SPECIFICATIONS CAPACITY

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1 DMV-ZRD(LE)/6 SERIES Installation Instructions SPECIFICATIONS DMV-ZRD/6 DMV-ZRDLE/6 Two normally closed safety shutoff valves in one housing. V1 and V2 are fast opening, fast closing. Two stage and adjustable max. flow on V2. Two normally closed safety shutoff valves in one housing. V1 fast opening, fast closing. V2 is a two stage, slow opening, fast closing valve. Adjustable max. flow and adjustable initial lift with V2. Body size Flange Size DMV-ZRD(LE) 701/6 1/2" - 1 NPT DMV-ZRD(LE) 702/6 1" - 2" NPT DMV-ZRD(LE) 703/6 1" - 2" NPT Gases Natural gas, Propane, Butane; Other Noncorrosive gases Maximum Operating Pressure 7 PSI (500 mbar) Ambient / Fluid Temperature -30 F to +150 F; (-35 C to +65 C) Electrical Ratings Available 110 to 120 Vac /50 to 60 Hz 220 to 240 Vac /50 to 60 Hz 24 Vdc, 24 Vac /50 to 60 Hz Power Consumption with all coils energized DMV-ZRD(LE) 701: 70 VA DMV-ZRD(LE) 702: 120 VA DMV-ZRD(LE) 703: 135 VA Electrical Connection DlN-Connector with 1/2 NPT conduit adapter V1, V2 stage 1; V2 stage 2 Terminal box with NPT 1/2 conduit connection Operating Time 100 % duty cycle Classification of Valve V1 and V2 Safety Shut Off Valve: UL 429 ANSI Z21.21 CGA 6.5 C/I Valves Closing Time (Valve 1 & Valve 2) < 1 second Opening Time DMV-ZRD/6: V1 &V2 < 1 sec. DMV-ZRDLE/6: V1 < 1 sec.; V2 10 to 20 sec. (70 F) Max. Flow Setting (DMV-ZR/6 & DMV-ZRDLE/6) Adjustable on V2, stage one: <5 to 30 % of total flow; <5 to 20% of stroke stage two: <5 to 100 % of flow; <5 to 100 % of stroke Initial Lift Adjustment (DMV-ZRDLE/6) Adjustable on V2 stage one: 0 to 70 % of total flow; 0 to 35% of stroke Materials in contact with Gas Housing: Aluminum, Steel Sealings on valve seats: NBR-based rubber Mounting Position Solenoid upright vertical to solenoid horizontal Strainer 23 Mesh, installed in the housing upstream V1 Test Port G 1/8 ISO 228 taps available on both sides upstream of V1, between V1 and V2 and p = 7 psi max. downstream of V2, and on both flanges Position Indication (optional) Visual Indicator 4 V1 V2 5 CPI 400 w/ visual indication and electrical switch (SPDT), Approvals UL Recognized Component: File No.MH16727 CSA: Certified File No FM Approved: ReportJ.1.1Z6A0.AF DMV-Z/6 Installation Manual / CAPACITY Capacity in CFH at pressure drop of 1 inch water column; natural gas, sp.gr.=0.64 1/2 3/ /4 1-1/2 2 DMV ZRD(LE) 701/ DMV ZRD(LE) 702/ DMV ZRD(LE) 703/ KARL DUNGS INC. 524 Apollo Drive,Suite 10 Lino Lakes, MN U.S.A. Phone: (651) Fax: (651) info@karldungsusa.com

