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Honeywell V4295, V8295 SERIES SOLENOID GAS VALVES PRODUCT HANDBOOK APPLICATION These series solenoid gas valves are used for control and regulation of gaseous fuels in gas power burners, atmospheric gas boilers, melting furnaces, incinerators and other gas consuming appliances. . CONTENTS APPLICATION ..................................................................... 1 GENERAL ............................................................................. 2 DESCRIPTION ..................................................................... 2 FEATURES ........................................................................... 2 ELECTRICAL CONNECTIONS ......................................... 2 MODEL CHART ................................................................... 3 TECHNICAL ......................................................................... 4 Subject to change without notice. All rights reserved. SPECIFICATIONS ............................................................... 4 POWER CONSUMPTION (A) ............................................ 5 PERFORMANCE CHARACTERISTICS .......................... 6 CAPACITY: ........................................................................... 7 DIMENSIONS ....................................................................... 8 INSTALLATION ................................................................... 9 INSTRUCTIONS ELECTRICAL CONNECTIONS ........ 13 CONSTRUCTION AND WORKING PRINCIPLES ....... 14 STANDARDS AND APPROVALS .................................. 15 STANDARDS ..................................................................... 15 REPLACEMENT PARTS AND ACCESSORIES .......... 16 EN2R9105 1602RA -NE 1 Honeywell GENERAL DESCRIPTION V4295/V8295 Series Gas Valve The V4295/8295 series solenoid valves offer a series of functionalities: Gas valves, Normally Closed, consisting of a direct ON/OFF operator for opening/ closing of the valve. POC switch optional Relief valves. Normally Opened, consisting of direct electric ON/OFF operator for opening/closing of the valve The V4295/8295 series solenoid valves series gas valves cover a wide range of pipe sizes from 3/8” up to and including 3”. V4295A,S valves are used with 110/120 Vac controllers V8295A,S are used with 24 Vac controllers. ELECTRICAL CONNECTIONS Supply voltages 24 V 50/60 Hz, 110/120 V 50/60 Hz. Electrical enclosure according to NEMA1. The V4295/8295 series solenoid valves are suitable for the control of gaseous fluids in gas consuming appliances according to international standards. The V4295/8295 series solenoid valves cover a wide range of pipe sizes and have treaded connections from 3/8" up to and including 3". The V4295/8295 series solenoid valves The V4295 series solenoid valves have a maximum supply pressure of 5 psi. V8295 series solenoid valves have a maximum supply pressure of 2 psi. The V4295/8295 series solenoid valves have test points for inlet and outlet gas pressure on each side of the valve. The V4295/8295 series solenoid valves have an inlet screen for protecting the valve against ingress of dirt. FEATURES Solenoid valves for control of gas consuming appliances. Models available in normally closed models (A type) and normally open (S type) configurations. The V4295/8295A series solenoid valves (for safety shut off applications) have a spring loaded valve disc, closed when de--energized. The V4295/8295 S series solenoid valves (double block and bleed) have a spring loaded valve disc, opened when de--energized. Incorporating time proven design concepts assuring reliability. All V4295/8295 series solenoid valves have an internal screen. Sizes from 3/4" up to 3” have two 1/4" connections for inlet pressure at each side of the gas valve. Sizes from 3/8” &1/2” have two 1/8" connections for inlet