V48A & V88A,J

Diaphragm Gas Valves

PRODUCT DATA

FEATURES
• 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.
• V88J rated for 150°F (66°C) ambient temperature.
• V48A and V88A rated for either 1/2 or 1 psi (3.4 or 6.9
kPa), depending on model. 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 installation by
OEM.
APPLICATION • Valve position indicator on 1-1/4 in. V48A2227.
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.

Contents
Application ........................................................................ 1
Features ........................................................................... 1
Specifications ................................................................... 2
Ordering Information ........................................................ 2
Installation ........................................................................ 4
Wiring ............................................................................... 6
Operation .......................................................................... 8
Checkout and Troubleshooting ......................................... 9
Service Information .......................................................... 10

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V48A & V88A,J DIAPHRAGM GAS VALVES

SPECIFICATIONS
Models: Maximum Fluid Temperature:
V48A (120 Vac) or V88A (24 Vac) solenoid operated V48A; V88A: 125°F (52°C).
diaphragm valves for 1/2 or 1 psi (3.4 or 6.9 kPa) maximum V88J: 150°F (66°C).
operating pressure.
Thermostat Heat Anticipator Setting: For 60 Hz V88, set at
V88J (24 Vac) solenoid operated diaphragm valves for 1 psi 0.6A.
(6.9 kPa) operating pressure and 150°F maximum ambient Dimensions: See Fig. 1.
temperature.
Weight: See Table 1.
Type of Gas: Suitable for liquefied petroleum (LP), natural,
manufactured, and sulfur-bearing gases. Table 1. Valve Weight.

Valve Capacity: See table in Fig. 2. Pipe Size (in.) lb kg

3/4 2-1/2 1.13
Valve Pattern: Straight-through, non-offset.
1 3 1.36
Valve Body Material: Die-cast aluminum. 1-1/4 3-1/2 1.59
Pilot Tapping: 1-1/2 4 1.81
3/4 through 1-1/2 inch valves: 1/8-27 NPT. 2 9 4.08
2 through 3 inch valves: 1/4-18 NPT.
2-1/2 8-1/2 3.86
Bleed Tapping: 1/8-27 NPT. 3 9-1/2 4.31
Valve Opening Time: Approvals: (60 Hz models only):
Five seconds maximum at 2 oz/in.2 (0.86 kPa) pressure. Underwriters Laboratories Inc. Listed: File No. MH1639;
Adjustable bleed valve assembly or fixed bleed orifices Guide No. YIOZ.
available for longer opening time (NPT threads only; see CSA 158158-2500005576 (Z21.21-CSA CI 6.5).
Accessories).
NOTE: All models rated at 50 Hz and all models with BSP.PI
Valve Closing Time (on power failure; measured at threads are not CSA Design Certified.
2 oz/in.2 [0.86 kPa] pressure): 2 seconds maximum.
Optional Feature: Valve position indicator is available on
Maximum Operating Pressure: See Table 2. 1-1/4 in. V48A2227.
Power Consumption (maximum): 9 watts or 15 VA. Replacement Coil Assemblies:
Ambient Temperature Rating: 116930: 24V, 60 Hz V88A
V48A and V88A: 32°F to 125°F (0°C to 52°C). 116931: 120V, 60 Hz V48A.
V88J: 32°F to 150°F (0°C to 66°C). 116932: 220V, 50 Hz V48A
116932: 240V, 60 Hz V48A
118888: 24V, 60 Hz V88J

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 Environmental and Combustion Controls Sales Office (check white pages of your phone directory).
2. Honeywell Customer Care
1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386
3. http://customer.honeywell.com or http://customer.honeywell.ca
International Sales and Service Offices in all principal cities of the world. Manufacturing in Belgium, Canada, China, Czech
Republic, Germany, Hungary, Italy, Mexico, Netherlands, United Kingdom, and United States.

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 V48A & V88A,J DIAPHRAGM GAS VALVES

Table 2. Models Available.

