MOTORIZED 3-WAY VALVE APPLICATION INSTRUCTIONS FOR
LOW TEMPERATURE PROTECTION
KIT VAL30002
MODELS PB 502 - 2001
INS70023 Rev B
CAUTION
Pump and motor unit are designed to be
supported by the inline piping only. Do not
support in any other manner. When placing
pump between flanges, tighten flange bolts
evenly and do not tighten excessively.
Figure 1 2-1/2" Motorized 3-Way Valve
A
AB
B
SYSTEM
WATER
BOILER
WATER
MIXED
WATER
WATER FLOW
WATER FLOW
WATER FLOW
Figure 2 2-1/2" Motorized 3-Way Valve Diagrams
Model
Part
Number
Component Description
PF 502 - 2001
VAL20009 2-1/2" Motorized 3-Way Valve
WRE7021 18 GA White Wire (5 ft.)
WRE7024 18 GA Blue Wire (5 ft.)
WRE7025 18 GA Pink Wire (5 ft.)
WRE7031 18 GA Yellow Wire (5 ft.)
INS70023 Instruction Sheet
Valve technical data
Power Supply: 22-26 VAC or 28-32 VDC
Max. Power Consumption: 6VA @ 26VAC at Full Load
Control Signals: 3 Wire 3 Point Floating
To r q u e : 50 in.lb. or 5.6 Nm at Rated Voltage
Rotation Time: 0-50 in.lb. / 20-30 Seconds Through 90˚
Actuator Ambient Temperature: 0˚F to +122˚F or -18˚C to +50˚C
Enclosure: Motor -UL recognized QMFZ Fire Rated 94 - 5 Gear
Train - Die Cast Zinc with a Steel Base
Valve B o dy : Forged Brass ASTM B283
Ball and Stem: Nickel Plated Brass
End Connections: 2-1/2" NPT Female
Max. Close-Off Pressure: 40 PSIG
List of kit components
NOTE: A-B-AB is noted on the valve to depict proper
orientation. Arrows depict flow direction.
CAUTION
Valve is intended for indoor use only.
(3.937)
HANDLE IN
MOUNTED
POSITION
11.500
7.850
5.540
7.956
6.650
4.350
IMPORTANT NOTE:
DISCONNECT POWER TO ACTUATOR BEFORE
DEPRESSING CLUTCH RELEASE. FAILURE TO DO
SO MAY DAMAGE THE DRIVE MECHANISM.
3.228
HANDLE IN
STORAGE
POSITION
2-1/2" NPT
FEMALE
THREAD
(3.535)
2 of 4
Wiring instructions
1. Locate the 18 GA white (WRE7021), blue (WRE7024),
pink (WRE7025), and yellow (WRE7031) wires provided
in the kit. As indicated by Steps 2 through 5 below, route
each wire from the connection board inside the motorized
3-way valve (VAL20009) to the connection board inside
the junction box on the back of the unit (FIG. 3).
NOTE
: Lift the cover on the motorized 3-way valve to
gain access to the connection board.
2. Route the yellow wire from the #1 terminal on the valve
(COM) to the #7 terminal on the PF connection board.
3. Route the blue wire from the #2 terminal on the valve (24V)
to the #8 terminal on the PF connection board.
4. Route the white wire from the #3 terminal on the valve
(DRIVE CW) to the #5 (OPEN) terminal on the PF
connection board.
5. Route the pink wire from the #4 terminal on the valve
(DRIVE CCW) to the #6 (CLOSE) terminal on the PF
connection board.
Pump sizing instructions
INS70023 Rev B
A
2
3
4
5
6
7
8
9
10
D
ETAIL
A
Figure 3 Route wires to connection boards
See Table 1 for the VAL20009 pressure drop information at
varying flows. Reference Table 2 below for heat exchanger
pressure drop information at varying flows.
The boiler pump must be sized based on the boiler, flow, and head
loss of your specific application.
WARNING
Pump must be properly sized to overcome
the head loss of: (1) the boiler heat
exchanger as detailed in Table 2; (2) the
VAL20009 valve as detailed in Table 1 and the
equivalent feet of piping specific to each
application.
