Honeywell V5197A1011, V5197A1003, V5197A Product Data

Page 1

APPLICATION

The V5197A is a firing rate valve used to provide variable flow control of air, natural gas, liquefied petroleum (LP), and manufactured gases. The V5197A is actuated by a firing rate motor that can be mounted directly on the valve. The V5197A is not applicable as a safety shutoff valve.

V5197A

Firing Rate Gas Valve

PRODUCT DATA

FEATURES

• Used with air, natural, manufactured or liquefied petroleum (LP) gases.

• For modulating applications that do not require final shutoff service of firing rate valve.

• Two valve body types (small and large) applicable to seven pipe sizes:

• Small body type for 3/4 in. (19 mm), 1 in. (25 mm), 1-1/4 in. (32 mm), 1-1/2 in. (38 mm) and 2 in. (51 mm) pipes, NPT or ISO 7 threads.

• Large body type for 2 in. (51 mm), 2-1/2 in. (64 mm) and 3 in. (76 mm) pipes, NPT or ISO 7 threads.

• Two downstream 1/4 in. NPT threaded pressure taps available.

• Accepts C6097 Pressure Switch mounted directly to flange (downstream pressure tap only).

• Unpainted cast aluminum body.

• Suitable for electric or pneumatic operators with the appropriate linkage.

• May be used with manufacturers own linkage and drive motor.

• Flow adjustment screw on bottom of valve controls maximum flow.

• Visual position indicator.

The V5197A is specially designed to provide fine control of gas flow in applications where a high turn down ratio is required.

The maximum flow adjustment screw on the bottom of the valve allows adjusting the maximum flow of gas through the V5197 while maintaining the linear modulating characteristics and stroke.

The V5197A is part of the Honeywell Integrated Valve Train System that allows gas train components to be directly bolted together.

Contents

Application ........................................................................ 1

Features ........................................................................... 1

Specifications ................................................................... 2

Ordering Information ........................................................ 2

Installation ........................................................................ 5

Checkout and Operation .................................................. 8

Service Information .......................................................... 8

65-0247-2

Page 2

V5197A FIRING RATE GAS VALVE

SPECIFICATIONS

IMPORTANT

The specifications in this publication do not include normal manufacturing tolerances; therefore, an individual unit may not exactly match the specifications listed. Also, this product is tested and calibrated under closely controlled conditions, and some minor differences in performance can be expected if those conditions are changed.

Models:

V5197A1003: Small body. V5197A1011: Large body.

Type of Gas: Air, natural, manufactured, mixed or liquefied

petroleum (LP) gases only.

Pipe Size of the gas train: 3/4 in. (19 mm), 1 in. (25 mm),

1-1/4 in. (32 mm), 1-1/2 in. (38 mm), 2 in. (51 mm), 2-1/2 in. (64 mm), 3 in. (76 mm).

Pressure Rating: Maximum operating pressure of 15 psi

(1 Bar).

Maximum Valve Capacities: SCFH gas: 0.64 sp. gr. at

1 in. wc pressure drop across valve (flow limit adjustment set at 100% open). See Table 1.

(natural gas at 0.64 sp.gr.) at 1 in. w.c. (2.5 mBar)

Pipe Size in in. (mm)

3/4 (19) 2450 69

1 (25) 3080 87

1-1/4 (32) 4430 125

1-1/2 (38) 5010 142

2 (51)—small body 5480 155

2 (51)—large body 12,600 356

2-1/2 (64) 14,800 419

3 (76) 16,900 478

Standard cubic feet per hour (SCFH) and standard cubic

meters per hour (SCMH) listed. For other gases, multiply the listed capacity by the square root of (0.64 divided by the specific gravity of the other gas).

Flow curves: See Fig. 1 through 8.

Table 1. Maximum Flow Capacity

Pressure Drop Across Valve.

Flow Capacity

SCFH SCMH

NOTE: The percentage settings listed on the figures refer

to the setting of the flow adjustment screw on the bottom of the V5197. Pressure drops are shown as solid, broken or dotted lines on the figures.

