Install Instructions

60-0074—4 G.R. Rev. 1-01 www.honeywell.com
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Home and Building Control Home and Building Control
Honeywell Honeywell Limited-Honeywell Limitée
1985 Douglas Drive North 35 Dynamic Drive
Golden Valley, MN 55422 Scarborough, Ontario
M1V 4Z9
CHECKOUT
WARNING
Explosion Hazard.
Can cause serious injury, death or property
damage.
Both bonnet seal and seat leak checks must be
performed after installation.
Bonnet Check
After the bonnet assembly is reinstalled, turn on the gas
at the manual valve and check for gas leakage around
the bonnet seal. Paint the seal area with a rich soap and
water solution. Bubbles indicate a gas leak. If a leak is
detected, check to see that the bonnet screws are tight. If
necessary, turn off the gas again and remove the bonnet
to be sure the seals are properly seated.
Seat Leak Check
Instructions for testing tightness closure of gas safety
shutoff valves on burner startup (by qualified personnel).
See Fig. 4.
1.
De-energize control system to assure no power to
the safety shutoff valve. (
C
)
2.
Close upstream manual gas cock. (
A
)
3.
Make sure manual test petcock (
F
) is closed in leak
test tap assembly. (
D
)
4.
Remove leak test tap plug and connect test
apparatus to leak test tap (
D
) as shown in Fig. 4.
5.
Close downstream manual gas cock. (
E
)
6.
Open upstream manual gas cock. (
A
)
7.
Program safety shutoff valve (
C
) to fully open
position (through safety system); then immediately
de-energize to seat valve operationally.
8.
Immerse 1/4-inch tube vertically 1/2 inch into jar of
water as shown in Fig. 4.
9.
Slowly open test petcock. (
D
)
10.
When rate of bubbles coming through water
stabilizes, count the number of bubbles appearing
during a 10 second period. Each bubble appearing
during a 10-second period represents a flow rate of
approximately 0.001 cf/h. If two safety shutoff
valves are used, check each valve for closure
tightness. To meet U.S. requirements, leakage
must not exceed the values given below:
Table 1. Valve allowable leakage rate.
a
Based on air at standard conditions, test pressures
provided by ANSI Z21.21, Section 24.2 and a maximum
of 235 cc/hr per inch of seal-off diameter. Seal-off
diameter is not to be confused with pipe size.
11.
Shut upstream manual gas cock. (
A
)
12.
Close test petcock (
F
), remove test apparatus, and
replace leak test tap plug. (
D
)
13.
Open upstream manual gas cock. (
A
)
14.
Open downstream manual gas cock. (
E
)
15.
Restore system to normal operation and observe
through one complete cycle to assure proper
operation. If two safety shutoff valves are used,
check each valve for closure and tightness.
Fig. 4. Valve Leak Test.
V5055/V5097 Pipe
Size (in.)
Allowable
Leakage (cc/hr)
a
Number of
Bubbles per ten
seconds
3/4, 1, 1-1/4, 1-1/2 458 16
2, 2-1/2, 3 752 26
4 1003 35
M9547E
GAS
SUPPLY
UPSTREAM
MANUAL
GAS COCK
DOWNSTREAM
MANUAL
GAS COCK
BURNER
D
LEAK
TEST
TAP
ABC E
F
PRV
MANUAL
TEST
PETCOCK
SSOV
1/4 IN. (6 MM)
FLEXIBLE
TUBING
1/4 IN. (6 MM)
ALUMINUM OR
COPPER PILOT
TUBING
JAR OR GLASS
WITH WATER
CUT AT
45 DEGREE
ANGLE
CAN ALSO BE A PERMANENT PETCOCK.
PRV = PRESSURE REGULATING VALVE.
SSOV = SAFETY SHUTOFF VALVE.
ONLY USE ONE OF THE DOWNSTREAM TAPS ON THE SS0V.
1
2
3
4
4
2 3
1
1
2
(13 MM)