Honeywell V5055B1002, V5055C1034, V5055C1018 Install Instructions

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Replacement Bonnet Assembly

for V5055, V5097 Gas Valves

INSTALLATION INSTRUCTIONS

APPLICATION

Models of the Replacement Bonnet Assembly are available for the valves listed in Table 1.

Table 1. Replacement Bonnets for

V5055/V5097 Gas Valves.

Replacement

Bonnet

133398AA V5055A V5097A 3/4, 1, 1-1/4, 1-1/2

133417AA 2, 2-1/2, 3

136911AA (on-off) 4

133398BA V5055B V5097B 3/4, 1, 1-1/4, 1-1/2

133417BA 2, 2-1/2, 3

136911BA (Characterized Guide) 4

133398CA V5055C V5097C 3/4, 1, 1-1/4, 1-1/2

133417CA 2, 2-1/2, 3

136911CA (Proof of Closure) 4

136308AA V5055D V5097D 3/4, 1, 1-1/4, 1-1/2

136307AA 2, 2-1/2, 3

136308BA V5055E V5097E 3/4, 1, 1-1/4, 1-1/2

136307BA 2, 2-1/2, 3

Each replacement assembly contains the bonnet assembly, two rubber seals and a tube of grease. It must be used only on the type of valve indicated above.

Valve Valve Size (inche s)

When Installing this Product...

1. Read these instructions carefully. Failure to follow them could damage the product or cause an unsafe condition.

2. Check the ratings given in the instructions and on the products to make sure the products are suitable for your application.

3. Installer must be a trained, experienced flame safeguard control technician.

4. After installation is complete, check out product operation as provided in the instructions.

The bonnet assembly and the valve seals may be replaced without removing the valve body from the gas line. Use the following procedure to replace the bonnet assembly and seals in the gas valve.

1. Turn off the gas supply at the manual shutoff valve.

2. Shut off all electrical to the valve actuator.

3. If a 7616BR Crank Arm Assembly is used with the

actuator, remove the crank arm assembly by pulling the clip and loosening the clamp screw.

4. Disengage the arm from the actuator.

5. Remove the actuator from the valve (loosen the two set

screws).

6. Remove the valve bonnet (four bolts on the 1- to 1-1/2-inch valves, six bolts on the 2- to 3-inch valves, eight bolts on the 4-inch valves).

7. Discard the old rubber seals.

8. Coat the new rubber seals with the grease provided and

position them in the valve body as shown in Fig. 1 or 2. (Small seal on the 4-inch valve is mounted on the bonnet assembly.)

INSTALLATION

WARNING

Explosion Hazard. Can cause equipment damage, serious injury or death.

1. Only a trained experienced flame safeguard technician should service the V5055 or V5097 Gas Val ves.

2. Before beginning installation, turn off the gas supply and disconnect the power supply to the valve actuator.

3. After installation, perform a complete checkout, including a gas leak check.

WARNING

Explosion Hazard. Can cause equipment damage, serious injury or death.

Position and seat the seals in the valve body properly to avoid a hazardous gas leak.

9. Carefully seat the new bonnet assembly on the valve body. Make sure the seals are in the proper position. (On the V5055/V5097 Gas Valves with a spring below the disk, make sure the spring is centered in the indentation on the inside of the valve body.

NOTE: The 4-inch bonnet assembly may be replaced in any

position on the valve body.

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FOR V5055, V5097 GAS VALVES

10. After positioning the bonnet assembly, replace the bolts removed in step 6.

BONNET SEAL

VALVE SEAL

NOTE: When replacing the bonnet assembly on the 4-inch

valve, draw it evenly into the valve body. Fingertighten the eight bolts. Draw the bonnet assembly into the valve by tightening, in order, bolts 1, 5, 7 and 3 (two turns each). See Fig. 3. Repeat until the bonnet assembly is seated. Tighten the remaining bolts. Torque the bolts as follows:

— 3/4 in. (19 mm) to 1-1/2 in. (38 mm) valves:

55 in.-lb.

— 2 in. (51 mm) to 4 in. (102 mm) valves: 75 in.-lb.

11. Remount the actuator.

12. Securely tighten the set screws (50 to 60 inch-pounds).

13. Replace the crank arm assembly if disconnected in

step 3.

14. With the gas still off, cycle the actuator to check for proper mechanical operation.

Fig. 1. Placement of valve and bonnet seals.

LARGE SEAL

SMALL SEAL

Fig. 2. Placement of valve and bonnet

seals in the four-inch valve.

M9578

M9579

M9582

Fig. 3. Replacement 4-inch valve bonnet assembly.

CHECKOUT

IMPORTANT

Bonnet Seal 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 make sure the seals are properly seated.

Tightness of Closure Check

Instructions for testing tightness of closure of gas safety shutoff valves on burner startup (by qualified personnel). See Fig. 4.

Both bonnet seal and seat leak checks must be performed after installation.

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GAS SUPPLY

UPSTREAM MANUAL GAS COCK

PRV

2 3

1/4 IN. (6 MM) FLEXIBLE TUBING

1/4 IN. (6 MM) ALUMINUM OR COPPER PILOT TUBING

DABC E

LEAK

TEST TAP

SSOV

DOWNSTREAM MANUAL GAS COCK

BURNER

MANUAL TEST PETCOCK

JAR OR GLASS WITH WATER

FOR V5055, V5097 GAS VALVES

7. Program the safety shutoff valve (C) to the fully open position (through the safety system), then immediately de-energize the SSOV to seat the valve operationally.

8. Immerse a 1/4-inch (6 mm) tube vertically 1/2 inch (13 mm) into a jar of water as shown in Fig. 4.

9. Slowly open the test petcock (F).

10. When the rate of the bubbles coming through the water

stabilizes, count the number of bubbles appearing

during a ten-second period. Each bubble appearing during a ten-second period represents a flow rate of approximately 0.001 cf/h. To meet U.S.A requirements, leakage must not exceed the values given in Table 2.

Table 2. Allowable leakage (cc/hr).

(13 MM)

CUT AT 45 DEGREE

CAN ALSO BE A PERMANENT PETCOCK.

PRV = PRESSURE REGULATING VALVE.

SSOV = SAFETY SHUTOFF VALVE.

USE THE DOWNSTREAM TAP ON THE SS0V.

ANGLE

M9547F

Fig. 4. Valve leak test.

1. De-energize the control system to make sure no power is applied to the safety shutoff valve (C).

2. Close the upstream manual gas cock (A).

3. Make sure the manual test petcock (F) in the leak test tap assembly (D) is closed.

4. Remove the leak test tap plug and connect the test apparatus to the leak test tap (D) as shown in Fig. 4.

5. Close the downstream manual gas cock (E).

6. Open the upstream manual gas cock (A).

Valve Size (in.)

Allowablea

Leakage (cc/hr)

Number of bubbles

per 10 seconds.

3/4, 1, 1-1/4, 1-1/2 458 16

2, 2-1/2, 3 752 26

4 1003 35

Based on air at standard conditions, test pressures provided

by ANSI Z21.21, section 2.4.2, and a maximum of 235 cc/h per inch of sealoff diameter. Sealoff diameter is not to be confused with pipe size.

NOTE: If two safety shutoff valves are used, check each

valve for tightness of closure.

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 at least one complete cycle to assure proper operation.

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Automation and Control Solutions

Honeywell International Inc. Honeywell Limited-Honeywell Limitée 1985 Douglas Drive North 35 Dynamic Drive Golden Valley, MN 55422 Scarborough, Ontario M1V 4Z9

95-6981—5 G.R. Rev. 7-00 www.honeywell.com