Honeywell Compact Corona Series Operation manual

V5442N Compact

4-way Rotary Mixing Valves

APPLICATION

The “Corona” series of Compact Rotary valves and

Actuators provide integrated mixing of boiler supply, boiler

return, loop supply, and loop return water in hydronic

heating systems. The V5442 is very effective for low

temperature loops such as radiant floor heating.

The V5442 4-way valve can mix both loop supply water

and boiler return water simultaneously to control loop supply

temperature and boiler shock or flue gas condensation

protection. They may be plumbed in either a direct mixing

or injection configuration.

The effective Cv of the valves is increased when piped in

an injection configuration.

PRODUCT DATA

FEATURES:

• 4-way mixing action for closed hydronic heating systems.

• Mixes loop supply with boiler supply and loop return.

• Mixes boiler return with boiler supply and loop return.

• Optimized mixing characteristics for most accurate

control.

• Cast iron body; chrome plated plug.

• NPT threads.

• Suitable for manual or automatic control.

• “Universal” body orients either to the left or right to

match piping.

• Functional replacement for Centra ZRK-series of

compact 4-way mixing valves.

• Can be automated with M6063 actuator.

Contents

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

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

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

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

Installation..............................................................................3

Settings ..................................................................................5

Operation................................................................................5

Checkout and Test ................................................................5

Troubleshooting......................................................................6

This is a legacy product document supported by

Resideo. This product is no longer manufactured.

V5442N “Corona” 4-way Compact Rotary Mixing Valves — SPECIFICATIONS • ORDERING INFORMATION

SPECIFICATIONS

Important

The specifications given in this publication do not

include normal manufacturing tolerances; therefore,

an individual unit may not exactly match the listed

specifications. 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:

The V5442N provides mixing of both loop supply and boiler

return water in hydronic heating systems. They can be automated

with an M6063A actuator and a tri-state (floating) controller.

V5442N

Mechanical Specifications:

Fittings: Female NPT threads, 3/4 to 1 1/4".

Dimensions: see Fig. 1, Table 1.

Materials: Cast iron body

Double O-rings

Chrome -plated interior cast iron parts

Water: maximum 50% glycol solution

Fig: 1 V5442N mounting dimensions in inches (mm).

a i

Table. 1 V5442N specifications by valve size.

NOTE: Cannot be used in open systems such as Combo

heating where fresh water is present. Valve will corrode.

Static pressure rating: 90 psi (600 kPa)

Differential pressure rating: 15 psi (100 kPa)

Cv: see Table 1.

Leakage: less than 1% of Cv

Weight: see Table 1.

Temperature Ratings:

Water: 36°F to 230°F (2° to 110°C).

Shipping: -40°F to 140°F (-40° to 60°C)

Humidity Ratings:

Less than 90% RH, non-condensing.

Controller Compatibility:

Must be used with M6063 actuator.

Cross Reference:

V5442N functionally replaces Centra ZRK compact rotary

mixing valves and Centra ZR series rotary mixing valves if

piping reconfigured to injection mixing.

Replacement Parts:

P/N 071161035 replacement O-ring.

350 mm

14" minimum

Size [ i ] [a] [SW] [C] [C] with actuator Net Weight Cv

3/4"

3 3/8"

(85 mm) 1 5/8" (41 mm) 13 3/8" (304 mm) 13 3/4"

(350 mm) 2.2 lb. (1.0 kg) 7.4

11.7

1 1/4" 4 1/8"

(105 mm) 1 13/16" (46 mm) 13 9/16" (345 mm) 3.3 lb. (1.5 kg) 18.7

ORDERING INFORMATION

When purchasing replacement or modernization products from your wholesaler or distributor, refer to the 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 Home and Building Control Sales Office (check white pages of your phone directory.)

2. Home and Building Control Customer Logistics

Honeywell Inc. 1885 Douglas Drive North

Minneapolis, Minnesota 55422-4386 (612) 951-1000

In Canada – Honeywell Limited-Honeywell Limitée, 155 Gordon Baker Road, North York, Ontario M2H 3N7.

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.

