A M E R I C A N F L A M E A F AF-1000 Seies Manual Gas Contol Valve APPLICATION The AF-1000 Manual Gas Contol Valve is designed fo use in gas in heath poducts, wall mount funaces, and space heating appliances. Fo use with Popane o natual gas. AF-1XXX MODEL IDENTIFICATION A F 1 X X X f i e - p a t s. c o m 0 = With Safety Seal 1 = With Safety Seal (3-Plunge) 5 = With-out Safety Seal Ameican Flame 0 = Manual without Solenoid. 1 = With ON/OFF Solenoid (Remote) 1000 Seies 2 = With ON/OFF/Vaiable DC Moto Dive (Remote) 3 = With High/Low Step Moto (Model AF-1000MOT) 4 = Manual fo 3-Plunge Safety Seal Type of Valve 0 = Vented Contol Valve 1 = Ventfee Contol Valve FEATURES Multi positional (All Plans) / Vesatile Mounting. Powe unit poweed by 30mv themocouple. CSA ated capacity 80,000 BTU/h at 1 wc pessue dop (All inlet/outlet configuations). AF-1000 seies available with 0ºF to 225ºF (-18 0 C to 107ºC) tempeatue ange. Multiple outlet connections single inlet connection (All 3/8 NPT). Fine mesh sceens on inlet. Multiple mounting holes (All 10-24 SAE theads) Low pofile / Compact size. Easy pilot adjustment scew (Located on the font of the valve) (Vented Only). No convesation fom natual to popane gas equied. White letteing on OFF/ON/ knob. Vented / Vent fee models available. 1 and 2 plastic extension knobs available. REV. 1/9/2010 Page 1 of 9
TABLE #1 AF-1000 VOLTAGE / CAPACITY RATINGS Model Position Themocouple Capacity@ 1 Pessue Dop Capacity@ 1 Pessue Dop Side inlet & Back outlet Back inlet & outlet All Models Multi positional 30 mv 55,000 BTU/h 55,000 BTU/h Pessue Dop in. w.c Pessue Dop & Capacity Cuve AF-1000 Seies Gas Contol 7.0 Inlet @ 3.5 outlet = 3.5 Pessue dop 6.0 Inlet @ 3.0 outlet = 3.0 pessue dop 5.0 Inlet & 2.5 outlet = 2.5 pessue dop 4.0 Inlet @ 2.0 outlet = 2..0 pessue dop 3.0 Inlet @ 1.5 outlet = 1.5 pessue dop 2.0 Inlet @ 1.0 outlet = 1.0 pessue dop 40 60 80 100 120 140 f i e - p a t Btu/h X s 1K. c o m This infomation is Ameican Flame lab geneated data and is to be used as efeence only. SPECIFICATIONS Main Gas Connections: Valve: 3/8 in. NPT thead on all Inlet and Outlet connections. Pilot Gas connections and flow: Pilot locations: Themocouple theads: Themocouple location Connection Size: 7/16-24 UNS. Flow: ~ 5,250 Btu/h at 7.0 in wc Maximum. Top of valve. 11/32-32 UNS double lead. Option: 8mm x1.0 connection. (Ventfee) Back of valve. Ambient Tempeatue Range: 0 0 F to 225 0 F (-18 0 C to 107 0 C) Voltage: Appovals: 30 mv Themocouple CSA Intenational Repot Numbe 224930-1650417 Model / Voltage / Capacity: Refeence Table #1 REV. 1/9/2010 Page 2 of 9
DIMENSIONS f i e - p a t s. c o m REV. 1/9/2010 Page 3 of 9
INSTALLATION When Installing this Poduct. Read these instuctions caefully. Failue to follow these instuctions completely could damage the poduct o cause a hazadous condition. Check the atings given in the instuctions and on the poduct to make sue the AF-1000 Gas Contol is suitable fo you application. Installe must be a tained, expeienced sevice technician. Afte installation is complete, check out poduct opeation as povided in these instuctions. Oxygen depletion hazad. Can cause injuy o death due to asphyxiation. 1. Use only vented gas pilot assemblies on vented appliances. 2. Use only unvented pilot assemblies on unvented appliances. Fie o explosion hazad. Can cause popety damage, sevee injuy o death. Follow these wanings exactly: 1. Disconnect powe befoe wiing to pevent electical shock o equipment damage. 2. To avoid dangeous accumlation of fuel gas, tun off gas supply at the appliance sevice valve befoe stating installation, and pefom a Gas Leak Test afte installation is complete. 3. Always f install i the sediment e tap - in the p gas supply a line to pevent t contamination s. of c the gas o contol. m 4. Do not foce the gas contol knob. Use only you hand to tun the gas contol knob. Neve use any tools. If the gas contol knob does not opeate by hand, a qualified sevice technician should eplace the gas contol. Foce o any attempt to epai the gas contol valve can esult in fie o explosion. Location: Locate the AF-1000 gas contol whee it cannot be affected by steam cleaning, high humidity, dipping wate, coosive chemicals, dust o gease accumulation o excessive heat. To assue pope opeation, follow these guidelines: 1. Locate gas contol in well-ventilated aea. 2. Mount gas contol high enough to avoid exposue to flooding o splashing wate. 3. Assue the ambient tempeatue does not exceed the ambient tempeatue atings fo each component. 