2 2 DMV-ZR 507 1/2 DMV-ZR 507 3/4 DMV-ZR DMV-ZR DMV-ZR /4 DMV-ZR /2 DMV-ZR DMV-ZR DMV-ZR /4 DMV-ZR /2 DMV-ZR Pressure drop [" W.C.] Based on 60 F; psia, dry 1, ,000 2,000 4,000 6,000 10,000 20,000 Flow (CFH) of natural gas s.g at 60 F ATTENTION Read these instructions carefully. Failure to follow them and/or improper installation may cause explosion, property damage and injuries. Installation must be done with the supervision of a licensed burner technician. The system must meet all applicable national and local code requirements. Check the ratings in the specifications to make sure that it is suitable for your application. Examine the DMV-ZRD(LE)/6 for shipping damage. The main gas supply must be shut off before starting the installation. The inside of the DMV-ZRD(LE)/6, the flanges, and piping must be clean and free of dirt, remove all dirt and debris before installing the DMV-ZRD(LE)/6. Failure to remove dirt/debris could result in valve damage or improper performance. Never perform work if gas pressure or power is applied, or in the presence of an open flame. Once installed, perform a complete checkout including leak testing. Label all wires prior to disconnection when servicing. Wiring errors can cause improper and dangerous operation Verify proper operation after servicing. Attach the DMV-ZRD(LE)/6 to the flanges using the M6 (M8) socket cap screws supplied. Use a 5mm Allen wrench for the DMV-ZRD(LE)/ Use a 6mm Allen wrench for the DMV-ZRD(LE)/ Tighten the screws in a crisscross pattern Do not overtighten the screws. Follow the maximum torque values below. Recommended Procedure to Mount the Flanges Unpack the DMV-ZRD(LE)/6 701 (702/703) and remove the 8 M6 (M8) socket cap head screws using a 5 mm (6 mm) Allen wrench. Remove the two white protective plastic covers from the DMV-ZRD(LE)/6 body. Make sure the O-rings and the grooves are clean and in good condition. Install the DMV-ZRD(LE)/6 with the gas flow matching the direction indicated by the arrows on the casting. Mount the DMV-ZRD(LE)/6 only with the solenoid vertical upright to horizontal. Clean the mounting surface of the flanges. Make sure they are in good condition. Recommended Torque Screws M6 M8 Screw Size [lb-in] CAUTION: If the flow is not in the same direction of the arrows the valves will not operate properly. for use with natural and propane gas for operation DMV:-40 F to 150 F install valves in accordance with current CSA C22.1 canadian electrical code 2 6

3 Recommended Piping Procedure Use new, properly reamed and threaded pipe free of chips. Apply good quality pipe sealant, putting a moderate amount on the male threads only. If pipe sealant lodges on the valve seat, it will prevent proper operation. If using LP gas, use pipe sealant rated for use with LP gas. Do not thread pipe too far. Valve distortion and/or mal function may result from excess pipe in the valve body. Apply counter pressure only a parallel jaw wrench only to the flats on the flange when screwing the pipe into the flanges. Do not overtighten the pipe. Follow the maximum torque values listed below. Recommended Torque for Piping 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" NPT pipe [Ib-in] Disconnect all power to the valves before wiring to prevent electrical shock and equipment damage. Do not exceed the electrical ratings given in the specifications and on the valve. For wiring valves V1, V2 Stage One: NOTE: Use 14 or 16 guage wire for at least 75 C (167 F). Attach a flexible 1/2 NPT conduit to the DIN connector. Route the wires through the conduit and the DIN connnector. Connect the wiring to the appropriate screw terminals in the DIN connector using wiring for V1, V2 stage 1. Plug the DIN connector into the AMP terminals. Fasten the DIN connector with the screw supplied. WIRING After installation is complete, perform a leak test. For wiring Valve V2, Stage Two: NOTE: Use 14 or 16 guage wire rated for 95 C(200 F). Remove the wiring box cover to expose the three terminals. The wiring box can be rotated to accommodate the conduit connection. Knock out only one of the conduit connections on the side of the terminal box you wish to make your conduit connection to. Support the opposite side of the electrical box when knocking out the conduit connection. (see below) Screwdriver Valve Wiring V1 V2-Stage One Figure 3 GROUND Flat area for support HOT (VALVE 1) L1 2 1 NEUTRAL L2 Use approprate tools to connect the conduit to the electrical box. Make electrical connections to the valve using the wiring diagram for V2 Stage 2. Replace wiring box cover. 3 L1 HOT (VALVE 2) Figure 2 Valve Wiring V2-Stage Two NEUTRAL L2 GROUND HOT L1 N Mp L P WARNING: The second stage coil must be integrated with the Flame Safeguard shutdown circuitry so that during any shutdown, voltage to ALL coils is removed to close both valves. Figure CAUTION: All wiring must comply with local electrical codes, ordinances and regulations. An ultimate electrical enclosure must be provided