pressure at each side of the gas valve. The V4295/8295 series solenoid valves have a wrench boss as well on inlet side as on outlet side for pipe fitting incorporated in the valve housing. The V4295/8295 series solenoid valves may be assembled on the pipe line with in plus or minus 90 degrees of the vertical axel. The V4295/8295 series solenoid valves have a field replaceable coil unit. (coil plus box) The V4295/8295 A & S series solenoid valves are equipped with or without a POC switch. TheV4295/8295 series solenoid valves have coils turnable over 360°. Connection box suitable for conduit wiring and terminal block on the circuit board EN2R9105 1602RA-NE 2 Honeywell MODEL CHART Table1: Models available Maximum Pressure Voltage/Frequency psi mbar Pipe size (inch) Thread type V4295A (N.C.) 110/120 Vac, 50/60 Hz 5.0 345 3/8, 1/2, 3/4, 1, 1-1/4, 1-1/2, 2, 2-1/2, 3 NPT V4295S (N.O.) 110/120 Vac, 50/60 Hz 2.0 140 3/4, 1, 1-1/4 NPT V8295A (N.C.) 24 Vac, 50/60 Hz 2.0 140 3/8, 1/2, 3/4, 1, 1-1/4, 1-1/2, 2 NPT V8295S (N.O.) 24 Vac, 50/60 Hz 2.0 140 3/4, 1, 1-1/4 NPT Model EN2R9105 1602RA-NE 3 Honeywell TECHNICAL SPECIFICATIONS Models V8295A types 3/8” – 2” pipe sizes: 2 psi V8295S types: 3/4" – 1 1/4” pipe sizes: 2 psi V4295A types 3/8” – 3” pipe sizes: 5 psi V4295S types: 3/4" – 1 1/4” pipe sizes: 2 psi Pipe Connections Inlet and outlet 3/8" up to 2.5" NPT internal parallel pipe thread according ASME/ANSI B1.20.1. Torsion and bending stress Pipe connections meet ANSI Z21.21, sections 2.3.2 and 2.3.3. Ambient temperature rating -5 °F ... 145 °F (-15 °C ... 63 °C) Maximum fluid temperature rating -5 °F ... 145 °F (-15 °C ... 63 °C) Supply voltage 24 V, 50/60 Hz 1)* 110/120 V, 50/60 Hz The applicable voltage is led to the solenoid coil via a rectified circuit. 1)*: only for 3/8” up to 2” Dimensions See page 8 Electrical connection Wiring on terminal block on circuit. Box suitable for conduit wring. Coil insulation solenoid valves Insulation material according class F Enclosure NEMA 1 Capacity See page 7 Maximum operating pressure Inlet V4295 V8295 Maximum operating pressure (psi) 5 2 EN2R9105 1602RA-NE 4 Honeywell POWER CONSUMPTION (A) Model number Vx295 Vx295 Vx295 Vx295 Vx295 Vx295 Vx295 Vx295 Vx295 24Volt, 50/60Hz nominal 3/8" 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 24 Volt, 50/60Hz 110% of nominal t.b.d t.b.d t.b.d t.b.d 1.93 1.93 2.50 t.b.d t.b.d t.b.d t.b.d t.b.d. t.b.d 1.75 1.75 2.27 t.b.d t.b.d 110 Volt, 50/60Hz nominal 110 Volt, 50/60Hz 110% of nominal t.b.d t.b.d 0.21 0.21 0.37 0.37 0.50 t.b.d t.b.d t.b.d t.b.d 0.19 0.19 0.34 0.34 0.46 t.b.d t.b.d POWER CONSUMPTION Version S – 2 psi Model 24Volt, 24 Volt, 24 Volt number 50/60Hz 50/60Hz (dc), nominal 110% of nominala) nominal (b) 24 Volt (dc), 110% of nominal 110 Volt, 50/60Hz nominal Vx295 21 14 16 19 17 110 Volt, 50/60Hz 110% of nominal 17 120 Volt, 50/60Hz nominal 120 Volt, 50/60Hz nominal t.b.d t.b.d 0.21 0.21 0.37 0.37 0.50 t.b.d t.b.d 120 Volt, 50/60Hz 110% of nominal t.b.d t.b.d 0.23 0.23 0.41 0.41 0.55 t.b.d t.b.d 120 Volt, 50/60Hz 110% of nominal EN2R9105 1602RA-NE 5 Honeywell PERFORMANCE CHARACTERISTICS Value size 3/8" 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" Test pressure 1 PSI (mbar) 0.09 (6) 0.09 (6) 0.09 (6) 0.09 (6) 0.09 (6) 0.09 (6) 0.09 (6) 0.09 (6) 0.09 (6) Test pressure 2 PSI (mbar) 7.5 (540) 7.5 (540) 7.5 (540) 7.5 (540) 3 (210) (24V) or 7.5 (540) 3 (210) (24V) or 7.5 (540) 3 (210) (24V) or 7.5 (540) 7.5 (540) 7.5 (540) Maximum allowable leakage rate Internal leakage (cm3/h) 40 40 40 60 60 60 60 60 60 External leakage (cm3/h) 40 40 40 60 60 60 60 60 60 Opening time Less than 1 second Closing time Less than 1 second Maximum working cycles/minute S versions: 20 3/8”– 1” 20 1 1/4” – 3” 1 Duty cycle The Coils are suitable for permanent energization. Operational voltage range The gas