Bolt/Nut Fasteners (Provided with the valve):

Small body: 3/8-16 by 1-3/8, Grade 5 bolt. Metric equivalent

M8x1.25x35mm, class 9.8. Tighten to 13 ft-lb (18 N•m).

Large body: 1/2-13 by 2.00, Grade 5 bolt. Metric equivalent

M12x1.75x50mm, class 9.8. Tighten to 25 ft-lb (34 N•m).

Tapping and plug: Two downstream 1/4 in. NPT taps.

Plugs : 1/4 in. hex socket.

Ambient Operating Temperature Rating: -40°F to +150°F

(-40°C to +66°C).

Material: Cast aluminum body, brass and stainless steel

internal parts, NBR seals.

Mounting: Directly bolted to Integrated Valve Train (IVT)

components or IVT adapters.

Mechanical Strength: Group 2.

Maximum flow adjustment (Fig 9):

Located on the bottom of the valve with a 1/4 in. (6 mm)

hex key: To decrease the maximum flow, turn clockwise ;

to increase the maximum flow, turn counterclockwise .

Mounting position: Any position.

Dimensions: See Fig. 10 and 11.

Weight:

Small Body—5-1/4 lb (2.4 kg). Large Body— 11-5/8 lb (5.3 kg).

Accessory: 201391 Shaft Adapter for 3/8 in. (10 mm) round

or square shaft (provided with both small body and large body valves.

Approvals:

Underwriters Laboratories, Inc. (UL). CSA. EN161 Approval requires the use of an EN161-approved

actuator.

CE.

ORDERING INFORMATION

When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the TRADELINE® Catalog or price sheets for complete ordering number.

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 Automation and Control Products Sales Office (check white pages of your phone directory).

2. Honeywell Customer Care

1885 Douglas Drive North

Minneapolis, Minnesota 55422-4386 In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9. International Sales and Service 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.

65-0247—2 2

Page 3

V5197A FIRING RATE GAS VALVE

FLOW 0.64 s.g. GAS (cfh)

V5197A1003

FLOW 0.64 s.g. GAS (cfh)

V5197A1003

M17523B

FLOW 0.64 s.g. GAS (cfh)

V5197A1003

FLOW 0.64 s.g. GAS (cfh)

V5197A1003

FLOW 0.64 s.g. GAS (cfh)

V5197A1011

FLOW 0.64 s.g. GAS (cfh)

V5197A1011

14000 12000 10000

8000 6000 4000 2000

0 10203040506070809010

1 INCH

20 INCH

100%

DEGREE OPEN

10 INCH 40 INCH

M17521

Fig. 1. V5197A (small body) flow curves at stated

pressure drops with flow adjustment set at 100%.

16000 14000

12000 10000

8000 6000 4000 2000

0 102030405060708090

1 INCH

75%

DEGREE OPEN

10 INCH

20 INCH

M17522B

3000

2500

2000

1500

1000

500

0 102030405060708090

1 INCH

25%

DEGREE OPEN

10 INCH

20 INCH

M17524

Fig. 4. V5197A (small body) flow curves at stated

pressure drops with flow adjustment set at 25%.

14000 12000 10000

8000 6000 4000 2000

020406080

1 INCH 5 INCH

25%

DEGREE OPEN

10 INCH

20 INCH

40 INCH

M17894A

Fig. 2. V5197A (small body) flow curves at stated

pressure drops with flow adjustment set at 75%.

10000

9000 8000 7000 6000 5000 4000 3000 2000 1000

0 102030405060708090

1 INCH

50%

DEGREE OPEN

10 INCH

20 INCH

Fig. 3. V5197A (small body) flow curves at stated

pressure drops with flow adjustment set at 50%.

Fig. 5. V5197A (large body) flow curves at stated pressure drops with flow adjustment set at 25%.

18000 16000 14000 12000 10000

8000 6000 4000 2000

020406080

1 INCH 5 INCH

50%

DEGREE OPEN

10 INCH

20 INCH

30 INCH

M17895

Fig. 6. V5197A (large body) flow curves at stated pressure drops with flow adjustment set at 50%.

