Page 1
V48A,F,J; V88A,J
Diaphragm Gas Valves
The V48 and V88 are solenoid-operated diaphragm valves suitable for LP (Liquefied Petroleum), natural, and manufactured gases. They are
normally used on atmospheric boilers, commercial
water heaters, and rooftop heaters.
■ Line voltage, 2-wire thermostat or controller used
with a V48; V88 used with 24V thermostat.
■ Valves provide slow opening and fast closing.
■ Two second maximum closing time for 2 through
3 in. valves.
■ One second maximum closing time for 3/4 through
1-1/2 in. valves.
■ V48J, V88J rated for 150° F ambient temperature.
■ V48F rated for 5 psi (lb. per sq in.) [34.5 kPa].
V48A and V88A rated for either 1/2 or 1 psi [3.4 or
6.9 kPa], depending on model. V48J and V88J rated
for 1 psi [6.9 kPa].
■ One model for natural and LP gases.
■ Wide range of sizes and capacities.
■ Firm closing; diaphragm is both weight and spring
loaded.
■ Valve closes on power failure; recommended for
final shutoff service.
■ Adjustable or fixed bleed orifices available for in-
stallation by OEM.
■ Valve position indicator on 1-1/4 in. V48A2227 and
2 in. V48F1103 Valves.
CONTENTS
Specifications............................................... 2
Ordering Information ..................................2
Installation................................................... 5
Operation ..................................................... 8
Checkout and Troubleshooting ................... 9
Service Information ................................... 10
F.P. • Rev. 9-94 • ©Honeywell Inc. 1994 • Form Number 60-2080—8
1 60-2080—8
Page 2
V48A,F,J; V88A,J
SPECIFICATIONS • ORDERING INFORMATION
Specifications
MODELS:
V48A (120 Vac) or V88A (24 Vac) solenoid operated
diaphragm valves for 1/2 or 1 psi [3.4 or 6.9 kPa]
maximum operating pressure.
V48F (120 Vac) solenoid operated diaphragm valve for
5 psi [34.5 kPa] maximum operating pressure.
V48J (120 Vac) or V88J (24 Vac) solenoid operated
diaphragm valves for 1 psi [6.9 kPa] operating pressure and 150° F maximum ambient temperature.
TYPE OF GAS: Suitable for liquefied petroleum (LP), natu-
ral, manufactured, and sulfur-bearing gases.
VALVE CAPACITY: See table in Fig. 2.
VALVE PATTERN: Straight-through, nonoffset.
VALVE BODY MATERIAL: Die-cast aluminum.
PILOT TAPPING (see Table 1 for thread type): 3/4 through
1-1/2 inch valves: 1/8-27 NPT or 1/8-28 BSP.PI.
2 through 3 inch valves: 1/4-18 NPT or 1/4-19 BSP.PI.
BLEED TAPPING (see Table 1 for thread type): 1/8-
27 NPT or 1/8-28 BSP.PI.
VALVE OPENING TIME: Five seconds maximum at 2 oz/
in.2 [0.86 kPa] pressure. Adjustable bleed valve assem-
bly or fixed bleed orifices available for longer opening
time (NPT threads only; see Accessories).
VALVE CLOSING TIME (on power failure; measured at
2 oz/in.2 [0.86 kPa] pressure): 2 seconds maximum for 2
through 3 inch valves; 1 second maximum for 3/4 through
1-1/2 inch valves.
MAXIMUM OPERATING PRESSURE: See Table 1.
POWER CONSUMPTION (maximum): 9 watts or 15 VA.
AMBIENT TEMPERATURE RATING:
V48A,F and V88A: 32° F to 125° F [0° C to 52° C].
V48J and V88J: 32° F to 150° F [0° C to 65° C].
MAXIMUM FLUID TEMPERATURE:
V48A,F; V88A: 125° F.
V48J; V88J: 150° F.
THERMOSTAT HEAT ANTICIPATOR SETTING: For
60 Hz V88, set at 0.6A.
DIMENSIONS: See Fig. 1.