valve will function satisfactory between 85% and 110% of the rated voltage. Rated voltage: 24 V, 50/60 Hz 110/120 V, 50/60 Hz EN2R9105 1602RA-NE 6 Honeywell CAPACITY: Table 2. Capacity in CFH at Pressure Drop of 1-Inch Water Column sp. gr. = 0.64 (for pressure drop 2.5mbar - air) Vx295A (N.C.) Vx295A (N.C.) [CFH ] m3/h Vx295S (N.O.) 5 psi Vx295S (N.O.) m3/h * V4295A only 3/8” 1/2” 3/4" 1“ 1 1/4” 1 1/2” 2” 2 1/2” * 3“ * 221 282 653 737 1,699 2,079 2,944 4,158 4,899 5 6.4 14.8 16.7 38.5 47.1 66.7 94.2 111 350 420 1,100 8 9.1 24.9 Imperial units Metric units EN2R9105 1602RA-NE 7 Honeywell DIMENSIONS Fig. 3 dimensions Table 4. Normally Closed (See Fig. 3). Pipe size 3/8 inch NPT 1/2 inch NPT 3/4 inch NPT 1 inch NPT 1-1/4 in. NPT 1-1/2 in. NPT 2 inch NPT 2-1/2 in. NPT 3 inch NPT A (inch) 2-27/32 2-77/32 3-13/32 3-13/32 5-7/8 5-7/8 6-11/16 9-1/2 9-1/2 B (inch) C (inch) 4-3/4 4-3/4 6-19/32 6-19/32 8-9/16 8-9/16 9-3/16 12-3/4 12-3/4 D (inch) 2-5/32 2-5/32 2-15/32 2-15/32 3-11/32 3-11/32 3-3/4 5-1/8 5-1/8 E (inch) (both sides) 3-7/8 3-7/8 4-7/32 4-7/32 5-3/32 5-3/32 5-1/2 6-7/8 6-7/8 2-1/16 2-1/16 2-23/32 2-23/32 4-11/32 4-11/32 5-5/16 7-7/8 7-7/8 Weight (lbs) 2.5 2.5 4.0 4.5 12.8 12.8 14.0 28.5 31.0 Table 5. Normally Opened (See Fig. 4). Pipe size 3/4 inch NPT 1 inch NPT 1-1/4 in. NPT A (inch) 3-13/32 3-13/32 5-7/8 B (inch) 5-25/32 5-25/32 8-3/4 C (inch) 2-5/32 2-15/32 3-11/32 D (inch) 3-7/8 4-7/32 5-3/32 E (inch) (both sides) 2-23/32 2-23/32 4-11/32 Weight (lbs) 4.0 4.5 12.8 EN2R9105 1602RA-NE 8 Honeywell INSTALLATION When installing this product... 1. 2. 3. 4. Read this instructions carefully. Failure to follow them could damage the product or cause a hazardous condition. Check the rating given in the instructions and on the product to make sure the product is suitable for your application. Installer must be a trained, experienced, flame safeguard control technician. After installation is complete, check out product operation as provided in these instructions CAUTION 1. 2. 3. Turn off gas supply before starting installation. Disconnect power supply before beginning installation to prevent electrical shock and equipment damage. Do not remove seal over valve inlet or outlet until ready to connect piping. Prepare piping and install valve (Fig. 5) 1. 2. 3. 4. 5. 6. Fig.5. Mounting positions Use new, properly reamed pipe which is free from chips. Do not thread pipe too far. Apply good quality pipe dope resistant to the action of LP gas, putting a moderate amount on the male threads only. If pipe dope lodges on the valve seat, it will prevent proper closure. Install valve in a horizontal pipe line, (refer to Fig. 5 for mounting position) with the gas flow matching the direction indicated by the arrow on the casting. Apply a parallel jaw wrench only to the wrench flats of the valve body, next to the pipe being inserted. A wrench applied to the valve body itself or to the end farthest from the pipe being inserted may distort the casting, resulting in malfunction on the gas valve. The gas flow must be in the same direction as the arrow on the body of the valve. 7. 8. Make electrical connections as illustrated in the wiring diagrams; see Fig. 6. Turn on main gas and with a soap solution, check valve installation for leaks. WIRING 1. 2. 3. 4. 5. WARNING If the flow is not in the same direction of arrow, valve may not shut off. 6. 