4. Cove gas contol if appliance is cleaned with wate, steam, o chemicals o to avoid dust and gease accumulation. 5. Avoid locating gas contol whee exposue to coosive chemical fumes o dipping wate is likely. Install Piping to Gas Contol All piping must comply with the local codes and odinances o with the National Fuel code (ANSI Z223.1 NFPA No. 54) which eve applies. Tubing installation must comply with appoved standads and pactices. 1. Use new, popely eamed pipe fee fom chips, When tubing is used, assue the ends ae squae, debued and clean. All tubing bends must be smooth and without defomation. 2. Run pipe o tubing to the contol. If tubing is used, obtain a tube-to-pipe coupling to connect the tubing to the contol. 3. Install sediment tap in the supply line to the gas contol. See Figue #1 Gas Leakage Hazad. Failue to follow pecautions can esult in a gas-filled wok aea. Shut off the main gas supply befoe emoving end cap. Test fo gas leakage when installation is complete. Figue #1 REV. 1/9/2010 Page 4 of 9
Install Contol 1. Mount contol 0 to 90 degees in any diection, fom the upight position of the gas contol knob, including vetically. 2. Mount the contol so gas flow is in the diection of the aow on the side Figue #2 o back of the contol. 3. Thead pipe 5/16 in. into the contol. Do not inset deepe than 3/8 in. Valve distotion o malfunction can esult if the pipe is inseted too deeply. 4. Apply a modeate amount of good quality pipe compond (do not use Teflon tape) to pipe only, leaving two (2) end theads bae. On LP installations, use compond esistant to LP gas. See Figue #2 5. Remove plastic dust seals ove the contol Inlet and Outlet if necessay. 6. Connect pipe to contol Inlet and Outlet. Use wench on eithe side of the pipe outlet. See Figue #3 Figue #3 Gas Contol Knob Settings Gas contol knob settings ae as follows: f i e - p a t s. c o m 1. OFF: Pevents main gas flow though the valve. 2. ON Pemits main bune and pilot flow. Gas contol and emote contol of main bune gas flow. 3. : Opens pilot valve and allows gas flow to pilot bune. NOTE: When emote contols and wied DC opeated heath/wall switches ae used, the gas contol knob must be in the ON position. Note Valve font (Face) views in Figues #4 & #5 & #6 ON/OFF SOLENOID FACE VIEW OF WITH OUT SOLENOID FACE VIEW OF WITH SOLENOID Figue #4 Figue #5 ON/OFF/VARIABLE DC MOTOR DRIVE ON/OFF/HI/LO STEP MOTOR DRIVE FACE VIEW OF WITH ON/OFF DC MOTOR DRIVE Figue #6 FACE VIEW OF WITH ON/OFF STEP MOTOR Figue #6-A REV. 1/9/2010 Page 5 of 9
Pilot Gas and Lighting Pocedue Tun the gas contol knob counteclockwise to the position, push the gas contol knob IN and HOLD in position. This will open the pilot valve and allows gas to flow to the pilot bune. Light the pilot bune while holding the gas contol knob in until a stong pilot flame is pesent. (Appoximately 60 seconds) Release the gas contol knob. The gas contol knob will hold in and engages the valve powe unit. Tun the gas contol knob counte clockwise to the ON position, the main bune valve will open and the main bune will ignite. NOTE: Gas contols with model numbe AF-1000 fo vented to decease the pilot flame tun the pilot adjustment scew clockwise. To incease the pilot flame tun the pilot adjustment counte clockwise. NOTE: Gas contols with model numbe AF-1100 fo vent fee applications have NO pilot adjustment, pe test standad. Shut off Pocedue 1. To shut OFF the system, tun the gas contol knob clockwise to the OFF position. This action will close the main gas valve and disengages the safety pilot valve. Howeve the powe unit must dop out befoe the lighting sequence can begin again. This may take as much as 3 minutes. 2. To elight f i the pilot, follow e the steps - in p the Pilot a Gas and Lighting t Pocedue s. section. c o m Pilot Bune Connections This gas contol uses a pilot bune with a themocouple, the connections ae as follows: 1. Connect the pilot tubing fitting into the gas contol connection and tighten. (Use caution on bass connectos) Note: Figue #7 & #8 2. Connect themocouple into powe unit at the back of the gas contol. Note: Figue #8 NOTE: A standad themocouple o quick dop out themocouple with 11/32-32 UNS theads and Ventfee ODS themocouple with 8mm x 1.0 thead can be used. Note: Figue #8 ASSEMBLY AF-1000 Valve Pilot Connection FITTING CONNECTION 3/8 NPT OUTLETS Themocouple Connection 3/8 NPT INLET THERMOCOUPLE CONNECTION Figue #7 Figue #8 REV. 1/9/2010 Page 6 of 9