WEIGHT:
Pipe Size (in.) lb. kg
3/4 2-1/2 1.13
1 3 1.36
1-1/4 3-1/2 1.59
1-1/2 4 1.81
2 9 4.08
2-1/2 8-1/2 3.86
3 9-1/2 4.31
APPROVALS: (60 Hz models only):
Underwriters Laboratories Inc. Listed: File No. MH1639;
Guide No. YIOZ.
American Gas Association Design Certified: Report
No. 21-7B.
Canadian Gas Association Certified: For use with natu-
ral, manufactured, and mixed gases (60 Hz models
only).
NOTE: All models rated at 50 Hz and all models with
BSP.PI threads are not AGA Design Certified.
OPTIONAL FEATURE: Valve position indicator is avail-
able on 1-1/4 in. V48A2227 and 2 in. V48F1103.
REPLACEMENT COIL ASSEMBLIESa:
116930: 24V, 60 Hz V88A
116931: 120V, 60 Hz V48A.
116932: 220V, 50 Hz V48A
116932: 240V, 60 Hz V48A
118888: 24V, 60 Hz V88J
139937: 120V, 60 Hz V48J
a
These V48/V88 bonnet assemblies and solenoid operators
are not compatible with old style valve bodies.
Ordering Information
When purchasing replacement and modernization products from your TRADELINE® wholesaler or your distributor, refer to the
TRADELINE
1. Order number. 5. Optional valve position indicator (1-1/4 inch and larger valves only),
2. Pipe size. if desired.
3. Operating pressure rating. 6. Replacement coil assembly, if desired.
4. Transformer for V88. 7. Accessories, if desired.
If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:
1. Your local Honeywell Home and Building Control Sales Office (check white pages of phone directory).
2. Home and Building Control Customer Logistics
60-2080—8 2
®
catalog or price sheets for complete ordering number, or specify—
Honeywell Inc., 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386 (612) 951-1000.
In Canada—Honeywell Limited/Honeywell Limitée, 740 Ellesmere Road, Scarborough, Ontario M1P 2V9. International Sales
Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico,
Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
Page 3
V48A,F,J; V88A,J
SPECIFICATIONS
TABLE 1—MODELS AVAILABLE.
Model Voltage and Frequency (Psi) (Kpa) Pipe Size (in.)
Maximum Operating Pressure
Thread
Type
V48A 100V, 50 Hz 1/2 3.4 1, 1-1/4, 1-1/2 BSP.PI
1 6.9 2
120V, 60 Hz 1/2 3.4 3/4, 1, 1-1/4, 1-1/2 NPT
1 6.9 1, 1-1/4, 1-1/2, 2, 2-1/2, 3
220V, 50 Hz 1 6.9 1, 1-1/4, 1-1/2, 2, 3 BSP.PI
240V, 50 Hz 1 6.9 2 NPT
V48F 120V, 60 Hz 5 34.5 2 NPT
V48J 120V, 60 Hz
1 6.9 3/4, 1, 1-1/4, 1-1/2, 2 NPT
110V, 50 Hz
V88A 24V,60 Hz 1/2 3.4 3/4, 1, 1-1/4, 1-1/2 NPT
1 6.9 3/4, 1, 1-1/4, 1-1/2, 2, 2-1/2, 3
V88J 24V, 60 Hz 1 6.9 1, 1-1/4 NPT
a
A valve position indicator is on 1-1/4 in. V48A2227 and 2 in. V48F1103 Valves. BSP.PI—British Standard Parallel Internal
Threads; NPT—American Standard Taper Pipe Threads.
a
Fig. 1—Mounting dimensions of V48A,F,J and V88A,J Diaphragm Gas Valves.
