Johnson Controls GM 20 Series User manual

Installation Sheets Manual 121
Gas Combustion Combination Controls and Systems Section G
Technical Bulletin GM-20/25
GM-40/45
Issue Date 1298
© 1998 Johnson Controls, Inc. 1
Part No. 24-8711-48, Rev. A www.johnsoncontrols.com
Code No. LIT-121892
Introduction Page 3
x Application 3
x Electrical Ratings 3
x Specifications 4
Installation 5
x Mounting 5
x Standard Wiring (From Burner Sequence Control) 6
x 4-Pin Connector Plug Wiring (From Burner Sequence Control) 8
x GM-4_6_ Connection of Impulse Lines 9
x Checkout Procedure 10
Adjustments 11
x GM-_ _1_ (Dual On/Off Fast Open with Flow Adjustment) 11
x GM-_ _2_ (Dual On/Off Step-slow Opening with Flow Adjustment) 12
x GM-_ _3_ (Dual On/Off with Pressure Regulator) 12
x GM-_ _4_ (Dual On/Off with Step-slow Opening with Pressure Regulator) 13
x GM-4_5_ (Dual On/Off with Servo Precision Regulator) 13
x GM-4_6_ (Dual On/Off with Gas/Air Ratio Control) 15
Repairs and Replacement 19
GM-20/25 and GM-40/45 Series
Dual-block Multi-function Gas Control Valves

2 G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin

G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin 3
Introduction
Figure 1: GM Series Dual-block Multi-function
Gas Control Valves
The GM Series dual-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 dual-block valve body
provides a compact answer to gas train applications. The GM 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 European and North American gas
valve standards.
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
GM-2_ _ _ 230 VAC +10/-15%, 50/60 Hz
120 VAC +10/-15%, 50/60 Hz
24 VAC +10/-15%, 50/60 Hz 46 VA
GM-4_ _ _ 230 VAC +10/-15%, 50/60 Hz
120 VAC +10/-15%, 50/60 Hz
24 VAC +10/-15%, 50/60 Hz 46 VA
Application
Electrical
Ratings

4 G—GM-20/25 and GM-40/45 Series Dual-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:
GM-_01 _ and GM-_02_: 360 mbar
GM-251_ and GM-252_: 200 mbar
All Other Models 100 mbar
North America:
GM-_01 _ and GM-_02_: 5 psi
GM-251_ and GM-252_: 2 psi
All Other Models 0.5 psi
Maximum
Regulating
Setting
20 mbar (8 in. W.C.) (GM-_ _3_ and GM-_ _4_)
50 mbar (20 in. W.C.) (GM-4_5_ and GM-4_6_)
Reverse
Pressure Rating 150 mbar (60 in. W.C.) minimum; Class A (EN 161)
Regulator
Classification Spring Regulator (GM-_ _3_ and GM-_ _4_): Class B (EN 88)
Servo Regulator (GM-4_5_): 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 or Rp
Valve Torsion
Group Group 2 (EN 88 and EN 161)
Pressure Taps Flanges: 9.0 mm (0.35 in.) spigot for flexible tubing
Body: Rp 1/8 thread standard (multi-position)
Rp 1/4 thread special (multi-position) GM-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: 0.05 mm (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 Standard Wiring: PG 13.5 compression fitting with cage-type
terminal blocks inside the electrical box
Optional Wiring: 1/2 in. NPT conduit adapter compression fitting or
4-pin connector plug (ISO 4400 [DIN 43650])
Coil Insulation
Class Class F
Agency Listings IAS (AGA/CGA) Certificate Numbers: C0197002
C0197004
European Certificate Number: CE 0063AN3731
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
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 GM-20/25 and GM-40/45 Series Product Bulletin (LIT-4350340) for necessary information on
operating and performance specifications of this product.
Specifications

G—GM-20/25 and GM-40/45 Series Dual-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 GM 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. The filter plate assembly should be installed (using the
longer bolts) between the inlet flange and the valve.
Mounting

6 G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin
The GM 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: GM 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 when using the standard
PG 13.5 cable compression electrical connection.
1. Observe that the operating voltage is identical to the information on
the product identification label.
2. Route the electrical cable for the valve solenoid from the burner
sequence control to the valve.
3. Remove the cover of one 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—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin 7
Note: Figure 3 shows wiring connections for individual valve opening.
For simultaneous valve opening, wire a jumper between
Terminals V1 and V2 of either the electrical box on the first or
second valve.
5. Use a wrench to tighten the PG 13.5 cable compression plug to secure
wires and prevent moisture from entering the terminal box.
Note: If an optional 1/2 in. NPT thread electrical connector or 4-pin
DIN 43650 (ISO 4400) electrical connector (each ordered
separately) is used for wiring, refer to the documentation supplied
with the electrical connector for specific wiring instructions.
V1 V2
V1
V2
N
NV2V1 NV1V2
V1
V2
V1
V2
Addtional Connection
(
Ma
y
be used to connect pilot
or b
y
pass valves. Break awa
y
plastic to open.
)
GND GND
GND
*
Electrical Box
Connection
*
PG 13.5 Cable
Compression Plu
g
(
Factor
y
Installed
)
Wirin
g
Connections
N = Common
V1 = Line Valve 1
V2 = Line Valve 2
GND = Earth Ground*
(
* Do not connect earth
g
round
for 24 VAC models.
)
Figure 3: Standard Wiring Electrical Connections

8 G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin
!
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.
Use the following procedure to wire the valve when using a factory-
installed 4-pin DIN 43650 (ISO 4400) electrical plug connection.
1. Observe that the operating voltage is identical to the information on
the product identification label.
2. Route the electrical cable for the valve solenoid from the burner
sequence control to the valve.
3. Make wiring connections in accordance with Figure 4.
Note: Figure 4 shows wiring connections for individual valve opening.
For simultaneous valve opening, wire a jumper between terminals
V1 and V2 of either the electrical box on the first or second valve.
PE
(
Ground
)
2
3
1N
(
Common
)
1
32
Line
(
Valve 1
)
Line
(
Valve 2
)
Terminal Desi
g
nations
V1 V2
Figure 4: 4-Pin Wiring Electrical Connections
4-Pin Connector
Plug Wiring
(From Burner
Sequence
Control)

G—GM-20/25 and GM-40/45 Series Dual-block Multi-function Gas Control Valves Technical Bulletin 9
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 5. 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.
P
F
P
A
Figure 5: Impulse Line Connections
GM-4_6_
Connection of
Impulse Lines

10 G—GM-20/25 and GM-40/45 Series Dual-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 GM
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