DC poweed featue of the AF1000 The AF-1000 has a non-leak safety featue that allows the installation of an ON/OFF solenoid. Note: Figue #9 With the use of this DC poweed latching ON/OFF solenoid allows the use of a DC poweed switch o emote contol (Model CON 1001) NOTE: The AF-1025 and AF-1125 (ONLY) do not have a non-leak safety featue. This model comes fom the factoy with the ON/OFF DC moto Dive pe installed Note: Figue #10 With the use of this DC poweed ON/OFF Moto Dive the valve will opeate ON/OFF (ONLY) with the use of a emote contol (Model RCAF 1005) Note: If the Hi/Lo Step Moto used on the AF-1035 and AF-1135 valve the (Motel AF-4000MOT) model must be used. If the Hi/Lo Step Moto used on the AF-1030 and AF-1130 valve the (Motel AF-1000MOT) model must used. Each model equies a unique opeating contol tansmitte and eceive specifically set-up fo the desied Hi/Lo incements equied by the bune installed in the appliance that the AF-1000 valve system is used on. 1/4 Male Connectos 1/4 Male Connectos ON/OFF ON/OFF/VARIABLE f i SOLENOID e - p a t DC MOTOR s DRIVE. c o m FACE VIEW OF WITH SOLENOID Figue # 9 Figue #10 FACE VIEW OF WITH ON/OFF DC MOTOR DRIVE 4 pin Connecto ON/OFF-HI/LO STEP MOTOR (AF-1000MOT & AF-4000MOT) FACE VIEW OF WITH ON/OFF STEP MOTOR Figue #11 Fie o explosion hazad. Can cause popety damage, sevee injuy o death. 1. Stand away fom the main bune while lighting, Hidden gas leaks can cause flashbacks in the appliance. 2. Check fo gas leaks with ich soap and wate solution any time wok is done on a gas system. Gas Leak Test 1. Paint the pipe connectos upsteam of the gas contol with ich soap and wate solution, Bubbles indicate a gas leak. 2. If a leak is detected, tighten the pipe connections. 3. Light the main bune. 4. With the main bune in opeation, paint the pipe joints (including adaptes) with ich soap and wate solution. 5. If anothe leak is detected, tighten the adapte scews, joints, and pipe conections. 6. Replace pat if leak cannot be stopped. REV. 1/9/2010 Page 7 of 9
Equipment Dange Hazad. Impope adjustment of gas input and bune can cause caboning and/o unnecessay shutdown of the system. 1. Do not exceed the input ating stamped on the appliance nameplate, o manufactue ecommended bune oifice pessue fo size oifice(s) used. Be sue pimay ai supply to the main bune is popely adjusted fo complete combustion. Follow the instuctions of the appliance manufactue. 2. IF CHECKING GAS INPUT BY CLOCKING GAS METER: Be sue thee is no gas flow though the mete othe that to the appliance being checked. Othe appliances must emain off with the pilots extinguished (o the consumption must be deducted fom the mete eading). Convet the flow ate to Btuh as descibed in the GAS Contols Handbook, fom 70-2602, and compae to the Btuh input ating on the appliance nameplate. Check Safety Shutdown Pefomance Fie o explosion hazad. Can cause popety damage, sevee injuy o death. 1. Pefom the safety shutdown test any time wok is done on a gas system. Place the gas contol knob in the position. Main bune should go off and the pilot should emain lit. 2. Extingush the pilot flame. The AF-1000 pilot gas flow should stop within thee (3) minutes when using a standad themocouple. When using a quick dop out themocouple, the pilot gas flow should stop within thity (30) seconds. Safety shutoff f of i the pilot gas e poves - complete p shutdown a because safety t shutoff s valve. pohibits c main o bune mand pilot gas flow. 3. Relight pilot bune and opeate the system though one (1) complete cycle to ensue all contols opeate popely. MAINTENANCE Fie o explosion hazad. Can cause popety damage, sevee injuy o death. Do not attempt to take apat the gas contol o to clean it. Impope assembly and cleaning can cause uneliable opeation. Regula peventive maintenance is impotant in applications that place a heavy load on the system such as those used in commeical cooking, agicultual, and industial application because: In many such applications, paticulaly commeical cooking, the equipment opeates 100,000 to 200,000 cycles pe yea. Such heavy cycling can wea out the gas contol in one to two yeas. Exposue to wate, dit, chemicals, and heat can damage the gas contol and shut down the contol system. The maintance pogam should include egula checkout of the system as outlined in the Checkout section, and