APPROXIMATE DIMENSIONS
4-5/8
117.5
127.0
149.2
149.2
241.3
241.3
241.3
3-1/2
3-11/16
5-5/16
5-5/16
8-3/8
8-3/8
8-3/8
A
5
5-7/8
5-7/8
9-1/2
9-1/2
9-1/2
88.9
93.7
134.9
134.9
212.7
212.7
212.7
1-5/8
2-1/16
2-3/8
2-3/8
3-9/16
3-9/16
3-9/16
41.3
3-13/16
52.4
4-5/16
60.3
5-5/16
60.3
5-5/16
90.5
5-5/16
90.5
9-5/16
90.5
9-5/16
11
3
[93.7]
16
2
E
VALVE
SIZE
(IN.)
3/4
1-1/4
1-1/2
2-1/2
1
2
3
ABCDEF
IN. MM IN. MM IN. MM IN. MM IN. MM IN. MM
4-11/16
119.1
3/4
C
1-1/4
1-1/4
2-1/4
2-1/4
2-1/4
[46]
19.1
1
25.4
31.8
31.8
57.2
57.2
57.2
5-1/16
5-9/16
5-9/16
6-15/16
6-15/16
6-15/16
128.6
141.3
141.3
176.2
176.2
176.2
13
1
16
1
96.8
109.5
134.9
134.9
236.5
236.5
236.5
B
D
1
BLEED TAPPING: 1/8-27 NPT, OR 1/8-28 BSP. PL.
2
PILOT TAPING (2): 1/8-27 NPT FOR 3/4 THROUGH 1-1/2 IN. SIZES, 1/4-18 NPT FOR 2 THROUGH 3 IN. SIZES;
OR 1/8-28 BSP. PL FOR 1 THROUGH 1-1/2 IN. SIZES, 1/4-19 BSP.PL FOR 2 THROUGH 3 IN SIZES.
F
3 60-2080—8
M8487
Page 4
V48A,F,J; V88A,J
SPECIFICATIONS
Valve Size (in.) No. Orifice
11 2 3
1-1/4 1 5 6
1-1/2 1 5 6
2 4 15 32
2-1/2 4 23 37
3 5 24 37
a
Time to reach 80% gas flow at fully open position. Inlet pressure; 4.2 in. wc [1.05 kPa] for 1 to 2 in. valves; 5 in. wc [1.25 kPa]
for 2-1/2 and 3 in. valves. Pressure drop across valves at fully open position. 0.2 in. wc [0.05 kPa] for 1 to 2 in. valves; 1 in. wc
[0.25 kPa] for 2-1/2 and 3 in. valves.
TABLE 2—EXTENDING VALVE OPENING TIME
Valve Opening Time (sec)
Orifice no. 122160,
0.018 in. [0.46 mm]
a
BY ADDING A BLEED ORIFICE.
Orifice no. 124674,
0.011 in. [0.28 mm]
ACCESSORIES:
Transformer AT72D: (40 VA) for all V88 models.
126590 Adjustable Bleed Valve Assembly: Consists of
adjustable bleed valve with sleeve and compression
nut for connecting to 1/4 in. tubing; see Fig. 8.
(Not available for valves with BSP.PI. threads.)
Bleed Orifice: Fixed (see Table 2 for appropriate size):
124674 Orifice: 0.011 in. [0.28 mm] diameter.
122160 Orifice: 0.018 in. [0.46 mm] diameter.
126070 Orifice Tool: Required for field mounting a
bleed orifice (in valves with NPT threads only).
GAS VALVE SIZING
1. Check the burner nameplate for (a) the type of gas
used, and (b) the gas flow capacity. The capacity will be
listed in Btu/h (Btu per hour) or in cf/h (cubic feet per
hour).
2. Call the gas utility for information on (a) the specific
gravity (sp gr) and (b) Btu per cubic feet (Btu/cu ft) for type
of gas used.
3. Find the capacity in cf/h. If the capacity is listed in
Btu/h, convert to cf/h by the following formula.
Capacity in cf/h = Btu/h (from burner nameplate)
Btu/cu ft (from gas utility)
4. For gases with specific gravities other than 0.64,
multiply the burner cf/h by the conversion factor in Table 3.