95C-10888 2

V5442N “Corona” 4-way Compact Rotary Mixing Valves — INSTALLATION

2. Check the ratings given in the instructions and on the

INSTALLATION

product to make sure the product is suitable for your

application.

When Installing this Product . . .

3. Installer must be a trained, experienced service technician.

4. After installation is complete, check out product operation

1. Read these instructions carefully. Failure to follow as provided in these instructions.

them could damage the product or cause a hazardous 5. Follow local codes for installation and application.

condition.

Fig: 2 V5442 installation and orientation (Boiler supply from left).

Mixed Supply

to Loop Loop

Return

Mixed

Loop

Return

Supply

boss

Supply Water

Boiler

Supply

Position

Indicator

32" min.

(≥0.8 m)

Manual

handle

Boiler

Boiler Return

Supply

Water

Mounting

Mixed

Boiler

Return

Supply boss

(actuator

mounting hub)

Valve

If you intend to control the valve with an outdoor temperature com- Fig: 3 V5442 handle assembly (Boiler supply from left;

pensator, we recommend installing the valve body within 20" (0.5 m) mixed output from top).

of the OTC panel to simplify the wiring.

The valve must be oriented correctly towards the boiler

supply water in order to work correctly. Boiler supply water may

enter vertically from below, or horizontally from the left, or right of

the valve. Mixed loop supply exits the valve horizontally (left or

right) with bottom boiler supply, or from the top with left-handed

or right-handed boiler supply. The position indication scale must

not point to the floor.

A. Mount the valve at least 32" (0.8 m) above the return line to

prevent thermal siphoning. See Fig. 2.

Position the valve body so that boiler water enters the port

Mixed

Output

Position

Indicator

Handle stop pin

marked by the boss.

Loop

See Fig.4 for possible mounting orientations for the V5442,

Supply

and select the appropriate configuration.

B. Install the valve body in the pipes. Use NPT-to-sweat

adapters if installing on copper pipe. Unions are not required

Alignment

mark

for serviceability, but may speed installation.

Note: Threaded fittings must have pipe dope or Teflon™ tape

to prevent leakage.

C.Identify the mixed output port, and select the corresponding

range on the valve position indicator scale. See Fig. 3.

D. If using the valve manually, clip the stop pin from the molding

sprue on the handle and insert the pin in the hole, according to

Fig.3. Assemble the handle onto the valve.

E. For other valve orientations, use the manual handle to align the

position indicator on the valve’s square drive socket with the

mixed output port. The mixed output will be either be 90°

counterclockwise or clockwise relative to the boiler supply

input port. Insert the stop pin into the appropriate hole on the

handle and assemble the handle to the valve body.

Refer to Fig.5 to 8 for piping options in various hydronic

systems. 3 95C-10888

V5442N “Corona” 4-way Compact Rotary Mixing Valves — INSTALLATION

Fig. 4 Valve and handle installation for other piping configurations

A. Boiler supply enters

from left, mixed output

exits from top.

B. Boiler supply enters

from right, mixed output

exits from top.

C. Boiler supply enters

from bottom, mixed

output exits from left.

D. Boiler supply enters

from bottom, mixed

output exits from right.

Fig. 5 Single mixing valve installation

ºC

9 9

Fig. 6. Multiple loop installation

1 1

V5442 valve always has flow from and to boiler.

Install expansion tank at point of lowest pressure.

Recommended location of boiler circulator,

if installed, to prevent serial pumping.

1 V5442 valve always has flow from and to boiler.

4 95C-10888

V5442N “Corona” 4-way Compact Rotary Mixing Valves — SETTINGS • OPERATION • CHECKOUT

Fig. 7 Primary-secondary loop installation Fig. 8 Injection configuration.

1 2

1 V5442 must be sized to secondary LOOP flow; acts

as balancing valve.

SETTINGS

The indicator scale on the V5442 ranges from 1 to 9,

where 1 (minimum) corresponds to no flow from boiler to

loop and full return of boiler supply to boiler return. This

scale is approximately proportional to radiation heat out-

put, and inversely proportional to boiler return water tem-

perature, but is not calibrated and intended for reference

only.