Maximum Operating
Pressure
Model Voltage and Frequency psi kPa Pipe Size (in.) Thread Typea
V48A 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
240V, 50 Hz 2 NPT
V88A 24V, 60 Hz 1/2 3.4 3/4, 1, 1-1/4, 1-1/2
1 6.9 3/4, 1, 1-1/4, 1-1/2, 2, 2-1/2, 3
V88J 24V, 60 Hz 6.9 1, 1-1/4
a
NPT—American Standard Taper Pipe Threads.

C 3-11/16
(94)
1-13/16
(46)

A
1

E 2

B D
F

APPROXIMATE DIMENSIONS
VALVE
SIZE A B C D E F
(IN.)
IN. MM IN. MM IN. MM IN. MM IN. MM IN. MM
3/4 4-11/16 119.1 3/4 19.1 4-5/8 117.5 3-1/2 88.9 1-5/8 41.3 3-13/16 96.8
1 5-1/16 128.6 1 25.4 5 127.0 3-11/16 93.7 2-1/16 52.4 4-5/16 109.5
1-1/4 5-9/16 141.3 1-1/4 31.8 5-7/8 149.2 5-5/16 134.9 2-3/8 60.3 5-5/16 134.9
1-1/2 5-9/16 141.3 1-1/4 31.8 5-7/8 149.2 5-5/16 134.9 2-3/8 60.3 5-5/16 134.9
2 6-15/16 176.2 2-1/4 57.2 9-1/2 241.3 8-3/8 212.7 3-9/16 90.5 5-5/16 236.5
2-1/2 6-15/16 176.2 2-1/4 57.2 9-1/2 241.3 8-3/8 212.7 3-9/16 90.5 9-5/16 236.5
3 6-15/16 176.2 2-1/4 57.2 9-1/2 241.3 8-3/8 212.7 3-9/16 90.5 9-5/16 236.5

1 BLEED TAPPING: 1/8-27 NPT.

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.

M8487A

Fig. 1. Mounting dimensions of V48A and V88A,J Diaphragm Gas Valves in inches. (mm).

Table 3. Extending Valve Opening Timea By Adding a Bleed Orifice.

Valve Opening Time (seconds)
Orifice No. 122160, Orifice No. 124674,
Valve Size (in.) No Orifice 0.018 in. (0.46 mm) 0.011 in. (0.28 mm)
1 1 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.

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V48A & V88A,J DIAPHRAGM GAS VALVES