5. Use the corrected capacity in cf/h when determining
the gas valve size in Fig. 2.
6. Determine the maximum pressure drop across the
valve, and draw a horizontal line at this pressure in Fig. 2.
TABLE 3—CONVERSION FACTORS.
Type of
Gas
Average Specific
Gravity
Multiply
cf/h by
Manufactured 0.60 1.033
Mixed 0.70 0.956
LP—Propane 1.53 0.647
LP—Butane 1.98 0.569
7. Draw a vertical line in Fig. 2 at the capacity (cf/h)
previously determined. Use the corrected capacity for a
gas with a specific gravity other than 0.64.
8. Use the valve size at the intersection of the horizontal
and vertical lines. If the intersection is between valve sizes,
use the next higher valve size to the right.
TO SIZE TWO IDENTICAL VALVES PIPED
IN SERIES
1. Find the cf/h for the type of gas used.
2. Consider both valves as one unit. Determine the total
maximum pressure drop across the unit.
3. Find the pressure drop across the first valve by assuming it to be 45 percent of the total pressure drop.
4. Find the valve size from Fig. 2.
5. The second valve will be the same size as the first
valve.
60-2080—8 4
Page 5
Fig. 2—Pressure drop vs. capacity chart for sizing gas valves.
V48A,F,J; V88A,J
SPECIFICATIONS • INSTALLATION
[2.5] 10
9
[2.0] 8
7
[1.5] 6
5
[1.0] 4
[0.75] 3
2.5
[0.5] 2
1.5
[0.25] 1.0
0.9
[0.2] 0.8
0.7
[0.15] 0.6
0.5
PRESSURE DROP—INCHES W.C. [kPa]
[0.1] 0.4
A.G.A.RATING FOR
0.64 SP. GR. GAS AT
1 IN. PRESSURE DROP
VALVE SIZE CAPACITY
3/4 IN.
1 IN.
1-1/4 IN.
1-1/2 IN.
2 IN.
2-1/2 IN.
3 IN.
668 cf/h
1021 cf/h
2100 cf/h
2400 cf/h
4178 cf/h
5100 cf/h
5562 cf/h
PRESSURE DROP VS. CAPACITY
FOR 0.64 SP GR. GAS
1
3/4
3
2-1/2
2
1-1/2
1-1/4
[0.075] 0.3
0.25
[0.05] 0.2
0.15
[0.025] 0.1
1 1.5 2 2.5 3 4 5 6 7 8 9 10 1.5 2 2.5 3 4 5 6 7 8 9 10
MULTIPLY BY 100 MULTIPLY BY 1000
CAPACITY IN CUBIC FEET PER HOUR (cf/h)
FOR GAS WITH SPECIFIC GRAVITY OF 0.64
WHEN INSTALLING THIS PRODUCT…
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a hazardous
condition.
2. Check the ratings given in the instructions and on
the product to make sure the product is suitable for your
application.
3
[1 cf/h = 0.0283 m
/hr]
3. Installer must be a trained, experienced, flame safe-
guard control technician.
4. After installation is complete, check out product
operation as provided in these instructions.
M8491
Installation
5 60-2080—8
Page 6
V48A,F,J; V88A,J
INSTALLATION
CAUTION
1. Turn off gas supply before starting installation.
2. Disconnect power supply before beginning installation to prevent electrical shock and equipment damage.
3. Do not remove seal over valve inlet or outlet
until ready to connect piping.
4. Do not bend tubing at the valve after the compression nut is tightened because this may
result in gas leakage at the connection.
5. Install valve in a horizontal pipe line in any
upright position with the gas flow in the direction indicated by the arrow on the casting.
3. Apply good quality pipe dope, putting a moderate
amount on the male threads only. If pipe dope lodges on the
valve seat, it will prevent proper closure. If using liquefied
petroleum (LP) gas, use pipe dope resistant to action of LP
gas.
4. Install valve in a horizontal pipe line in an upright
position with the gas flow in the direction indicated by the
arrow on the casting.
