Johnson Controls GS-20 Series User manual

Installation Sheets Manual 121
Gas Combustion Combination Controls and Systems Section G
Technical Bulletin GS-20/25
GS-40/45
Issue Date 1298
© 1998 Johnson Controls, Inc. 1
Part No. 24-8711-21, Rev. A www.johnsoncontrols.com
Code No. LIT-121900
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) 7
x GS-406_ Connection of the Impulse Lines 8
x Checkout Procedure 9
Adjustments 11
x GS-_ _1_ (On/Off with Flow Adjustment) 11
x GS-_ _2_ (On/Off Step-slow Opening with Flow Adjustment) 12
x GS-_03_ (On/Off with Pressure Regulator) 12
x GS-405_ (On/Off with Servo Precision Regulator) 12
x GS-406_ (On/Off with Gas/Air Ratio Control) 14
Repairs and Replacement 17
GS-20/25 and GS-40/45 Series
Single-block Multi-function Gas Control Valves

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

G—GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin 3
Introduction
Figure 1: GS Series Single-block
Multi-function Control Valves
The 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
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
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

4G—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 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) 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: 0.05 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 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 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—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

6G—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 magnetic operator 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 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 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—GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin 7
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.
NV2V1
V1
N
Electrical Box
Connection
V1
V2
*
GND
GND
*
PG 13.5 Cable
Compression Plu
g
(
Factor
y
Installed
)
Wirin
g
Connections
N = Common
V1 = Line Valve 1
V2 = Not Connected
GND = Earth Ground*
(
* Do not connect earth
g
round
for 24 VAC models.
)
Figure 3: Standard Wiring Electrical Connections
!
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 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.
4-Pin Connector
Plug Wiring
(From Burner
Sequence
Control)

8G—GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin
N
(
Common
)
1
32
Line
Not Connected
Terminal Desi
g
nations
1
2
3
Figure 4: 4-Pin 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 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
GS-406_
Connection of
the Impulse
Lines

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

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