Table 1 – VAL20009 Pressure Drop
2-1/2" 3-Way Valve
Head Loss Flow
3.9 Ft/hd 95 GPM
3.7 Ft/hd 90 GPM
2.8 Ft/hd 85 GPM
2.8 Ft/hd 80 GPM
2.5 Ft/hd 75 GPM
2.1 Ft/hd 70 GPM
1.6 Ft/hd 65 GPM
1.4 Ft/hd 60 GPM
1.2 Ft/hd 55 GPM
1.2 Ft/hd 50 GPM
0.7 Ft/hd 45 GPM
0.7 Ft/hd 40 GPM
0.5 Ft/hd 35 GPM
0.5 Ft/hd 30 GPM
0.2 Ft/hd 25 GPM
0.2 Ft/hd 20 GPM
Table 2 – Heat Exchanger Pressure Drop
SYSTEM TEMPERATURE RISE CHART
BTU/HR 30°F ΔT 35°F ΔT 40°F ΔT 45°F ΔT 50°F ΔT 55°F ΔT 60°F ΔT
Input Output GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd
500,000 435,000 29.0 0.9 24.9 0.7 21.8 0.5 19.3 0.4 17.4 0.3 15.8 0.2 14.5 0.1
750,000 652,500 43.5 2.1 37.3 1.8 32.6 1.3 29.0 1.0 26.1 0.8 23.7 0.7 21.8 0.6
1,000,000 870,000 58.0 4.8 49.7 3.3 43.5 2.4 38.7 2.0 34.8 1.6 31.6 1.2 29.0 1.1
1,300,000 1,131,000 75.4 9.8 64.7 6.9 56.6 4.6 50.3 3.6 45.3 2.9 41.1 2.2 37.7 1.9
1,500,000 1,275,000 87.9 9.8 75.3 7.7 65.9 6.3 58.6 5.2 52.9 4.2 47.9 3.3 43.9 2.7
1,700,000 1,445,000 99.6* 14.1 85.4 10.2 74.7 7.9 66.4 6.5 59.8 5.3 54.3 4.6 49.8 3.9
2,000,000 1,700,000 117.2* 20.2 100.4* 14.9 87.9 11.9 78.1 9.2 70.3 7.2 63.9 6.4 58.6 5.2
* The Asterisk indicates flow rates that exceed the Maximum Allowable Flow Rate of the Heat Exchanger and must not be used.
Cupro-Nickel heat exchanger required at flows above 75 GPM on Models 502 - 1302 and above 90 GPM on Models 1501 - 2001.
PF CONNECTION BOARD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
VAL20009
CONNECTION BOARD
)
OM (Y
C
24V (BL)
DRIVE CCW (P)
DRIVE CW (W H)
4
3
2
1
N
O
123
DIR/REV
Typical piping applications:
Figure 4 Primary/Secondary Piping of a Single Boiler - 2-1/2" Motorized 3-Way Valve
A
DETAIL A
B = BOILER WATER
A = SYSTEM WATER
AB = MIXED WATER
NOTE: VALVE MUST BE INSTALLED WITH PROPER PORT
ORIENTATION. FAILURE TO OBSERVE PORT MARKINGS ON
THE VALVE BODY PRIOR TO INSTALLING THE VALVE COULD
RESULT IN DAMAGE TO THE UNIT.
* BEST PRACTICE FOR OUTDOOR RESET.
** BEST PRACTICE FOR SET POINT OPERATION.
NOT TO EXCEED
4 PIPE DIA. OR
MAX OF 12" APART
MIN. 10 PIPE DIA.
MIN. 10 PIPE DIA.
**REMOTE
SENSOR
REQUIRED
*REMOTE
SENSOR
REQUIRED
3 of 4
INS70023 Rev B
Installation instructions
1. Install the motorized 3-way valve in the piping as shown in FIG’s. 4 and 5.
2. Unit(s) high limit must be set at max.
3. Inlet and outlet connections to the boiler are shown for reference only. Actual connections may vary from those represented here.
Consult the Installation and Service Manual for actual locations.
4. Unit(s) pump should operate only during firing periods.
4 of 4
INS70023 Rev B
Startup instructions
1. When there is no call for the heat, the valve will remain at its default position of 0˚ where it will be closed to bypass (the running
time through the 90˚ going from closed to bypass to fully open is 20-30 seconds).
2. Observe the unit when there is a call for heat.
3. Check to see that the valve slowly opens to the bypass water, blending with the return water to bring the inlet temperature to the
boiler up to 140˚F.
4. Monitor the valve to make sure it maintains a constant temperature and does not make dramatic jumps.
5. As the return water heats up to 140˚F or above, the valve will close to the bypass.
10/08 - Printed in U.S.A.
Figure 5 Primary/Secondary Piping of Multiple Boilers - 2-1/2" Motorized 3-Way Valve for each boiler
*
Revision Notes: Revision A (ECO C01815)
initial release.
Revision B (ECO C02223) reflects the
revision of FIG. 5.
**REMOTE
* BEST PRACTICE FOR OUTDOOR RESET.
** BEST PRACTICE FOR SET POINT OPERATION.
SENSOR
REQUIRED
MIN 10 PIPE DIA.
NOT TO EXCEED
4 PIPE DIA. OR
MAX OF 12" APART
*REMOTE
SENSOR
REQUIRED
MIN 10 PIPE DIA.
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