5. Apply a parallel jaw wrench only to the flat 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, causing a malfunction.
6. The gas flow MUST be in the same direction as the
arrow on the bottom of the valve body.
PREPARE PIPING AND INSTALL VALVE (FIG. 3)
1. Use new, properly reamed pipe free from chips.
2. Do not thread pipe too far. Valve distortion or mal-
function may result from excess pipe in valve.
Fig. 3—Preparing piping and installing valve.
EXCESS DOPE
MAY BLOCK
DISC OFF
VALVE
SEAT
LOOSE CHIPS
REAM PIPE,
BLOW OUT
CHIPS (THEY MAY
LODGE ON SEAT)
WRONG
TOO LONG,
DISTORTS VALVE
SEAT
WRONG
TOO LONG,
DISTORTS VALVE
SEAT
RIGHT
NORMAL FULL
THREAD
RIGHT
NORMAL FULL
THREAD
RIGHT
VISE GRIPS
END NEXT
TO PIPE
BEING
INSERTED
BLEED
GAS
TAPPING
2 CLEAN
THREADS,
MODERATE
AMOUNT
OF DOPE
PILOT GAS
TAPPING
WARNING
If flow is not in direction of the arrow, the valve
may not shut off.
WRONG
NEVER USE VALVE
AS A HANDLE
WRONG
WRENCH HERE
RIGHT
WRENCH
CORRECTLY
APPLIED
NEXT TO
PIPE BEING
INSERTED
STRAINS VALVE BODY
60-2080—8 6
M7299
Page 7
V48A,F,J; V88A,J
INSTALLATION
CONNECT PILOT AND BLEED GAS TUBING
(FIG. 4)
1. Square off and remove burrs from end of the tubing.
Bend tubing to the desired form for routing to the pilot
burner. Do not bend tubing at the valve after the compres-
sion nut is tightened because this may result in gas leakage
at the connection.
2. Unscrew brass compression fitting from pilot gas
tapping (Fig. 3). Slip the fitting over the tubing and slide out
of the way.
IMPORTANT: When replacing a valve, cut off old com-
pression fitting and replace with a new compression
fitting. Never use the old compression fitting because
it may not provide a tight gas seal.
3. Push tubing into the pilot gas tapping on the outlet
end of the valve until it bottoms. While holding tubing all
the way in, slide fitting into place and engage threads—turn
until finger tight. Then use wrench and tighten one turn
beyond finger tight.
4. Connect other end of tubing to pilot burner according
to pilot burner manufacturer’s instructions.
5. If required, connect the tubing to bleed gas tapping
(Fig. 3 and 4) as described in step 3. Connect other end of
bleed tubing to main burner or to outside atmosphere.
b. If a conduit is required, run the conduit through the
opening in the actuator housing, and run the external
wires through the conduit.
c. Using solderless connectors, connect the external
wires to the two 6 in. [152.4 mm] black leadwires
(from the coil).
d. Locate the connections inside the actuator housing.
e. Replace the housing cover, and tighten the cover
screw holding it to the actuator housing.
8. Recheck the wiring circuits before putting the valve
into service.
Fig. 5—Typical wiring diagram for V48.
VALVE ACTUATOR
(BLACK LEAD WIRES)
LINE VOLTAGE
THERMOSTAT OR
CONTROLLER
JUNCTION
BOX
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
LIMIT(S)
1
FLAME
SAFEGUARD
CONTROL
M8490
L2
L1
(HOT)
Fig. 4—Connecting tubing to pilot for bleed
gas tapping.
GAS VALVE
TUBING
GAS FLOW
SLEEVE CLINCHES AROUND TUBING
AS NUT IS TIGHTENED
COMPRESSION FITTING
M7300
WIRING
1. Disconnect the power supply before making wiring
connections to prevent electrical shock and equipment
damage.
2. All wiring must comply with applicable electrical
codes, ordinances, and regulations. Use NEC Class 1 (line
voltage) wiring.