4 2 2 Flow Setting Valve V2, Stage One The valves are supplied with the max. flow adjustment fully open. To adjust the gas flow proceed as follows: CAUTION: Make sure the flow of gas does not create a hazard. Locate the flow adjustment on top of valve 2 on the DMV-ZRD/6 (black knob) DMV-ZRDLE/6 (base of the hydraulic brake). There are two screws, the holding screw is recessed and has a blue sealing compound on it, while the pan head screw protrudes from the cap. Loosen the pan head screw until you can manually rotate the flow adjustment dial. Locate the max. flow adjustment dial between the top of the DMV-ZRD(LE) housing and the upper coil for the second stage. Turn the dial clockwise for less gas or counterclockwise for more gas. Check the flow at the burner with an orifice or flow meter until you have achieved the desired flow. Flow Setting Valve V2, Stage Two The valves are supplied with the flow adjustment fully open. To adjust the gas flow proceed as follows: CAUTION: Make sure the flow of gas does not create a hazard. Locate the max. flow adjustment cap on top of valve 2. There are two screws in the cap. The holding screw is recessed and has a blue sealing compound on it, while the pan head screw protrudes from the cap. Loosen the pan head screw until you can manually rotate the max. flow adjustment cap for 1-1/2 to 2 turns. Turn the cap clockwise for less gas or counterclockwise for more gas. Check the flow at the burner with an orifice or flow meter until you have achieved the desired flow. Tighten the pan head screw on the adjustment cap. V Stage II. DMV-ZRD VALVE ADJUSTMENT Initial Lift Adjustment (DMV-ZRDLE/6 only) The initial lift adjustment varies the initial gas flow through the valve as the valve seat begins to open. This adjustment can vary the initial flow between 0 % and 70% of the total gas flow; 0 to 35% of stroke. All DMV-ZRDLE/6 valves are shipped from the factory with no initial lift. To adjust the lift proceed as follows: Unscrew the small black cap on top of the flow adjustment cap to expose the initial lift adjustment knob. The black cap also serves as tool; turn the cap over and insert it into the corresponding slot on the adjustment knob. Turn the knob clockwise for a Min. initial lift or counterclockwise for a Max. initial lift. Once the desired initial lift has been achieved, reinstall the black cap. Test Ports The G 1/8 ISO 228 taps are available on both sides upstream V1, between V1 and V2, downstream V2, and on both flanges. The G 1/8 test nipple (Ordering Number: D ) can be screwed in any of these pressure tap ports. DMV-ZRD Inital Lift Adjustment Max Flow Adjustment Stage 2 Max Flow Adjustment Stage 1 DMV-ZRDLE Figure 6 DMV-ZRD DMV-ZRDLE p = 7 psi max. Stage I. 4 V1 V2 5 DMV-ZRDLE t Figure 5 CAUTION: Do not adjust or remove any screws or bolts which are sealed with a red or blue colored compound. Doing so will void all approvals and warranties. Figure