Accessories:
Transformer AT72D: (40 VA) for all V88 models.
INSTALLATION
126590 Adjustable Bleed Valve Assembly: Consists of adjust-
able bleed valve with sleeve and compression nut for con-
necting to 1/4 in. tubing; see Fig. 8.
When Installing This Product…
Bleed Orifice: Fixed (see Table 3 for appropriate size): 1. Read these instructions carefully. Failure to follow them
124674 Orifice: 0.011 in. (0.28 mm) diameter. could damage the product or cause a hazardous condi-
122160 Orifice: 0.018 in. (0.46 mm) diameter. tion.
2. Check the ratings given in the instructions and on the
product to make sure the product is suitable for your
Gas Valve Sizing application.
1. Check the burner nameplate for (a) the type of gas used, 3. Installer must be a trained, experienced, flame safeguard
and (b) the gas flow capacity. The capacity will be listed control technician.
in Btu/h (Btu per hour) or in cf/h (cubic feet per hour). 4. After installation is complete, check out product opera-
2. Call the gas utility for information on (a) the specific grav- tion as provided in these instructions.
ity (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.
WARNING
Explosion or Electrical Shock Hazard.
4. Capacity in cf/h = Btu/h (from burner nameplate) Can cause severe injury, death or property damage.
Btu/cu ft (from gas utility) 1. Turn off gas supply before starting installation.
5. For gases with specific gravities other than 0.64, multiply 2. Disconnect power supply before beginning
the burner cf/h by the conversion factor in Table 4. installation to prevent electrical shock and equipment
6. Use the corrected burner capacity in cf/h when determin- damage.
ing the gas valve size in Fig. 2. 3. Do not remove seal over valve inlet or outlet until
7. Determine the maximum pressure drop across the valve, ready to connect piping.
and draw a horizontal line at this pressure in Fig. 2. 4. Do not bend tubing at the valve after the
compression nut is tightened because this may
Table 4. Conversion Factors. result in gas leakage at the connection.
Average Specific 5. Install valve in a horizontal pipe line in any upright
Type of Gas Gravity Divide cfh by: position with the gas flow in the direction indicated by
the arrow on the casting.
Manufactured 0.60 .968
Mixed 0.70 1.046 Note: Per industry standards, a conduit seal or a cable type
LP—Propane 1.53 1.546 what is sealed is required to be installed in a device that can
result in flammable gas or flammable liquid flow through a
LP—Butane 1.98 1.759 conduit or cable to an electrical ignition source in the event of
8. Draw a vertical line in Fig. 2 at the capacity (cf/h) previ- a seal leakage, or diaphragm failure.
ously determined. Use the corrected capacity for a gas
with a specific gravity other than 0.64. Prepare Piping and Install Valve (Fig. 3)
9. Use the valve size at the intersection of the horizontal
and vertical lines. If the intersection is between valve 1. Use new, properly reamed pipe free from chips.
sizes, use the next higher valve size to the right. 2. Do not thread pipe too far. Valve distortion or malfunction
may result from excess pipe in valve.
3. Apply good quality pipe dope, putting a moderate
To Size Two Identical Valves Piped in amount on the male threads only. If pipe dope lodges on
Series the valve seat, it will prevent proper closure. If using liq-
uefied petroleum (LP) gas, use pipe dope resistant to
1. Find the cf/h for the type of gas used. action of LP gas.
2. Consider both valves as one unit. Determine the total 4. Install valve in a horizontal pipe line in an upright position
maximum pressure drop across the unit. with the gas flow in the direction indicated by the arrow
3. Find the pressure drop across the first valve by assuming on the casting.
it to be 45 percent of the total pressure drop. 5. Apply a parallel jaw wrench only to the flat next to the
4. Find the valve size from Fig. 2. pipe being inserted. A wrench applied to the valve body
5. The second valve will be the same size as the first valve. 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.

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 V48A & V88A,J DIAPHRAGM GAS VALVES

[2.5] 10 PRESSURE DROP VS. CAPACITY

FOR 0.64 SP GR. GAS
9
[2.0] 8
7
A.G.A.RATING FOR
[1.5] 6 0.64 SP. GR. GAS AT
1 IN. PRESSURE DROP
5 VALVE SIZE CAPACITY

3/4 IN. 668 cf/h

[1.0] 4
1 IN. 1021 cf/h
1-1/4 IN. 2100 cf/h
1-1/2 IN. 2400 cf/h
[0.75] 3 2 IN. 4178 cf/h
2-1/2 IN. 5100 cf/h
2.5 3 IN. 5562 cf/h

[0.5] 2

1.5
PRESSURE DROP—INCHES W.C. [kPa]

3
2-1/2
[0.25] 1.0
2
0.9
[0.2] 0.8 1-1/2
0.7 1-1/4

[0.15] 0.6
1

0.5 3/4

[0.1] 0.4

[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 M8491A

CAPACITY IN CUBIC FEET PER HOUR (cf/h)

FOR GAS WITH SPECIFIC GRAVITY OF 0.64
[1 cf/h = 0.0283 m3/hr]

Fig. 2. Pressure drop vs. capacity chart for sizing gas valves.

Connect Pilot and Bleed Gas Tubing

WARNING (Fig. 4)
Explosion or Fire Hazard.
Can cause severe injury, death or property damage. 1. Square off and remove burrs from end of the tubing.
If the flow is not in the same direction as the arrow on Bend tubing to the desired form for routing to the pilot
the bottom of the gas valve, the valve may not shut off, burner. Do not bend tubing at the valve after the com-
causing an accumulation of gas in the combustion pression nut is tightened because this may result in gas
chamber. leakage at the connection.
2. Unscrew brass compression fitting from pilot gas tapping
(Fig.4). Slip the fitting over the tubing and slide out of the
way.