3. For normal installations, use moisture-resistant No.
14 wire suitable for at least 167° F [75° C] if using a flame
safeguard primary control, or for at least 194° F [90° C] if
using a flame safeguard programming control.
4. For high temperature installation, use moisture-re-
sistant No. 14 wire selected for a temperature rating above
the maximum operating temperature.
5. Check the power supply circuit. The voltage and
frequency must match those of the valve.
6. Refer to Fig. 5 or 6 for typical field wiring connections. Follow the burner manufacturer’s wiring diagram if
provided.
7. Make wiring connections inside the actuator housing
(Fig. 7):
a. Loosen the cover screw in the front of the actuator
housing, and remove the housing cover.
Fig. 6—Typical wiring diagram for V88.
VALVE ACTUATOR
(BLACK LEAD WIRES)
LIMIT(S)
1
L1
(HOT)
L2
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
TRANSFORMER
24 VOLT
THERMOSTAT
FLAME
SAFEGUARD
CONTROL
Fig. 7—Making wiring connections.
6 IN. [152.4 MM] INTERNAL
BLACK LEADWIRES
(FROM COIL)
SOLDERLESS
CONNECTORS
GROUNDING
SCREW
ACTUATOR
HOUSING
OPENING IN
ACTUATOR
HOUSING
CONDUIT
(IF REQUIRED)
M7302
COVER
SCREW
EXTERNAL
WIRES
M8488
7 60-2080—8
Page 8
V48A,F,J; V88A,J
INSTALLATION • OPERATION
INSTALLATION OF AN OPTIONAL ADJUSTABLE
BLEED VALVE (FIG. 8)
NOTE: This device is not available for valves with BSP.PI
threads.
Screw the 126590 Adjustable Bleed Valve into the
tapping marked BLEED. Be sure to screw the end with the
1/8-NPT threads into the BLEED tapping. Complete the
bleed line connection. Then alternately energize and deenergize the valve actuator, and adjust the screw on the
bleed valve for the desired valve opening time.
Fig. 8—Installing optional 126590 adjustable
bleed valve.
1
126590 ADJUSTABLE BLEED VALVE
COMPRESSION NUT
1/4 INCH
TUBING
7/16-24 UNS
SLEEVE
BLEED TAPPING
INSTALLATION OF AN OPTIONAL BLEED
ORIFICE (FIG. 9)
NOTE: The orifice tool cannot be used on valves with
BSP.PI threads.
Press the selected bleed orifice (see Table 2) over the
slotted end of the 126070 Orifice Tool. With the tool, insert
the orifice into the bleed port until the tool, threads mate
with the threads in the bleed port. Finger-thread the tool
into the bleed port (turn clockwise ) as far as possible; then use pliers to seat the orifice. Seating occurs
when the threading stops. Withdraw the tool and complete
the connection of the bleed tubing.
Fig. 9—Installing optional bleed orifice.
BLEED PORT
1/8-27 NPT
ADJUSTING SCREW
THIS DEVICE WILL NOT FIT VALVES
1
WITH BSP.PL THREADS.
1/8-27 NPT
7/16 INCH HEX
M7290
OPERATION OF THE V48 AND V88 (FIG. 10)
When the controller is not calling for heat, the coil is deenergized. The plunger in the 3-way actuator is in the
DOWN position so the bleed port is closed and the supply
port is open. Gas flows into the top part of the valve. The
gas pressure on top of the diaphragm, the weight, and the
spring hold the valve closed.
On a call for heat, the controller contacts close and the
coil is energized. This pulls the plunger to the UP position,
opening the bleed port and closing the supply port. The gas
in the top of the valve flows out through the bleed port. This
reduces the pressure on top of the diaphragm, allowing the
gas pressure below to lift the diaphragm and open the
valve.
BLEED ORIFICE
(SELECTED)
1
ORIFICE TOOL
THIS TOOL WILL NOT FIT VALVES
1
WITH BSP.PL THREADS.