OPERATION

The rotary control plug of the V5442 diverts boiler supply

water to both the loop supply and boiler return. At the

same time, the control plug also diverts loop return water

to the boiler return and back to the loop supply. When the

loop does not use much boiler water, most of it is returned

to the boiler. The loop supply water temperature is the

result of mixing boiler supply and loop return water, and

boiler return water temperature is the result of mixing loop

return water with boiler supply water.

The control plug has a modified equal percentage mixing

characteristic on the mixed loop output to give linear

heat output in the space. The plug uses a linear mixing

characteristic on the mixed boiler return to give linear

temperature control of boiler return water.

The V5442 may be used to control space temperature for

comfort, boiler return water temperature to prevent boiler

shock and condensation, or both simultaneously, depend-

ing on the sophistication of the control system.

In low temperature systems such as radiant floor heating,

the V5442 may be used for mixing in an injection configura-

tion (See Fig. 8). In these configurations, the V5442 has an

effective Cv of a much larger valve.

1 V5442 valve always has flow from and to boiler.

2 V5442 must be sized to INJECTION flow; acts

as balancing valve.

CHECKOUT AND TEST

Checkout

1. Turn on loop (and main) circulators. Set the boiler

Aquastat control to its operating setpoint at design

conditions.

2. Rotate valve handle to 9. Verify that all boiler supply

water is being sent to the loop, that is, that the loop sup-

ply pipe is the same temperature as the boiler supply,

and the boiler return pipe is the same temperature as the

loop return pipe.

3. Rotate valve handle to 1. Verify that all boiler supply

water is being sent to the boiler return, that is, that the

loop supply pipe is the same temperature as the loop

return pipe, and the boiler return pipe is the same tem-

perature as the boiler supply pipe.

4. Rotate the handle to set desired mixed loop tempera-

ture. Verify that the boiler return water temperature

meets the boiler manufacturer’s or industry recommen-

dations. Make

a prominent note of the setting for future reference.

Note: If the boiler is fitted with a reset control such as the

AQ475 Aquatrol Outdoor Temperature Compensator, loop

temperature will vary proportionately with the boiler supply

temperature.

95C-10888 5

V5442N “Corona” 4-way Compact Rotary Mixing Valves — TROUBLESHOOTING • SERVICING

TROUBLESHOOTING

Table 2. Troubleshooting

Symptom Possible Causes Action

Space temperature too low. 1. Thermostat set too low.

2. Mixed supply water not hot enough. 1. Turn up thermostat.

2. Set V5442 to higher number

Boiler return temperature

too low. 1. Boiler Aqustat control set too low.

2. Mixed return water not hot enough.

3. Aquatrol minimum temperature too low.

1. Turn up Aquastat.

2. Set V5442 to lower number

3. Increase Aquatrol minimum temperature

setting

Space gets colder as higher

valve settings selected Loop supply and boiler return pipes

are reversed. Switch control handle to opposite scale.

Fig. 9 O-Ring replacement

SERVICING

The V5442 is designed to give years of trouble-free operation,

provided it is used in an oxygen-depleted hydronic heating

system. The V5442 may be used in a combo heating system

only with heat exchangers between the potable and hydronic

heating systems.

Since the V5442 is a gate-type valve, we recommend that

the hydronic system be flushed before putting the valve into

operation to minimize potential damage to the seals by

debris in the system. We also recommend adding Y-strainers

and a 10% side-stream filter to the system after flushing to

capture debris that may be added in future through the boiler

feed water valve.

In automatic control systems where the V5442 has been

motorized with an M6063 actuator, the V5442 should be

operated every 3 days or so during the off season to ensure

the valve does not seize up.

If the valve stem starts to leak, replace the O-ring as shown

in Fig.9.

07116 1035

Home and Building Control

Honeywell Inc. Honeywell Limited-Honeywell Limitée

1885 Douglas Drive North 155 Gordon Baker Road

Minneapolis, MN North York, ON

55422-4386 M2H 3N7

95C-10888 RJ 10/99 Printed in U.S.A. www.honeywell.com

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