5 60-2080-10
V48A & V88A,J DIAPHRAGM GAS VALVES

EXCESS DOPE
2 CLEAN MAY BLOCK
THREADS, DISC OFF WRONG
MODERATE VALVE
NEVER USE VALVE
AMOUNT SEAT
AS A HANDLE
OF DOPE

LOOSE CHIPS
RIGHT WRONG TOO LONG,
NORMAL FULL DISTORTS VALVE
THREAD SEAT

RIGHT REAM PIPE, WRONG

NORMAL FULL BLOW OUT TOO LONG,
THREAD CHIPS (THEY MAY DISTORTS VALVE
LODGE ON SEAT) SEAT

RIGHT BLEED
WRONG
VISE GRIPS GAS
TAPPING WRENCH HERE
END NEXT
STRAINS VALVE BODY
TO PIPE RIGHT
BEING WRENCH
INSERTED CORRECTLY
APPLIED
NEXT TO
PIPE BEING
INSERTED
PILOT GAS
TAPPING

M7299A

Fig. 3. Preparing piping and installing valve.

IMPORTANT:
When replacing a valve, cut off old compression fitting
WIRING
and replace with a new compression fitting. Never use
the old compression fitting because it may not provide Note: Per industry standards, a conduit seal or a cable type
a tight gas seal. what is sealed is required to be installed in a device that can
result in flammable gas or flammable liquid flow through a
3. Push tubing into the pilot gas tapping on the outlet end of conduit or cable to an electrical ignition source in the event of
the valve until it bottoms. While holding tubing all the way a seal leakage, or diaphragm failure.
in, slide fitting into place and engage threads—turn until
finger tight. Then use wrench and tighten one turn 1. Disconnect the power supply before making wiring con-
beyond finger tight. nections to prevent electrical shock and equipment
4. Connect other end of tubing to pilot burner according to damage.
pilot burner manufacturers instructions.
5. If required, connect the tubing to bleed gas tapping
(Fig. 3 and 4) as described in step 3. Connect other end
GAS VALVE
of bleed tubing to main burner or to outside atmosphere.
TUBING
GAS FLOW

COMPRESSION FITTING
SLEEVE CLINCHES AROUND TUBING
AS NUT IS TIGHTENED M7300B

Fig. 4. Connecting tubing to pilot for bleed gas tapping.

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 V48A & V88A,J DIAPHRAGM GAS VALVES

2. All wiring must comply with applicable electrical codes, connection. Then alternately energize and de-energize the
ordinances, and regulations. Use NEC Class 1 (line valve actuator, and adjust the screw on the bleed valve for the
voltage) wiring. desired valve opening time.
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 LIMIT(S)
24 VOLT
using a flame safeguard programming control. 1
THERMOSTAT
4. For high temperature installation, use moisture-resistant L1
No. 14 wire selected for a temperature rating above the (HOT)

maximum operating temperature. L2

5. Check the power supply circuit. The voltage and fre- TRANSFORMER
24V
quency must match those of the valve. FLAME
SAFEGUARD
6. Refer to Fig. 5 or 6 for typical field wiring connections. CONTROL
Follow the burner manufacturers wiring diagram if pro-
vided.
7. Make wiring connections inside the actuator housing
(Fig. 7): V88
a. Loosen the cover screw in the front of the actuator VALVE ACTUATOR
(BLACK LEAD WIRES)
housing, and remove the housing cover.
b. If a conduit is required, run the conduit through the 1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
opening in the actuator housing, and run the external M8488B

wires through the conduit.

c. Using solderless connectors, connect the external Fig. 6. Typical wiring diagram for V88.
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. 6 IN. [152.4 MM] INTERNAL
BLACK LEADWIRES
8. Recheck the wiring circuits before putting the valve into (FROM COIL)
service.
SOLDERLESS
LINE VOLTAGE FLAME CONNECTORS
THERMOSTAT OR SAFEGUARD
CONTROL GROUNDING
CONTROLLER
SCREW
LIMIT(S)
COVER
SCREW
L1 1
(HOT)

EXTERNAL
L2 WIRES

ACTUATOR
HOUSING

OPENING IN
ACTUATOR CONDUIT
VALVE ACTUATOR HOUSING (IF REQUIRED) M7302A
(BLACK LEAD WIRES)

1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD Fig. 7. Making wiring connections.
PROTECTION AS REQUIRED. M8490A

Fig. 5. Typical wiring diagram for V48.