7. Disconnect power supply before making wiring connections to prevent electrical shock and equipment dam- age. Installation and wiring must be in conformance with National Electrical Code ANSI/NFPA 70, local codes and regulations. For supply connections use moisture-resistance No. 14 wire suitable for at least 194ºF (90ºC). For high temperature installations, use moisture resistant No. 14 wire selected for a temperature rating above the maximum operating temperature. Check the power supply circuit. The voltage and frequency must match those of the valve. Refer to Fig. 6 for typical V4295A,S field wiring with RM7800 (typical) Primary Safety Control. Refer to Fig. 7 for typical V8295A,S field wiring with Primary Safety Control. Follow the burner manufacturer’s wiring diagram, when provided. Refer to burner controller (primary safety control) wiring diagram for specific wiring terminal designations. Make wiring connections at the electrical terminations provided in the wiring compartment of the valve. EN2R9105 1602RA-NE 9 Honeywell CHECKOUT AND TROUBLESHOOTING WARNING Do not allow fuel to accumulate in the combustion chamber. If fuel is allowed to enter the chamber for longer than a few seconds without igniting, an explosive mixture could result. CAUTION 1. 2. Do not put the system into service until you have satisfactorily completed all applicable tests described in the Checkout section of the instructions for the flame safeguard control and any other test required by the burner manufacturer. Close all manual fuel shut off valves as soon as trouble occurs. CHECKOUT 1. Fig.6. Wiring V4295A, S. 2. 3. 4. Check the performance of the valve by measuring the pressures at the inlet and outlet pressure taps. The pressure reading at the outlet tap may be slightly higher than a downstream measurement due to dynamic gas flow effects. The measurement at the outlet tap is for reference only. Shut off gas supply to valve and make sure valve is closed when setting up pressure measuring equipment. Set thermostat or controller to energize the valve and check final outlet pressure. Start the system and observe its operation through at least one complete cycle to ensure the valve functions as described in the section “Operation” on page 6. Valve Leak Test (Fig.8) This is a test for checking the closure tightness of the gas safety shutoff valve. It should be performed only by trained, experienced flame safeguard control technicians during the initial startup of the burner system or whenever the valve is replaced (see Service Information section). It is recommended that this test also be included in the scheduled inspection and maintenance procedures. Fig.7. Wiring V8295A, S. OPERATION 1. De-energize the control system to make sure no power goes to the valve (C, Fig. 8). 2. Close the upstream manual gas cock (A). 3. Make sure the manual test petcock (F) is closed in the leak test tap assembly (D). 4. Remove the leak test tap plug and connect the test apparatus to the leak test tap (D). 5. Close the downstream manual gas cock (E). 6. Open the upstream manual gas cock (A). 7. Run the V4/8295A Valve to its open position (through the safety system); then immediately de-energize the system to close the V4/8295A Valve. 8. Immerse a 1/4 inch (6 mm) tube vertically 1/2 inch (13 mm) into a jar of water. 9. Slowly open the manual test petcock (F). 10. When the rate of bubbles coming through the water stabilizes, count the number of bubbles appearing during a ten-second period. Each bubble appearing represents a flow rate of 0.001 cfh. The V4295A and V8295A Normally Closed series gas valves are Class B fail safe shut off valves. The valve is opened by energizing the direct ON/OFF operator. The direct ON/OFF operator consists of a coil and stop sleeve assembly. Inside the stop sleeve assembly is a plunger which is able to move up and down, thus opening or closing the valve. The plunger glides on two anti-friction bearings. A strainer, made of AISI 303 stainless steel, is incorporated into the valve. EN2R9105 1602RA-NE 10 Honeywell IMPORTANT To meet U.S. requirements, make sure leakage does not exceed the rates in Table 6. Table 6. Valve allowable leakage rate. V4295A/V8295A Pipe Size (in) Medium 3/8” - 1/2" 0.64 gas Allowable Maximum Number of Bubbles in 10 Minimum Number of Seconds for Leakage SCCH* Seconds 10 Bubbles 294 7 13 3/4" - 1” 1.57 LP 0.64 gas 188 301 4 7 20.4 12.7 1.57 LP 192 5 19.9 1 1/4" - 1 1/2" 0.64 gas 532 13 7.2 1.57 LP 341 8 11.2 2” 0.64 gas 578 15 6.6 1.57 LP 370 9 10.3 2 1/2" 0.64 gas 752 19 5.1 1.57 LP 481 12 8 3” 0.64 gas 925 24 4.1 1.57 LP 592 15 6.5 * Based on air at standard conditions, test pressures provided by ANSI Z21.21. Section 2.42 and a maximum of 235 cc/h per inch of seal-off diameter (not pipe size). 