M7298
Operation
When all the gas has bled off the top of the diaphragm,
the valve is fully open, permitting gas flow to the main
burner.
After the controller is satisfied, the procedure is reversed.
The controller contacts open so the coil is de-energized. The
plunger is released, moving to the DOWN position. This
closes the bleed port and opens the supply port so gas flows
again into the top port of the valve. As the gas pressure on
top of the diaphragm increases, the diaphragm begins to
close. When the pressures on both sides of the diaphragm
are balanced, the valve will be closed. The weight and
spring help to close the valve. If the gas supply fails and
there is no pressure below the diaphragm, the weight and
spring will close the valve.
60-2080—8 8
Page 9
Fig. 10—Operation of V48 and V88 diaphragm
gas valves.
PLUNGER
GAS
SUPPLY
WEIGHT
DIAPHRAGM
MAIN
GAS
SUPPLY
WEIGHT
DIAPHRAGM
SPRING
VALVE CLOSED
PLUNGER
SPRING
PASSAGE
BLEED
PORT
TO BURNER
GAS
SUPPLY
PASSAGE
BLEED
PORT
V48A,F,J; V88A,J
OPERATION • CHECKOUT AND TROUBLESHOOTING
In the event of a power failure during automatic operation, all V88 and V48 valves will close. Normal operation
will be resumed upon power restoration.
OPERATION OF THE VALVE POSITION
INDICATOR (FIG. 11)
An optional valve position indicator is available in the
1-1/4 in. V48A2227 and 2 in. V48F1103 Valves. When the
valve is open, a yellow disk shows in the window. When the
valve is closed, only the black top of the disk is visible.
Fig. 11—Valve position indicator (optional).
MAIN
GAS
SUPPLY
WEIGHT
DIAPHRAGM
MAIN
GAS
SUPPLY
VALVE OPENING
SPRING
VALVE OPEN
PLUNGER
TO BURNER
GAS
SUPPLY
PASSAGE
BLEED
PORT
TO BURNER
M8489
Checkout and Tr oubleshooting
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. 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 tests required by the burner
manufacturer.
2. Close all manual fuel shutoff valves as soon as
trouble occurs.
9 60-2080—8
Page 10
V48A,F,J; V88A,J
CHECKOUT AND TROUBLESHOOTING • SERVICE INFORMATION
CHECKOUT
Start the system and observe its operation through at
least one complete cycle to be sure the valve functions as
described in the Operation section.
TROUBLESHOOTING
CAUTION
Use utmost care during troubleshooting. Line voltage is present at the actuator for a V48 Valve, and
is present in all controller circuits for all V48 and
V88 Valves.
IMPORTANT: Do not assume that the valve must be
replaced until all other sources of trouble have been
eliminated.
If the valve will not open when the thermostat or
controller is calling for heat:
1. Check that there is voltage at the valve actuator
(black leadwires, Fig. 7). Be careful—there should be line
voltage at the actuator of a V48.
2. If there is no voltage at the actuator, first make sure
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.
3. For a V88 only: If a line voltage power is okay, check
the transformer. Replace it if necessary.
4. If there is still no voltage at the actuator, make sure all
the appropriate contacts in the thermostat (or controller),
limit(s), and flame safeguard control are closed. If one or
more is open, determine the cause(s) and correct the condition(s) before proceeding.
5. If there is proper voltage at the valve actuator but the
valve still does not open, first check that the gas pressure at
the valve is normal. Then make sure that the bleed line is
unobstructed.
6. If the gas pressure and bleed line are okay but the
valve still does not open, replace the coil assembly. (Refer
to the Specifications section for the proper part number,
and to the Service Information section for the proper
procedure.)
7. If you replace the coil assembly and the valve still
does not open, replace the 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:
1. Make sure that the gas flow is in the direction of the
arrow on the valve body.
2. Make sure the valve actuator is wired in the correct
circuit. Open the master switch to remove power from the
valve actuator. If the valve closes now, the actuator may not
be wired properly.