Installation of an Optional Bleed Orifice
(Fig. 9)
Installation of an Optional Adjustable NOTE: The orifice tool cannot be used on valves with BSP.PI
Bleed Valve (Fig. 8). threads.

NOTE: This device is not available for valves with BSP.PI Press the selected bleed orifice (see Table 2) over the 1/8 in.
threads. diameter dowel and press until the orifice cup bottoms in the
bleed port. Complete the connection of the bleed tubing.
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

7 60-2080-10
V48A & V88A,J DIAPHRAGM GAS VALVES

OPERATION
Operation of the V48 and V88 Valves
(Fig. 10)
When the controller is not calling for heat, the coil is
de-energized. The plunger in the 3-way actuator is in the
DOWN position so the bleed port is closed and the supply port
BLEED TAPPING
is open. Gas flows into the top part of the valve. The gas
126590 ADJUSTABLE BLEED VALVE pressure on top of the diaphragm, the weight, and the spring
COMPRESSION NUT hold the valve closed.
7/16-24 UNS
1/4 INCH SLEEVE
TUBING PLUNGER

GAS
SUPPLY
SPRING PASSAGE
1/8-27 NPT WEIGHT
ADJUSTING SCREW BLEED
7/16 INCH HEX DIAPHRAGM
PORT

MAIN
GAS TO BURNER
SUPPLY

M7290A
VALVE CLOSED
Fig. 8. Installing optional 126590 adjustable bleed valve.

PLUNGER

GAS
SUPPLY
SPRING PASSAGE
WEIGHT
BLEED
DIAPHRAGM
PORT

BLEED PORT MAIN

GAS TO BURNER
SUPPLY
1/8-27 NPT

VALVE OPENING

PLUNGER

GAS
SUPPLY
BLEED ORIFICE SPRING PASSAGE
(SELECTED) WEIGHT
BLEED
1/8 INCH DIAMETER ROD DIAPHRAGM
PORT

MAIN
GAS TO BURNER
M7298A SUPPLY

Fig. 9. Installing optional bleed orifice.

VALVE OPEN M8489A

Fig. 10. Operation of V48 and V88 diaphragm gas valves.

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.

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 V48A & V88A,J DIAPHRAGM GAS VALVES

When all the gas has bled off the top of the diaphragm, the
valve is fully open, permitting gas flow to the main burner.
CHECKOUT AND
After the controller is satisfied, the procedure is reversed. The
TROUBLESHOOTING
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
WARNING
Explosion Hazard.
diaphragm increases, the diaphragm begins to close. When Can cause severe injury, death or property damage.
the pressures on both sides of the diaphragm are balanced, Do not allow fuel to accumulate in the combustion
the valve will be closed. The weight and spring help to close chamber. If fuel is allowed to enter the chamber for
the valve. If the gas supply fails and there is no pressure below longer than a few seconds without igniting, an explosive
the diaphragm, the weight and spring will close the valve. mixture could result.
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. CAUTION
Equipment Damage Hazard.
Can cause equipment damage and improper
Operation of the Valve Position Indicator operation.
(Fig. 11) 1. Do not put the system into service until you have
satisfactorily completed all applicable tests
An optional valve position indicator is available in the 1-1/4 in. described in the Checkout section of the instructions
V48A2227 Valve. When the valve is open, a yellow disk shows for the flame safeguard control, and any other tests
in the window. When the valve is closed, only the black top of required by the burner manufacturer.
the disk is visible. 2. Close all manual fuel shutoff valves as soon as
trouble occurs.

Checkout
YELLOW Start the system and observe its operation through at least one
WINDOW DISC complete cycle to be sure the valve functions as described in
the Operation section.

Troubleshooting

WARNING
VALVE OPEN Electrical Shock Hazard.
Can cause severe injury or death.
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.
WINDOW BLACK TOP
OF DISC
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:
VALVE CLOSED 1. Check that there is voltage at the valve actuator (black
leadwires, Fig. 7). Be careful—there should be line volt-
age at the actuator of a V48.
M18856A
2. If there is no voltage at the actuator, first make sure line
voltage power is connected to the master switch, the
Fig. 11. Valve position indicator (optional). 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
con-dition(s) before proceeding.