5 This valve seat leakage test checks the sealing capabilities of the DMV-ZRD(LE)/6 gas safety shutoff valve. The test described below is the bubble test method. Only qualified personnel should perform this test at the initial burner system startup, and annually or more depending on the application, environmental parameters, and the requirements of the authority having jurisdiction. It is recommended that this test be included in scheduled inspection and maintenance procedures. Use the illustration below as a reference. 1) Externally leak test the valve. KDI recommends using an all purpose liquid leak detector solution (Snoop or a soapy water solution). Apply the liquid leak detector solution to the areas indicated below. The presence of bubbles within 10 seconds indicates a excessive leak. Be sure to include any accessories mounted to the Valve. 2) De-energize valve # 1 and #2. 3) Close the upstream manual ball valve, and close the downstream manual ball valve. 4) Be sure that both test nipples are properly installed in port 2 and 3 and are leak tight. 5) Fill a glass of water at least 1 inch from the bottom, Connect a 1/4 flexible hose to a rigid tube. The rigid tube shall be 1/4 in. diameter and have a 45 cut at the end that is not connected to the flexible hose. The rigid tube can be made from either aluminum, copper or plastic. 6) Using a screw driver, slowly open the V1 test nipple VALVE LEAKAGE TEST (port 2) by turning it counter clockwise and depressurize the volume between the two safety valves. 7) Connect the 1/4 flexible hose to test nipple. 8) Open the upstream manual ball valve. 9) Immerse the 1/4 in. tube vertically 1/2 in. (12.7 mm) into the glass of water. 10) When the rate of bubbles coming through the water stabilizes, count the number of bubbles appearing during a 10 second period. Each bubble appearing during a 10 second period represents a flow rate of approximately cfh (28.8 cc/hr). To meet UL and CSA valve seat leakage requirements, leakage must not exceed the values listed in the table below. 11) Repeat the same procedure for valve V2 (port 3), except that valve #1 needs to be opened at step 7 above. (Energize only terminal 2 on the DIN connector). After completing the above tests: 12) De-energize the safety shutoff valves. 13) Close the upstream manual ball valve. 14) Remove the flexible hose, and close the test nipple. 15) Open the upstream manual ball valve, and energize safety shutoff valve #1 (See #11). 16) Use soapy water to leak test all test nipples to ensure that there are no leaks. 17) De-energize the safety shutoff valves. 18) Open the downstream manual ball valve. Allowable Valve Seat Leakage* # of Bubbles in 10 sec Model Allowable Leakage* AIR Natural Gas LP DMV ZD(LE) 701/6 (507/11) 264 cc/hr DMV ZD(LE) 702/6 (512/11) 494 cc/hr DMV ZD(LE) 703/6 (520/11) 494 cc/hr *Based on air, and test conditions per UL 429 Section 29. (Air or inert gas at a pressure of 1/4 psig and also at a pressure of one and one-half times maximum operating pressure differential, but not less than 1/2 psig. This test shall be applied with the valve installed in its intended position.) Volume of bubble defined in Table 2 of FCI WARNING: If leakage values are exceeded, replace valve immediately. 1/4 Rigid Tube 1/4 Flex Hose G 1/8 Test Nipple # /2 1 Port 2 Leak Test for V1 Port 3 LeakTest for V2 Figure 8 5 6

6 DIMENSIONS AND FLANGES c d e a b Figure 9 A B C D E Weight Order # [inches] [lb] Vac / Hz DMV-ZRD 701/6 (507) 3-5/8 5-5/8 1-3/8 7-1/2 2-7/8 6.6 D DMV-ZRD 702/6 (512) 4-7/8 6-7/8 1-7/ / D DMV-ZRD 703/6 (520) 4-7/8 6-7/8 1-7/8 1-7/8 18 D DMV-ZRDLE 701/6 (507) 3-5/8 5-5/8 1-3/8 8-1/2 2-7/8 6.8 D DMV-ZRDLE 702/6 (512) 4-7/8 7-7/8 1-7/8 10-5/8 3-7/ D DMV-ZRDLE 703/6 (520) 4-7/8 7-7/8 1-7/ / D Flange NPT Rp for DMV ZRD(LE) 1/2" D D DMV-ZR 701/6 (507) 3/4" D D DMV-ZR 701/6 (507) 1 D D DMV-ZR 701/6 (507) 1" D D DMV-ZR 702/6 703/6 (512/520) 1-1/4" D D DMV-ZR 702/6 703/6 (512/520) 1-1/2" D D DMV-ZR 702/6 703/6 (512/520) 2" D D DMV-ZR 702/6 703/6 (512/520) 6 6

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