PP Series Piping Packages for VG000 Series Ball s Product Bulletin PP2xxxxx- Series, PP8xxxxx- Series Code No. LIT-20974 Issued August, 204 PP Series Piping Packages are designed to provide an easier way to deploy control valve solutions to a job site. Built around Johnson Controls field-proven VG000 Series Ball s using standard components, each piping package is tested under 00 psig (689 kpa) for 24 hours and then reduced to 40 psig (276 kpa) before shipping to ensure leak-free control valve solutions. Johnson Controls piping packages are manufactured by United Association of Journeymen & Apprentices of the Plumbing and Pipe Fitting Industry of USA and Canada pipe fitters and provide defect-free solutions for to -/4 in. pipe sizes for both two-way and three-way applications. Johnson Controls piping packages significantly reduce site labor. A piping package can be secured using the ProPress fitting system or by soldering to fasten it to the piping infrastructure. Table : Features and Benefits Features Assembly in a Factory Environment Following the Recommended Component Manufacturer Procedure 00% Tested under 00 psig (689 kpa) for 24 hours VG000 Series Ball s Manufactured by United Association of Journeymen & Apprentices of the Plumbing and Pipe Fitting Industry of USA and Canada Pipe Fitters Refer to the QuickLIT website for the most up-to-date version of this document. Benefits Figure : PP Series Piping Packages Ensures the components are not affected by overheating during sweating. Provides leak-free assurance. Allow for a wide range of application options, high close-off pressures, and accurate control under all conditions. Ensures superior workmanship for a high-quality assembly. PP Series Piping Packages for VG000 Series Ball s Product Bulletin
Ordering Information Table 2: PP Series Piping Packages Selection Matrix PP x x x xxx- PP Piping Package for VG000 Series Ball s 2 Two-Way Models 8 Three-Way Models B Piping Package Size in. C Piping Package Size in. D Piping Package Size -/4 in. M Manual Balancing s 00 Sequential Number A Automatic Balancing s 005 0.5 GPM 090 9 GPM 00 GPM 00 0 GPM 05.5 GPM 0 GPM 020 2 GPM 20 2 GPM 025 2.5 GPM 30 3 GPM 030 3 GPM 40 4 GPM 035 3.5 GPM 50 5 GPM 040 4 GPM 60 6 GPM 045 4.5 GPM 70 7 GPM 050 5 GPM 80 8 GPM 055 5.5 GPM 90 9 GPM 060 6 GPM 200 20 GPM 070 7 GPM 20 2 GPM 080 8 GPM 220 22 GPM IMPORTANT: The PP Series Piping Packages are intended to control hot water and chilled water flow under normal equipment operating conditions. Where failure or malfunction of any component of the piping package could lead to personal injury or property damage to the controlled equipment or other property, additional precautions must be designed into the system. Incorporate and maintain other devices, such as supervisory or alarm systems or safety or limit controls, intended to warn of or protect against failure or malfunction of the piping package. Control Components The PP Series Piping Packages include a two-way automatic flow control valve, a two-way manual flow control valve, or a three-way manual flow control valve. Select the piping package appropriate for your application. 2 PP Series Piping Packages for VG000 Series Ball s Product Bulletin
Two-Way Automatic Flow Control s Two-way automatic flow control valves consist of an automatic flow control valve, a union connection, a VG000 Series Ball and actuator, and a Y-strainer with a union end ball valve. Table 3: Two-Way Automatic Flow Control Models Code Number GPM PP2BA005-0.5 PP2BA00- PP2BA05-.5 PP2BA020-2 PP2BA025-2.5 PP2BA030-3 Pipe Size, in. Supply Pipe Y-Strainer with a Union End Ball Automatic Flow Control Return Pipe Union Connection VG000 Series Ball Size, in. Cv (DN).2.2,.9, 2.9 UBY S x S AC S x /2 M UA S x /2 M /2 (DN5) PP2BA035-3.5.2,.9, PP2BA040-4 2.9, 4.7 PP2BA045-4.5 PP2BA050-5 PP2BA055-5.5 PP2CA060-6 Figure 2: Two-Way Automatic Flow Control 2.9, 4.7, 7.4 PP2CA070-7 4.7, 7.4 PP2CA080-8 UBY S x S AC S x M UA S x M (DN20) PP2CA090-9 4.7, 7.4, PP2CA00-0.8 PP Series Piping Packages for VG000 Series Ball s Product Bulletin 3