9 60-2080-10
V48A & V88A,J DIAPHRAGM GAS VALVES

5. If there is proper voltage at the valve actuator but the 5. Remove the holding nut from the top of the coil assembly
valve still does not open, first check that the gas pressure (Fig. 13).
at the valve is normal. Then make sure that the bleed line 6. Lift the coil assembly straight up and off the plunger tube
is unobstructed. assembly (Fig. 14).
6. If the gas pressure and bleed line are okay but the valve 7. Snap out the wraparound metal cover and remove the
still does not open, replace the coil assembly. (Refer to metal base (Fig. 15). Save these parts for the replace-
the Specifications section for the proper part number, ment coil.
and to the Service Information section for the proper pro- 8. Carefully unhook the cardboard insulator (Fig. 15) and
cedure.) remove it. Save the insulator for the replacement coil.
7. If you replace the coil assembly and the valve still does 9. Make sure the new coil assembly has the same part
not open, replace the valve. number as the old one; then discard the old coil assem-
bly.
10. Wrap the cardboard insulator around the new coil
If the valve will not close when one or more of assembly and carefully hook it together around the two
black leadwires (Fig. 15).
the appropriate contacts in the thermostat (or 11. Insert the two black leadwires through the opening in the
controller), limit(s), or flame safeguard control metal base, and insert the new coil assembly into the
is open: metal base (Fig. 15).
12. Snap the wraparound metal cover into place around the
1. Make sure that the gas flow is in the direction of the new coil assembly (Fig. 15).
arrow on the valve body. 13. Slip the new coil assembly over the plunger tube assem-
2. Make sure the valve actuator is wired in the correct cir- bly (Fig. 14).
cuit. Open the master switch to remove power from the 14. Replace the holding nut on top of the coil assembly (Fig.
valve actuator. If the valve closes now, the actuator may 13) and tighten it securely.
not be wired properly. 15. Replace the actuator housing and tighten the two torx
3. Look for a short in the electrical circuit. screws holding it in place (Fig. 13).
16. Reconnect the external wires to the two internal black
leadwires (Fig. 12).
SERVICE INFORMATION 17. Replace the housing cover, and tighten the cover screw
holding it to the actuator housing (Fig. 12).
18. Close the master switch.
WARNING 19. Test the valve to make sure it opens and closes as
described in the Operation section.
Electrical Shock Hazard. 20. Verify proper operation after servicing.
Can cause severe injury or death.
1. Only qualified service technicians should attempt to
service or repair flame safeguard controls and
burner systems.
6 IN. [152.4 MM] INTERNAL
2. Open the master switch before replacing the coil BLACK LEADWIRES
assembly or the valve. Line voltage is present in the (FROM COIL)
electrical circuits to the valve.
SOLDERLESS

Scheduled Inspection and Maintenance CONNECTORS

GROUNDING
SCREW
A schedule should be set up and followed for periodic
inspection and maintenance for the burner and all other COVER
SCREW
controls and the valve(s). Refer to the instructions for the flame
safeguard control for more information.

Replacing the coil assembly (Figs. 12 EXTERNAL

WIRES
through 15) ACTUATOR
HOUSING
1. Open the master switch to disconnect all power to the
valve actuator.
2. Loosen the cover screw in the front of the actuator hous- OPENING IN
ACTUATOR CONDUIT
ing (Fig. 12) and remove the housing cover. HOUSING (IF REQUIRED) M7302A
3. Disconnect the external wires from the two internal black
leadwires (Fig. 12). Fig. 12. Wiring connections and actuator housing.
4. Remove the two torx screws inside the actuator housing
(Fig. 13) and lift off the housing.

60-2080-10 10
 V48A & V88A,J DIAPHRAGM GAS VALVES

WRAPAROUND
HOLDING NUT METAL COVER

COIL ASSEMBLY COIL

ASSEMBLY

CARDBOARD
INSULATOR
HOOKED TOGETHER
GROUNDING
SCREW

CARDBOARD
INSULATOR

METAL BASE
ACTUATOR
HOUSING BLACK LEADWIRES M7304A

2 TORX 20
SCREWS HOLDING Fig. 15. Coil assembly, insulator, and cover.
ACTUATOR HOUSING

CAUTION
M7301A

Fig. 13. Internal view of actuator housing. Equipment Damage Hazard.