3 65-0247—2

Page 4

V5197A FIRING RATE GAS VALVE

FLOW 0.64 s.g. GAS (cfh)

V5197A1011

16000 14000 12000 10000

8000 6000 4000 2000

020406080

1 INCH 2 INCH

75%

DEGREE OPEN

5 INCH

10 INCH

20 INCH

Fig. 7. V5197A (large body) flow curves at stated

pressure drops with flow adjustment set at 75%.

V5197A 1011

18000 16000 14000 12000 10000

8000 6000 4000

FLO W 0.64 s.g. G AS (cfh)

2000

100%

M17896

32000109-005 2 in. (51 mm—small body valve only. 32001605-001 2 in. (51 mm)—large body valve only. 32001605-002 2-1/2 in. (64 mm). 32001605-003 3 in. (76 mm).

Pipe Adapters, BSP:

32000109-006 3/4 in. (19 mm). 32000109-007 1 in. (25 mm). 32000109-008 1-1/4 in. (32 mm). 32000109-009 1-1/2 in. (38 mm). 32000109-010 2 in. (51 mm)—small body valve only. 32001605-004 2 in. (51 mm)—large body valve only. 32001605-005 2-1/2 in. (64 mm). 32001605-006 3 in. (76 mm).

4074EYE Bag Assembly (bolts, nuts and washers for large

body valve), supplied.

4074EYF Bag assembly (bolts, nuts and washers for small

body valve), supplied.

4074EYK Bag Assembly (O-rings and tube of lubricant for

small body valve), supplied.

4074EYL Bag Assembly (O-rings and tube of lubricant for

large body valve), supplied.

The following non-part-numbered items are provided with

the valve: ML7999 Actuator Mounting Bracket Mounting Bracket Screws Valve Drive Stem

020406080

DEGREE OPEN

.5 INCH 1 INCH

5 INCH

10 INCH

20 INCH 60 INCH

100

M17897

Fig. 8. V5197A (large body) flow curves at stated

pressure drops with flow adjustment set at 100%.

Accessories:

201391 3/8 in. Shaft Adapter for mounting ML7999A/B to

V5197.

Pipe Adapters, NPT:

32000109-001 3/4 in. (19 mm). 32000109-002 1 in. (25 mm). 32000109-003 1-1/4 in. (32 mm). 32000109-004 1-1/2 in. (38 mm).

FLOW ADJUSTMENT

Fig. 9. V5197 Flow Adjustment.

M1763

65-0247—2 4

Page 5

V5197A FIRING RATE GAS VALVE

)

V D S

V P I S

0-5/16 (277)

4-27/32 (123)

2-1/2 (64)

6-7/16 (165)

7-1/8 (181

3-25/3

(96)

M17528

2-11/16

(322)

4-13/16 (122)

4 (102)

9-1/4 (235)

7-15/1

(202)

4-3/4 (121)

M17898

Fig. 10. V5197A Firing Rate Gas Valve (small body), with

mounting bracket (included) and ML7999 Actuator

(not supplied), dimensions in in. (mm).

Fig. 11. V5197A Firing Rate Gas Valve (large body), with

mounting bracket (included) and ML7999 Actuator (not

supplied), dimensions in in. (mm).

INSTALLATION

Installing the Valve Drive Stem in the V5197

When Installing this product…

1. Read these instructions carefully. Be sure to follow Warning information carefully.

2. Check the ratings given in the instructions and on the product to make sure the product is 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 these instructions.

1. Place the short end of the Valve Drive Stem in the top of the V5197 Valve drive so that the square portion of the drive stem is fully engaged in the square hole in the valve drive assembly. See Fig. 12.

NOTE: The short end of the Valve Drive Stem is

1 in. (25 mm) in length (measured from the square portion of the stem); the long end of the Valve Drive Stem is 1-1/8 in. (35 mm) long.

2. Tighten the valve position indicator setscrew (located in the valve drive assembly) to a torque setting of 5 inch-pounds (80 inch-ounces/6 kg-cm).

WARNING

Explosion Hazard and Electrical Shock Hazard. Can cause explosion, serious injury or death.

1. Turn off gas supply before starting installation.

2. Disconnect power supply for valve actuator

(if applicable) before beginning installation. More than one disconnection can be involved.