Table 3: Two-Way Automatic Flow Control Models Code Number GPM PP2DA0- PP2DA20-2 PP2DA30-3 PP2DA40-4 PP2DA50-5 PP2DA60-6 PP2DA70-7 PP2DA80-8 PP2DA90-9 PP2DA200-20 PP2DA20-2 PP2DA220-22 Pipe Size, in. Supply Pipe Y-Strainer with a Union End Ball Automatic Flow Control Return Pipe Union Connection -/4 UBY -/4 S x /4 AC -/4 S x M UA -/4 S x M VG000 Series Ball Size, in. Cv (DN) (DN25) 7.4,.8, 8.7.8, 8.7 Two-Way Manual Flow Control s Table 4: Two-Way Manual Flow Control Models Code Number GPM Pipe Size, in. Figure 3: Two-Way Manual Flow Control Supply Pipe Y-Strainer with a Union End Ball Manual Balancing Return Pipe Union Connection VG000 Series Ball Size, in. Cv (DN).2,.9, PP2BM00-0.5 7 UBY S x S MC S x /2 M UA S x /2 M /2 2.9, 4.7 (DN5) PP2CM00- MC S x /2 M UA S x /2 M 4.7, 7.4.5 4 UBY S x S PP2CM002- MC S x M UA S x M PP2DM00-4.5 3 -/4 UBY /4 S x /4 S MC -/4 S x M UA /4 S x M (DN20) (DN25) 4.7, 7.4,.7 7.4,.7, 8.7 4 PP Series Piping Packages for VG000 Series Ball s Product Bulletin
Three-Way Manual Flow Control s Table 5: Three-Way Manual Flow Control Models Code Number GPM Pipe Size, in. Figure 4: Three-Way Manual Flow Control Supply Pipe Return Pipe Bypass Pipe Y-Strainer with a Union End Ball Manual Balancing Union Connection VG000 Series Ball Size, in. Cv (DN).2,.9, PP8BM00-0.5 7 UBY S x S MC S x /2 M UA S x /2 M /2 2.9, 4.7 (DN5) PP8CM00- MC S x /2 M UA S x /2 M 4.7, 7.4.5 4 UBY S x S PP8CM002- MC S x M UA S x M PP8DM00-4.5 3 -/4 UBY /4 S x /4 S MC -/4 S x M UA /4 S x M (DN20) (DN25) 4.7, 7.4,.7 7.4,.7, 8.7 Ball UBV /2 S x /2 M UBV S x M UBV S x M PP Series Piping Packages for VG000 Series Ball s Product Bulletin 5
Supply Pipe Components The supply pipe components include an all-in-one valve with a Y-strainer, with a union end ball valve and a pressure gauge. Y-strainers are furnished with a 20 mesh stainless steel screen, hose end drain valve for purging, one pressure and temperature port for commissioning, and one plugged bypass port. Three additional /4 in. taps are plugged and available for accessories when needed. The supply pipe is rated for 400 psig (2,758 kpa) and 250 F (2 C). Y-Strainer with a Union End Ball The Y-strainer with a union end ball valve includes the following accessories: Blowdown drain with in. hose bib and cap Lever handle for the ball valve Pressure gauge Pressure and temperature test plug See Figure 5 and Table 6 for the dimensions of the Y-strainer. Table 6: Y-Strainer with a Union End Ball Dimensions, in. (mm) Size A B C D E F G H J K T (max) L (max) Weight, lb (kg) (9) -/4 (32).45 (37).43 (36).7 (43) 6.60 (67) 7.85 (99) 8.2 (209) 3.76 (96) 4.63 (8) 4.88 (24) 2.08 (53) 2.29 (58).27 (32) Pressure Gauge The pressure gauge is an industry standard, Grade B component with a minimum accuracy of ±3.75% per ASME B40.00. The piping stick is pressurized for 24 hours at 00 psig (689 kpa) before shipping to test all connection point and gaskets. The pressure is reduced to 40 psig (276 kpa) prior to shipping. Figure 5: Y-Strainer with Union End Ball 2.29 (58) 2.65 (67) 2.44 (62) 2.73 (69) 2.04 (52).89 (48) 2.69 (68) 3.60 (9) 3.80 (97) 3.50 (89) 4.00 (02) 5.38 (37).90 (48) 2.0 (53) 2.8 (7) 0.95 (24).05 (27).4 (36).55 (39) 2.00 2.00 6.97 (77) 9.07 (230) 9.40 (239) 3.8 (.7) 4.3 (2) 5.6 (2.5) Figure 6: Pressure Gauge 6 PP Series Piping Packages for VG000 Series Ball s Product Bulletin
