Johnson Controls UL Listed 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. 24-8711-374, Rev. — www.johnsoncontrols.com
Code No. LIT-121905
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 GS-406_ Connection of the Impulse Lines 7
x Checkout Procedure 8
Adjustments 9
x GS-_ _1_ (On/Off with Flow Adjustment) 9
x GS-_ _2_ (On/Off Step-slow Opening with Flow Adjustment) 10
x GS-_03_ (On/Off with Pressure Regulator) 10
x GS-405_ (On/Off with Servo Precision Regulator) 10
x GS-406_ (On/Off with Gas/Air Ratio Control) 12
Repairs and Replacement 15
UL Listed GS-20/25 and GS-40/45 Series
Single-block Multi-function Gas Control Valves

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

G—UL Listed GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin 3
Introduction
Figure 1: UL Listed GS Series Single-block
Multi-function Control Valves
The UL Listed 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 gas
valve standards, including UL 429.
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

4 G—UL Listed 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
Valve Torsion
Group Group 2 (EN 88 and EN 161)
Pressure Taps Flanges: Rp 1/8 blank plug
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: 0.05mm (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 1/2 in. NPT conduit adapter compression fitting with cage-type terminal
blocks inside the terminal box
Coil Insulation
Class Class F
Agency
Listings IAS (AGA/CGA) Certificate Numbers: C0197002
C0197004
European Certificate Number: CE 0063AN3731
UL Listed File Number MH25441 (Guide YIOZ)
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
UL Standard 429
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—UL Listed 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

6 G—UL Listed 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 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: 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.
1. Observe that the operating voltage is identical to the information on
the product identification label.
2. Connect conduit from the burner sequence control to the valve
solenoid electrical box 1/2 in. NPT conduit adapter.
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—UL Listed GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin 7
L1
N
NL1
GND
GND
*
Electrical Box
Connection
*
1/2 in. NPT Conduit
Thread Adapter
(
Factor
y
Installed
)
N = Common
L1 = Line
GND = Earth Ground*
(* Do not connect earth ground for 24 VAC models.)
Wirin
g
Connections
Figure 3: Standard 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 4). 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 4: Impulse Line Connections
GS-406_
Connection of
the Impulse
Lines

8 G—UL Listed GS-20/25 and GS-40/45 Series Single-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 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

G—UL Listed GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin 9
Adjustments
IMPORTANT: All adjustments must be made in conjunction with the
gas appliance and in accordance with the appliance
manufacturer’s instructions. Only authorized
personnel should make adjustments. See each valve
model version for specific adjustments.
!
WARNING: Explosion hazard. The minimum flow rate of the
valve must not be adjusted below the minimum safe
working rate of the appliance.
It is recommended that pressure connections be used to monitor the inlet
and outlet valve pressure while performing each of the specific adjustment
procedures.
This valve provides manual flow adjustment throughout the full range of
zero to maximum flow. For flow rate adjustment, loosen the unsealed
mounting screw on the plastic adjustment knob at the top of the solenoid
coil. Hand turn the adjustment knob clockwise to decrease or
counterclockwise to increase the flow rate through the valve
(see Figure 5). Tighten the mounting screw to secure the adjustment knob
at the desired flow rate.
Figure 5: Manual Flow Adjustment Knob
GS-_ _1_
(On/Off
with Flow
Adjustment)

10 G—UL Listed GS-20/25 and GS-40/45 Series Single-block Multi-function Gas Control Valves Technical Bulletin
This valve provides adjustable step/slow opening for smooth ignition in a
burner application. The valve is factory set to maximum start gas position
and maximum flow position. Adjust the hydraulic damper at the top of the
solenoid coil to set the desired flow rate through the valve as well as the
desired start gas flow rate.
To adjust the maximum flow rate, loosen the unsealed mounting screw on
the aluminum hydraulic damper housing. Hand turn the housing clockwise
until the desired setting is obtained. Tighten the mounting screw to secure
the adjustment knob at the desired flow rate.
To adjust the start gas position, remove the plastic cap from the hydraulic
damper housing and turn the brass screw clockwise until the desired
setting is obtained (see Figure 6). Replace the plastic cap.
A
V
M
A
X
.
Figure 6: Hydraulic Damper Housing
This valve provides spring regulation to maintain the gas pressure at the
valve outlet. For outlet pressure adjustment, loosen the unsealed mounting
screw on the plastic regulator knob at the top of the solenoid coil. Hand
turn the regulator knob clockwise to increase or counterclockwise to
decrease the outlet pressure of the valve (see Figure 7). Tighten the
mounting screw to secure the adjustment knob at the desired outlet
pressure.
S
O
L
L
W
E
R
T
S
T
.
/ R
E
G
.
S
E
T
P
O
I
N
T
Figure 7: Spring Pressure Regulator Adjustment Knob
This valve provides servo regulation for precision control of the valve
outlet pressure. Before setting the valve for the desired outlet pressure,
adjust the start gas pressure.
GS-_ _2_
(On/Off Step-
slow Opening
with Flow
Adjustment)
GS-_03_
(On/Off with
Pressure
Regulator)
GS-405_
(On/Off with
Servo Precision
Regulator)