly tighten the fixing screws in a diagonally opposed
pattern.
• Open the upstream shutoff cock and check for leakage along the flanged ring. (Refer to the Checkout
Procedure section).
• Remove the cover of the terminal box by loosening the four cover screws.
• Connect field wiring to the terminal box.
• If necessary, make switch adjustments. Refer to the Adjustments section for details.
• Reattach the terminal box cover by tightening the four cover screw.
• Apply power to the actuator.
• Observe at least three complete operating cycles to ensure that all components are functioning correctly.
Page:16
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130 4280 010 E
Spare Parts, Replacement Actuators
Electro- Hydraulic Actuator
Gas Valve
Code Number * (Size)
Replacement
Actuator
Code Number *
Replacement
Terminal - Box
Code Number
Terminal - Box
Function
AH – 5100 – 01_0 130 3430 111 On-Off
AH – 5100 – 03_0 130 3430 131 On-Low-Off
AH – 5100 – 05_0 130 3430 151 Ignition-On-Low-Off
AH – 5109 – 04_0 130 3431 141 On-Low-Off+CPI **
AH – 5109 – 06_0 130 3431 161 On-Off+CPI **
GH – 51.. – 2._. (¾ inch / Rp ¾)
GH – 51.. – 3._. (1 inch / Rp 1)
GH – 51.. – 5._. (1½ inch / Rp 1½)
GH – 51.. – 1._. (1½ inch / DN 40) AH – 5109 – 09_0 130 3431 191 On-Off+CPI ** +MR ***
AH – 5200 – 01_0 130 3430 211 On-Off
AH – 5200 – 03_0 130 3430 231 On-Low-Off
AH – 5200 – 05_0 130 3430 251 Ignition-On-Low-Off
AH – 5209 – 04_0 130 3431 241 On-Low-Off+CPI **
AH – 5209 – 06_0 130 3431 261 On-Off+CPI **
GH – 52.. – 6._. (2 inch / Rp 2)
GH – 52.. – 2._. (2 inch / DN 50)
GH – 56.. – 7._. (2½ inch / Rp 2½)
GH – 56.. – 3._. (2½ inch / DN 65)
GH – 56.. – 8._. (3 inch / Rp 3)
G
H
–
56
..
–
4. .
(3
in
c
h
/
DN
80)
AH – 5209 – 09_0 130 3431 291 On-Off+CPI ** +MR ***
AH – 5400 – 01_0 130 3430 411 On-Off
AH – 5400 – 03_0 130 3430 431 On-Low-Off
AH – 5400 – 05_0 130 3430 451 Ignition-On-Low-Off
AH – 5409 – 04_0 130 3431 441 On-Low-Off+CPI **
AH – 5409 – 06_0 130 3431 461 On-Off+CPI **
GH – 54.. – 5._. (4 inch / DN 100)
GH – 54.. – 6._. (5 inch / DN 125)
GH – 54.. – 7._. (6 inch / DN 150)
GH – 57.. – 5._. (4 inch / DN 100)
GH – 57.. – 6._. (5 inch / DN 125)
G
H
–
5
7..
–
7. .
(6
in
c
h
/
DN 1
50)
AH – 5409 – 09_0 130 3431 491 On-Off+CPI ** +MR ***
* Excluding Voltage, complete Code Number by inserting a 1or 3for the blank digit.
1= 230 VAC (50/60 Hz) models and 3= 120 VAC (50/60 Hz) models.
** CPI = Closed Position Indicator
*** MR = with switch for manual restart
Gasket II
Valve Cover
Filter
Valve Seat Plug
Gasket I Flanged
Ring
Grub Screw
Extension
Piece
Figure 7: Detailed drawing, spare parts
Johnson Controls SA/NV - Leuvensesteenweg 248D - B-1800 Vilvoorde - [phone] - www.johnsoncontrols.be
Page:17
Johnson Controls SA/NV - Leuvensesteenweg 248D - B-1800 Vilvoorde - [phone] - www.johnsoncontrols.be