checkout of the system as discibed in the appliance manufactues liteatue. Maintance fequency must be detemined individually fo each application, Some consideations ae: Cycling fequency. Appliances that may cycle 20,000 times annually should be checked monthly. Intemittent use. Appliances that ae used seasonally should be checked befoe shutdown and again befoe the next use. Consequence of unexpected shutdown, Whee the cost of an unexpected shutdown would be high, the system should be checked moe often. Dusty, wet, o coosive envionment. Because these envionments can cause the gas contol to deteioate moe apidly, the system should be checked moe often. Any contol should be eplaced if it does not pefom popely on checkout o sevice. In addition, eplace any module if it is wet o looks like it has been wet. Fie o explosion hazad. Can cause popety damage, sevee injuy o death. Do not disassemble the gas contol; it contains non eplaceable components. Attempted disassembly o epai can damage the contol. REV. 1/9/2010 Page 8 of 9
Fie o explosion hazad. Can cause popety damage, sevee injuy o death. Exactly follow the wanings and the lighting instuctions. 1. Befoe lighting, smell aound the appliance aea fo gas. If the appliance uses LP (bottled) gas, be sue to smell next to the floo because LP gas is heavie than ai. If you smell gas, immediately shut off the manual valve in the gas piping to the appliance o, on LP at the tank. Do not ty to light any appliance. Do not touch any electical switch o use the phone. Leave the building and call you gas supplie. If you gas supplie cannot be eached, call the fie depatment. 2. Do not foce the gas contol knob on the appliance. Use only you hand to tun the gas contol knob. Neve use any tools. If the knob does not opeate by hand, have a qualified sevice technician eplace the contol. Foce o any attempted epai can esult in fie o explosion. 3. The gas conol must be eplaced if it has been flooded with wate. Call a qualified sevice technician. 4. The gas contol is a safety device. It must be eplaced in case of any physical damage such as bent teminals, missing pats, stipped theads, o evidence of exposue to heat. IMPORTANT: Follow the opeating instuctions povided by the manufactue of you heating appliance. TROUBLESHOOTING IMPORTANT: Toubleshooting pocedues should only be pefomed by an expeienced qualified sevice technician. f i e - p a t s. c o m If the pilot will not stay lit: 1. Confim that the themocouple is making tight pope conection to the valves powe unit 2. With the pilot buning and the gas contol knob tuned to the position, the voltage should be18 mv fo a new themocouple. You must pess and hold the gas contol knob in the position to maintain the gas flow to the pilot. If the output does not meet the minimum voltage, eplace the themocouple. The powe unit will hold in down to 3 mv. If the output of the themocouple is below 3 mv, eplace the themocouple. If main bune does not come ON when the emote contol is tuned ON o the DC poweed wall switch is tuned ON o if the DC moto dive on models AF-1025 o AF-1125 will not un and tun the bune ON when the button on the emote tansmitte is pessed: 1. Confim that the pilot is lit. 2. Confim that the gas contol knob is in the ON position. 3. If a DC poweed switch o emote contol is used to tun the valve ON/OFF confim that the switch o emote is in the ON position. 4. Check the connections on the RED and BLACK wies fom the emote eceive. 5. Check the DC powe supply of the emote eceive o the wall switch. Limited Waanty Ameican Flame, Inc. waants the AF-1000 Valve seies fo 12 months fom the date of puchase o installation to the oiginal puchase to be fee fom defects in mateials and wokmanship. Damage to the AF-1000 Valve caused by accident, misuse, abuse, o installation eo, whethe pefomed by a contacto, sevice company, o owne, is not coveed by this waanty. Ameican Flame will not be esponsible fo labo chages and/o damage incued in installation, epai, eplacement, o fo incidental o consequential damage. Some states, povinces, and nations do not allow exclusion o limitations of incidental o consequential damages, so the above limitations o exclusions may not apply. This waanty gives you specific legal ights. You may also have othe ights that vay by state, povince, o nation. Ameican Flame, Inc. 9230 Consevation Way Fot Wayne, IN 46809 Phone (260) 459-1703 Fax (260) 459-1592 REV. 1/9/2010 Page 9 of 9