2. 3. 4. 5. 6. 7. 8. Close the manual test petcock (F), remove the test apparatus, and close the leak test tap (D). Make sure the downstream manual gas cock (E) is Open the upstream manual gas cock (A) and energize the V4/8295A Valve through the safety system. Test with rich soap and water solution to make sure there is no leak at the leak test tap (D) or any pipe adapter/valve mating surfaces. De-energize the V4/8295A Valve (C). Open the downstream manual gas cock (E). Restore the system to normal operation. If two safety shutoff valves are used, check each valve separately for closure tightness. TROUBLESHOOTING CAUTION Use utmost care during troubleshooting. Line voltage is present at the actuator for V4295A,S and present in controller circuits. Low voltage (24 Vac) is present at the actuator for V8295A,S and present in controller circuits. IMPORTANT Do not assume that the valve must be replaced until all other sources of trouble have been eliminated NOTE: For international leak test requirements, contact the appropriate approval agency. 1. After the Test 1. If the valve will not open when the thermostat or controller is calling for heat: a. Check that there is voltage at the valve actuator lead wires or terminal block. Close the upstream manual gas cock (A). EN2R9105 1602RA-NE 11 Honeywell CAUTION SERVICE INFORMATION Line voltage (120 Vac) should be present when the primary safety control energizes the V4295A,S valve actuator. 24 Vac should be present when the primary safety control energizes the V8295A,S valve actuator. CAUTION 1. Only qualified service technicians should attempt to service or repair flame safeguard control and burner. 2. Line voltage is present in the electrical circuits to the valve. Open the master switch before replacing the valve. b. 2. If there is no voltage at the actuator, first ensure line voltage power is connected to the master switch, the master switch is closed and overload protection (circuit breaker, fuse or similar device) has not opened the power line. c. If there is still no voltage at the actuator, make sure all appropriate contacts in the thermostat (or controller), limit(s) and flame safeguard control are closed. If one or more are open, determine the cause(s) and correct condition(s) before proceeding. d. If there is proper voltage at the actuator but the valve still does not open, first check that the gas pressure is normal. e. If the valve still does not open, replace valve. If the valve will not close when one or more of the appropriate contacts in the thermostat (or controller), limit(s) or flame safeguard control is open: a. Make sure that the gas flow is in the direction of the arrow on the valve body. b. Make sure the valve actuator is wired in the correct circuit. Open the master switch to remove power from the actuator. If the valve closes now, the actuator may not be wired properly. c. Look for a short in the electrical circuit. CAUTION 1. Label all wires prior to disconnection when servicing valves. Wiring errors can cause improper and dangerous operation. 