Johnson Controls GH-5000 Bedienungsanleitung

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 - +32(2) 709 40 00 - 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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130 4280 010 E

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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130 4280 010 E

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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130 4280 010 E

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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130 4280 010 E

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

None

On-Off

System Neutral

(

(1)

(5)

On-Low-Off 6

None

On-Off

Low-Position

System Neutral

low

(

(2)

(5)

(1)

On-Low-Off + CPI 7

Opening Contact

Closing Contact

Common

None

On-Off

Low-Position

System Neutral

low

(

(2)

(5)

(1)

CPI

Ign. On-Low-Off 6

Ignition Position

On-Off

Low-Position

System Neutral

low

(

(3)

(5)

(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

Opening Contact

Closing Contact

Common

None

On-Off

System Neutral

(

(1)

(5)

CPI

On-Off + CPI + MR 7

Opening Contact

Closing Contact

Common

On-Off

None

System Neutral

6on

(

(1)

(5)

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

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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