Installation

ALVE

RIVE

TEM

ALVE OSITION

NDICATOR

ETSCREW

IMPORTANT

Install the valve so the arrow on the valve body points in the gas flow direction.

M17686

Fig. 12. Inserting the Valve Drive

Stem in the V5197 Valve.

5 65-0247—2

Page 6

V5197A FIRING RATE GAS VALVE

Installing the V5197 in the IVT

Refer to the Integrated Valve Train Installation instructions (form 66-1099) for complete instructions on mounting a V5197A in a Honeywell Integrated Valve Train System.

Allow sufficient clearance for assembling the motor and linkage (if applicable), and for general servicing.

IMPORTANT

Install the valve so the arrow on the valve body points in the gas flow direction. Make sure the O-ring seals (provided) are properly positioned and seated at the inlet and outlet flange connections.

1. Install the V5197 Valve so the arrow on the valve body points in the gas flow direction.

NOTE: Normally, the V5197 will be located

downstream of the safety shutoff valve(s) in the Integrated Valve Train.Refer to form 66-1099 or the following steps.

2. Using the grease packet provided (or equivalent, general purpose, lithium grease), grease the O-rings provided with the valve. Make sure the grease is applied evenly around the O-ring. See Fig. 13.

3. Connect the V5197 Valve to the safety shutoff valve (SSOV) using three bolts, nuts and lockwashers as shown in Fig. 13.

NOTE: Tightening torque for nuts/bolts:

• Small body flanges: 13 ft-lb (18 N-m).

• Large body flanges: 25 ft-lb (34 N-m).

4. Connect the pipe adapter to the other end of the V5197 Valve using three bolts, nuts and lockwashers.

5. Assemble the downstream gas piping: a. Use new, properly reamed, pipe, free from chips. b. Apply moderate amounts of good quality pipe dope,

resistant to the action of liquid propane (LP) gas, on the pipe threads. See Fig. 14.

c. Do not thread pipe too far into pipe adapter.

The pipe should end flush with the O-ring sealing surface of the pipe adapters. Valve distortion or malfunctions can result from excess pipe in the valves.

6. Mount the ML7999 Actuator on the V5197 Valve and secure the actuator to the mounting bracket.

7. Wire the ML7999 Actuator according to instructions in form no. 65-0239.

8. Restore power to the system.

GREASE PACKET

O-RING

PIPE ADAPTER

Fig. 13. Mounting the V5197 Valve in the IVT.

Mounting the ML7999 Mounting Bracket

The ML7999 Actuator and mounting bracket can be installed in one of four positions, depending on accessibility of the valve and actuator. See Fig. 15.

VALVE

V5197

O-RING

3 BOLTS ON EACH SIDE

M17681

1. Choose the actuator and bracket position best suited for your location and place the mounting bracket over the drive shaft of the V5197 valve. See Fig. 16.

2. Manually open the V5197 valve for proper alignment of the ML7999 Actuator.

3. Secure the mounting bracket with the three screws provided.

65-0247—2 6

Page 7

V5197A FIRING RATE GAS VALVE

INCORRECT:

CORRECT: NORMAL

2 S A

FULL THREAD

TWO CLEAN THREADS WITH MODERATE AMOUNT OF DOPE

PIPE ADAPTER

CORRECT

USE PIPE DOPE RESISTANT

TO ACTION OF LP GAS.

DISTORTS VALVE SEAT

LOOSE CHIPS

REAM PIPE AND BLOW OUT CHIPS (TO AVOID LODGING ON SEAT)

TOO LONG,

EXCESS DOPE CAN BLOCK DISK FROM VALVE SEA

PIPE ADAPTER

INCORRECT:

TOO LONG, DISTORTS VALVE SEAT

M1641

Fig. 14. Preparing pipes.

Mounting the ML7999 Actuator

1. Insert the shaft adapter and place the actuator over the shaft. Position and seat the actuator.

ML7999 MOUNTIN BRACKET

Fig. 15. Possible mounting positions of the

ML7999 Actuator and mounting bracket.

V519

M17682

NOTE: Use the 201391 shaft adapter (included with

the valve) to mount the ML7999 Actuator to the V5197 Valve drive stem. Place the adapter as shown in Fig. 16 so that the valve drive shaft is between the adapter and the four setscrews.