2. Verify proper operation after servicing. Scheduled inspection and maintenance For periodic inspection and maintenance, set up a schedule and follow it. Include the burner, valves and all other burner controls. It is recommended that “Valve Leak Test (Fig. 8)” on page 6 be included in the schedule. Refer to the flame safeguard control instructions for more information. EN2R9105 1602RA-NE 12 Honeywell INSTRUCTIONS ELECTRICAL CONNECTIONS CONNECTION INSTRUCTIONS WITH CONDUIT On each side of the connection box there are break out area’s. See Fig 8. After removing the central part of one of these break outs providing a 27/32” hole where the conduit can be fitted. Fig 10 After connecting wires (L, N & PE) to dedicated connectors on connector block, the connection needs to be closed by mounting the front cover. Before placing the cover, please check the correct position of seal as shown in Fig 11. The cover can only be mounted in one orientation. This is shown in Fig 12. Specified torque for cover screw: 0.5 Nm. Fig 8 After removing the nut from the conduit, the conduit can be placed in the break out. The nut needs to be turned onto the conduit inside the box. The nut needs to be tightened as shown in Fig 9. Specified torque for the nut: 4 Nm. Mounted conduit shown in Fig 10. Specified torque conduit: 3 Nm. Fig 11 Fig 9 Fig 12 EN2R9105 1602RA-NE 13 Honeywell CONSTRUCTION AND WORKING PRINCIPLES The V4295/V8295 Normally Closed series gas valves are fail safe shut-off valves. The valve is opened by energizing the direct ON/OFF operator. The direct ON/OFF operator consists of a coil and stop sleeve assembly. Inside the top sleeve assembly is a plunger which is able to move up and down and thus opening or closing the valve. A strainer made out of steel AISI 303 is incorporated in the gas valve. Valve closing spring is made out of steel AISI 302. Seals and gaskets are manufactured out of hydrocarbon resistant NBR. The plunger is gliding on two antifriction bearings. Flow regulation is done by adjustable plunger stroke. EN2R9105 1602RA-NE 14 Honeywell STANDARDS AND APPROVALS STANDARDS APPROVALS Underwriters Laboratories, Inc., File Number MH xxxxx, Guide number XXXX AGA and CGA, File Number CXXXXXXX Complies with standard ANSI Z21.21- CGA6.5 Automatic Valves for gas appliances and automatic safety shut-off gas valves (revised edition of the former ANSI Z21.21, CAN/CGA6.5-M89, CAN/CGA-3.9-M87) Factory Mutual: V4/8295A: to be tested V4/8295S: to be tested CSD-1 to be tested EN2R9105 1602RA-NE 15 Honeywell REPLACEMENT PARTS AND ACCESSORIES WARNING Take care that only qualified persons carry out the installation of parts, accessories, and add on components. Follow the installation instructions included in the package. Check that the selected part, accessory or add on component is the correct one for the application in question. Specification of data is given in the instruction leaflet in the package .Replace the old gaskets with the new ones supplied in the package and check for leakage when the supply is switched on again. After installation and/or replacement has been completed, a gas leak test must be carried out. Also check the gas valve for satisfactory operation after fitting accessories. REPLACEMENT CONNECTION BOXES IMPORTANT When ordering replacement connection box include the complete valve O.S. number, in order to provide the correct box. Versions with PG connection IP65 Size / A types 3/8” - 1/2" 3/4” - 1” 1 1/4” - 11/2” 2” 2 1/2” - 3” Ordering nr.: BB0xxxxx BB0xxxxx BB0xxxxx BB0xxxxx BB0xxxxx Size / S types 3/8” - 1/2” 3/4” - 1” 1 1/4” - 11/2” 2” 2 1/2” - 3” Ordering nr.: BB0xxxxx BB0xxxxx BB0xxxxx BB0xxxxx BB0xxxxx 16 EN2R9105 1601RA-NE Honeywell Honeywell Manufactured for and on behalf of the Environmental and Combustion Controls Division of Honeywell Technologies Sàrl, Z.A. La Pièce 16, 1180 Rolle, Switzerland or its Authorized Representative: Automation and Control Solutions Combustion Controls EMEA Honeywell BV Phileas Foggstraat 7 7821 AJ Emmen The Netherlands Tel.: +31 (-) 591 695 911 Fax: +31 (-) 591 695 200 http://ecc.emea.honeywell.com/default.htm EN2R9105 1602RA-NE 17