130 4280 010 E
Electro- Hydraulic Actuator
Gas Valve (Size)
Extension
Piece Grub Filter
Flanged
Ring
GH – 51.. – 2... (¾ inch / Rp ¾)
GH – 51.. – 3... (1 inch / Rp 1)
GH – 51.. – 5... (1½ inch / Rp 1½)
GH – 51.. – 1... (1½ inch / DN 40)
- - - - - - - - 130 3015 010
GH – 52.. – 6... (2 inch / Rp 2)
GH – 52.. – 2... (2 inch / DN 50) 130 3083 010 130 3055 010
GH – 56.. – 7... (2½ inch / Rp 2½)
GH – 56.. – 3... (2½ inch / DN 65)
GH – 56.. – 8... (3 inch / Rp 3)
GH – 56.. – 4... (3 inch / DN 80)
130 4413 010 130 4256 010
GH – 54.. – 5... (4 inch / DN 100) 130 2162 010 130 2156 010
GH – 54.. – 6... (5 inch / DN 125) 130 2136 010 130 2157 010
GH – 54.. – 7... (6 inch / DN 150) 130 2137 010 130 2158 010
GH – 57.. – 5... (4 inch / DN 100) 130 5497 010 130 5373 010
GH – 57.. – 6... (5 inch / DN 125) 130 5498 010 130 2157 010
GH – 57.. – 7... (6 inch / DN 150) 130 5499 010
212 4649 111
130 2158 010
2 x
130 2160 010
Electro- Hydraulic Actuator
Gas Valve (Size)
Valve Seat Plug
(flat)
Valve Seat Plug
(contoured)
Gasket I
Actuator - Valve
Gasket II
Valve - Cover
GH – 51.. – 2... (¾ inch / Rp ¾) 130 4433 011
GH – 51.. – 3... (1 inch / Rp 1) 130 4432 011
GH – 51.. – 5... (1½ inch / Rp 1½)
GH – 51.. – 1... (1½ inch / DN 40)
130 3067 011
130 4429 011
130 3165 010 130 3165 010
GH – 52.. – 6... (2 inch / Rp 2)
GH – 52.. – 2... (2 inch / DN 50) 130 3069 031 130 4428 011 130 3165 010 130 3166 010
GH – 56.. – 7... (2½ inch / Rp 2½)
GH – 56.. – 3... (2½ inch / DN 65) 130 4411 011
GH – 56.. – 8... (3 inch / Rp 3)
GH – 56.. – 4... (3 inch / DN 80)
- - - -.
130 4417 011
130 2811 010 130 4306 010
GH – 54.. – 5... (4 inch / DN 100)
GH – 57.. – 5... (4 inch / DN 100) 130 2276 131 130 4425 111 130 2131 010
GH – 54.. – 6... (5 inch / DN 125)
GH – 57.. – 6... (5 inch / DN 125) 130 2277 131 130 4424 111 130 2132 010
GH – 54.. – 7... (6 inch / DN 150)
GH – 57.. – 7... (6 inch / DN 150) 130 2278 111 130 4423 111
130 2811 010
130 2133 010
See also Figure 7.
Johnson Controls SA/NV - Leuvensesteenweg 248D - B-1800 Vilvoorde - [phone] - www.johnsoncontrols.be
Page:18
Johnson Controls SA/NV - Leuvensesteenweg 248D - B-1800 Vilvoorde - [phone] - www.johnsoncontrols.be

130 4280 010 E
Troubleshooting
Symptom Possible Cause Corrective Action
Supply voltage incorrect or missing
Check switches, fuses, circuit breakers,
and actuator wiring connections (refer to
Table 1)
Flow rate set too low
Turn the ‘M’ adjustment screw
counterclockwise to increase the flow rate
(refer to chapter Adjustments)
Motor does not
run
Internal defect Replace actuator (refer to chapter
Actuator Replacement)
Operating pressure too high
Verify that the maximum operating
pressure is not exceeded (refer to chapter
Specifications)
Incorrect mounting position of horizontal
actuator
Turn actuator. Observe mounting positions
as indicated on actuator label
Stroke setting set below 3 mm
Turn the ‘R’ or ‘S’ adjustment screw
counterclockwise to increase the stroke
(refer to chapter Adjustments)
Flow direction Check flow direction: the flow direction is
indicated by an arrow on the valve body
Motor runs but
valve does not
open
Internal defect Replace actuator (refer to chapter
Actuator Replacement)
Motor does not
turn off Limit switch defective Replace terminal box (refer to chapter Repairs and Replacement)
Incorrect wiring Check wiring (refer to Table 1)Actuator moves
through Low
Position Switch defect Replace terminal box (refer to chapter
Repairs and Replacement)
Leakage Flanges, fittings Replace seals or screws or replace valve
Dirt on valve seat Replace valve
Inner leakage Flow direction Check flow direction: the flow direction is
indicated by an arrow on the valve body
Fault diagnosis Effects Cause Remedial
action/Minimising risks
Valve body,
flanges, actuator:
Cracks, holes,
damage, leakage
Piping stressed beyond permitted
limits, recoil forces, pressure
surges, valves used as fixed
point, not permitted pressure and
temperature limits
Reduce pressure and
stress, change piping
position, install
compensators, select other
materials. The piping must
meet all applicable
codes/standards (i.e. TRB,
TRR).
Replace valve
Improper transport, bending
stresses too great, thermal stress
Replace valve, ensure that
piping is laid free of stress
or tension
Flange fitting not
tight, leakage
Danger of explosion
Danger of flying
shrapnel, danger of
poisoning, burns
danger, environmental
pollution
Bolts not tightened diagonally
Proper installation in
accordance with these
operating instructions
Hot surface Burns danger Wrong operating voltage,
actuator surface becomes hot
Replace actuator, check
operating voltage
Johnson Controls SA/NV - Leuvensesteenweg 248D - B-1800 Vilvoorde - [phone] - www.johnsoncontrols.be
Page:19
Johnson Controls SA/NV - Leuvensesteenweg 248D - B-1800 Vilvoorde - [phone] - www.johnsoncontrols.be

130 4280 010 E
Declaration of conformity
Johnson Controls SA/NV - Leuvensesteenweg 248D - B-1800 Vilvoorde - [phone] - www.johnsoncontrols.be
Page:20
Johnson Controls SA/NV - Leuvensesteenweg 248D - B-1800 Vilvoorde - [phone] - www.johnsoncontrols.be