2. Secure the actuator to the mounting bracket using a bolt, nut and locking washer. See Fig. 17.

CAUTION

Equipment Damage Hazard. Improper alignment can damage the actuator.

Align the ML7999 Actuator bottom panel parallel with the ML7999 mounting bracket (Fig. 18). Failure to do so will cause undue stress on the actuator motor and shorten its operating life.

3. Partially tighten the four hub setscrews to ensure that the actuator seats firmly against the mounting bracket with the shaft centered in the actuator hub. See note 1 in Fig. 18.

4. Tighten the anti-rotation bolt to the torque recommendation for the selected bolt/nut.

5. Tighten the hub setscrews against the shaft to a torque of 60 in-lb (69 kg-cm). See Fig. 17.

M17685

Fig. 16. Attaching the ML7999 Actuator mounting bracket

to the V5197 Valve (valve in the open position).

01391 HAFT DAPTER

ML7999A/B ACTUATOR HUB

V5197 DRIVE STEM

7 65-0247—2

Fig. 17. Proper positioning of 201391 shaft adapter

and V5197 drive shaft.

ML7999 SETSCREWS

M2102

Page 8

V5197A FIRING RATE GAS VALVE

)

ML7999

HUB SCREWS

V5197

ML7999 MUST BE MOUNTED PARALLEL WITH MOUNTING BRACKET.

ANTI-ROTATION BOLT AND LOCKING NUT (NOT SUPPLIED

ML7999 MOUNTING BRACKET

M17683

replaced (see Service Information section). It is recommended that this test also be included in the scheduled inspection and maintenance procedures.

NOTE: Additional leakage and closure tests may be required

for other gas train components (for example, safety shutoff valves [SSOV]).

1. Close the downstream manual gas valve(s).

2. Energize the valve train to apply gas pressure.

3. Test with rich soap and water solution to make sure

there is no leak at any pipe adapter/valve mating surfaces.

4. Restore the system to normal operation.

Fig. 18. Mounting the ML7999 Actuator

on the V5197 Valve.

CHECKOUT AND OPERATION

Checkout

WARNING

Explosion Hazard and Electrical Shock Hazard. Can cause explosion, serious injury or death.

1. Do not allow fuel to accumulate in the combustion

chamber for longer than a few seconds without igniting. An explosive mixture can result.

2. Do not put the system into service until you have satisfactorily completed the following Valve Leak Test, 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.

3. All tests must be performed by a trained, experienced flame safeguard control technician.

4. Close all manual fuel shutoff valves as soon as trouble occurs.

After the installation is completed, cycle the valve several times with the manual fuel shutoff cock closed. Make sure the valve and actuator function properly. Also perform the Valve Leak Test before putting the valve into service.

Valve Leak Test

This is a test for checking the leakage tightness of the firing rate gas valve only. 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

Operation

A V5197A Firing Rate Gas Valve is operated by an actuator. The valve opens counterclockwise and closes clockwise . When closed, the valve does not totally seal off the gas flow and has no safety shutoff function. For further information, refer to the actuator instructions. Make sure that the actuator does not force the V5197 Valve beyond the limits of the valve stroke (90 degrees). This can damage or destroy the valve position indicator setscrew.

SERVICE INFORMATION

WARNING

Explosion Hazard and Electrical Shock Hazard. Can cause explosion, serious injury or death.

1. Turn off the gas supply and disconnect all electrical

power to the valve actuator before servicing.

2. Properly position and seat the seals in ends of the valve body to prevent a hazardous gas leak. Read these instructions and form 66-1099 carefully for servicing information.

IMPORTANT

Only trained, experienced flame safeguard control technicians should attempt to service or repair flame safeguard controls and burner assemblies.

Scheduled Inspection and Maintenance

Set up and follow a schedule for periodic inspection and maintenance for the burner, all other controls and the valves. It is recommended that the valve leak test in the Operation and Checkout section be included in this schedule. Refer to the instructions for the primary safety control and safety shutoff valve(s) for more information.

Automation and Control Solutions

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

65-0247—2 G.R. Rev. 06-03 www.honeywell.com

M1V 4Z9

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