3. Look for a short in the electrical circuit.
CAUTION
1. Only qualified service technicians should attempt to service or repair flame safeguard controls and burner systems.
2. Open the master switch before replacing the
coil assembly or the valve. Line voltage is
present in the electrical circuits to the valve.
SCHEDULED INSPECTION AND MAINTENANCE
A schedule should be set up and followed for periodic
inspection and maintenance for the burner and all other
controls and the valve(s). Refer to the instructions for the
flame safeguard control for more information.
REPLACING THE COIL ASSEMBLY (FIGS. 12
THROUGH 15)
1. Open the master switch to disconnect all power to the
valve actuator.
2. Loosen the cover screw in the front of the actuator
housing (Fig. 12) and remove the housing cover.
3. Disconnect the external wires from the two internal
black leadwires (Fig. 12).
4. Remove the two torx screws inside the actuator hous-
ing (Fig. 13) and lift off the housing.
Service Inf ormation
5. Remove the holding nut from the top of the coil
assembly (Fig. 13).
6. Lift the coil assembly straight up and off the plunger
tube assembly (Fig. 14).
7. Snap out the wraparound metal cover and remove the
metal base (Fig. 15). Save these parts for the replacement
coil.
8. Carefully unhook the cardboard insulator (Fig. 15)
and remove it. Save the insulator for the replacement coil.
9. Make sure the new coil assembly has the same part
number as the old one; then discard the old coil assembly.
10. Wrap the cardboard insulator around the new coil
assembly and carefully hook it together around the two
black leadwires (Fig. 15).
11. Insert the two black leadwires through the opening in
the metal base, and insert the new coil assembly into the
metal base (Fig. 15).
12. Snap the wraparound metal cover into place around
the new coil assembly (Fig. 15).
13. Slip the new coil assembly over the plunger tube
assembly (Fig. 14).
14. Replace the holding nut on top of the coil assembly
(Fig. 13) and tighten it securely.
15. Replace the actuator housing and tighten the two torx
screws holding it in place (Fig. 13).
16. Reconnect the external wires to the two internal
black leadwires (Fig. 12).
60-2080—8 10
Page 11
17. Replace the housing cover, and tighten the cover
WRAPAROUND
METAL COVER
M7304
BLACK LEADWIRES
METAL BASE
CARDBOARD
INSULATOR
COIL
ASSEMBLY
CARDBOARD
INSULATOR
HOOKED TOGETHER
screw holding it to the actuator housing (Fig. 12).
18. Close the master switch.
19. Test the valve to make sure it opens and closes as
described in the Operation section.
20. Verify proper operation after servicing.
Fig. 12—Wiring connections and actuator
housing
6 IN. [152.4 MM] INTERNAL
BLACK LEADWIRES
(FROM COIL)
SOLDERLESS
CONNECTORS
GROUNDING
SCREW
COVER
SCREW
EXTERNAL
WIRES
ACTUATOR
HOUSING
OPENING IN
ACTUATOR
HOUSING
CONDUIT
(IF REQUIRED)
M7302
V48A,F,J; V88A,J
SERVICE INFORMATION
Fig. 14—Coil assembly fits on plunger tube
assembly
COIL ASSEMBLY
PLUNGER TUBE
ASSEMBLY
M7303
Fig. 13—Internal view of actuator housing.
HOLDING NUT
COIL ASSEMBLY
GROUNDING
SCREW
ACTUATOR
HOUSING
2 TORX 20
SCREWS HOLDING
ACTUATOR HOUSING
M7301
Fig. 15—Coil assembly, insulator, and cover.
11 60-2080—8
Page 12
Home and Building Control Home and Building Control Helping You Control Your World
Honeywell Inc. Honeywell Limited—Honeywell Limitée
1985 Douglas Drive North 740 Ellesmere Road
Golden Valley, MN 55422 Scarborough, Ontario
M1P 2V9
60-2080—8 12
Printed in U.S.A.
QUALITY IS KEY
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