Operation without proper checkout can damage the
equipment.
1. Do not put the system into service until you have
COIL ASSEMBLY 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.
2. All tests must be performed by a trained,
experienced flame safeguard control technician.
3. Close all manual fuel shutoff valves as soon as
trouble occurs.
After the installation is complete, 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 that follows before putting the valve into service.

Valve Leak Test (Fig. 7)

This is a test for checking the closure tightness of a gas
PLUNGER TUBE safety shutoff valve. It should be performed by qualified
ASSEMBLY
personnel during the initial startup of a burner system, or
whenever the valve or valve bonnet is replaced (see
Service Information section). It is recommended that this
test also be included in the scheduled inspection and
maintenance procedures. For a periodic inspection test,
follow steps 1, 3, 4, 5, 8, 9, 10, 12, 13, 16, and 17.

M7303A

Fig. 14. Coil assembly fits on plunger tube assembly.

11 60-2080-10
V48A & V88A,J DIAPHRAGM GAS VALVES

Table 5. Allowable Leakage for V48/V88 Valves.

A B C D E DOWNSTREAM
LEAK MANUAL V48/V88 Bubbles/10
4
TEST GAS COCK Pipe Size Natural Gas ( sec.; Max @
TAP
GAS
(in.) Air (cc/h) cc/h)a 45 degreesb
BURNER
SUPPLY
PRV SSOV 3/4 266 332.5 8
UPSTREAM
2 3
MANUAL F 1 302 377.5 9
GAS COCK 1/4 IN. (6 MM)
FLEXIBLE MANUAL 1-1/4 442 552.5 13
TUBING TEST 1
1/4 IN. (6 MM) PETCOCK 1-1/2 442 552.5 13
ALUMINUM OR
COPPER PILOT
2 650 812.5 20
TUBING JAR OR GLASS
WITH WATER
2-1/2 650 812.5 20
3 650 812.5 20
a
Natural gas: multiply air by 1.25.
1 (13 MM)
b
2 Bubble leakage: Divide natural gas by 573, then multiply by
CUT AT 14.
45 DEGREE
ANGLE
1 CAN ALSO BE A PERMANENT PETCOCK. NOTE: For international leak test requirements, contact
the office of the appropriate approval agency.
2 PRV = PRESSURE REGULATING VALVE.

3 SSOV = SAFETY SHUTOFF VALVE. After the test:

4 USE ONLY ONE OF THE DOWNSTREAM TAPS ON THE SS0V.
M9547G
1. Close the upstream manual gas cock (A).
2. Close the test petcock (F), remove the test apparatus,
Fig. 16. Valve leak test. and replace the leak test tap plug (D).
3. Open the upstream manual gas cock (A) and energize
1. De-energize the control system to assure that there is the safety shutoff valve (C).
no power to the safety shutoff valve (C) shown in Fig. 7. 4. Test with soap bubbles to assure that there is no leak
2. Close the upstream manual gas cock (A). at the test tap (D).
3. Make sure the manual test petcock (F) is closed in the 5. De-energize the safety shutoff valve (C).
leak test tap assembly (D). 6. Open the downstream manual gas cock (E).
4. Remove the leak test tap plug and connect the test 7. Restore the system to normal operation. If two safety
apparatus to the Leak Tap (D). shutoff valves are utilized, each V48/V88 valve is to be
5. Close the downstream manual gas cock (E). checked for tightness of closure.
6. Open the upstream manual gas cock (A).
7. Run the safety shutoff valve (C) to its fully open position
(through the safety system); then immediately
de-energize the system to close the valve.
8. Immerse a 1/4 in. tube vertically 1/2 in. (12.7 mm) into
a jar of water.
9. Slowly open the test petcock (F).
10. When the rate of bubbles coming through the water sta-
bilizes, 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 cfh.

To meet U.S. requirements, leakage must not exceed the

values listed in Table 5.

Automation and Control Solutions

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