Return Pipe Components The return pipe components include: Combination commissioning valve and automatic flow limiting valve, or a calibrated manual balancing valve with shut-off ball valve. These valves are rated for 400 psig (2,758 kpa) and 250 F (2 C). VG000 Series Ball, rated for water usage for 580 psig (3,999 kpa) at 203 F (95 C) (brass stem models) or 464 psig (3,99 kpa) at 284 F (40 C) (stainless steel stem model). Union connection with pressure taps, rated for 400 psig (2,758 kpa) and 250 F (2 C). Union Connection The union connection includes the following accessories: /4 in. male national pipe thread (MNPT) pressure and temperature test plug /4 in. MNPT coin operated manual air vent See Figure 7 and Table 7 for the dimensions of the union connection. Table 7: Union Connection Dimensions, in. (mm) Size A B C D E F T (max) L (max) Weight, lb (kg) (9) -/4 (32) 2.98 (76) 3.9 (8) 3.73 (95) 0.88 (22) 0.97.24 (3) 2.0 2.4 (54) 2.40 (6) Figure 7: Union Connection 2.96 (75) 3.9 (8) 3.80 (97) 0.86 (22) 0.89 (23).08 (27).28 (33).5 (38).89 (48).55 (39) 2.00 2.00 3.59 (9) 4.4 (2) 4.2 (05).3 (0.59).6 (0.73) 2.4 (.09) PP Series Piping Packages for VG000 Series Ball s Product Bulletin 7
Combination Commissioning and Automatic Flow Limiting The combination commissioning valve and automatic flow limiting valve include the following accessories: Removable flow limiting diaphragm cartridge Note: The diaphragm cartridge allows easy access for inspection, cleaning, or flow rate changes without disturbing the piping. Two in. pressure and temperature ports Hanging ID tag for commissioning See Figure 8 and Table 8 for the dimensions of the combination commissioning valve and automatic flow limiting valve. Table 8: Combination Commissioning and Automatic Flow Limiting Dimensions, in. (mm) Size A B C D E F G H T (max) L (max) Weight, lb (kg) (9) -/4 (32).42 (36).42 (36).65 (42) Figure 8: Combination Commissioning and Automatic Flow Limiting.93 (49).93 (49) 2.87 (73).38 (35).46 (37).85 (47) 3.74 (95) 3.74 (95) 5.2 (32).8 (30).8 (30).89 (48) 2.36 (60) 2.36 (60) 2.95 (75) 3.03 (77) 3.03 (77) 4.67 (9).77 (45).77 (45) 2.46 (62) 0.98.69 (43).93 (49) 5.39 (37) 6.8 (57) 8.45 2.4 (.09) 2.6 (.8) 7. (3.22) 8 PP Series Piping Packages for VG000 Series Ball s Product Bulletin
Calibrated Manual Balancing with Shut-Off Ball This valve includes the following accessories: Lockable adjustment knob with scale Two /4 in. MNPT pressure and temperature test plugs Commissioning tag See Figure 9 and Table 9 for the dimensions of the calibrated manual balancing valve with shut-off ball valve. Table 9: Calibrated Manual Balancing with Shut-Off Ball Dimensions, in. (mm) Size A B C D E F L (max) G L (max) T (max) Weight, lb (kg) (9) -/4 (32) 2.03 (52) 2.8 (55) 2.32 (59) Figure 9: Calibrated Manual Balancing with Shut-Off Ball 3.2 (79) 3.42 (87) 3.70 (94) 0.66 (7) 0.8 (2).00 2.20 (56) 2.5 (64) 3.29 (84) 2.28 (58) 2.62 (67) 3. (79) 3.66 (93) 4.36 () 5.05 (28) Calibrated Manual Balancing Flow Charts See Figure 0 through Figure 2 for flow charts of the in., in., and -/4 in. calibrated manual balancing valves. - 4.68 (9) - 5.55 (4) - 6.25 (59) 6.23 (58) 7.55 (92) 8.25 (20).55 (39) 2.00 2.00 2.4 (.09) 3.4 (86) 5.2 (32) PP Series Piping Packages for VG000 Series Ball s Product Bulletin 9
Figure 0: Flow Chart for the in. Calibrated Manual Balancing Figure : Flow Chart for the in. Calibrated Manual Balancing 0 PP Series Piping Packages for VG000 Series Ball s Product Bulletin
Figure 2: Flow Chart for the -/4 in. Calibrated Manual Balancing PP Series Piping Packages for VG000 Series Ball s Product Bulletin
Bypass Pipe Components (Three-Way Models) Ball The ball valve includes four ports each with a plug installed. Figure 3: Bypass Pipe Ball Table 0: Calibrated Manual Balancing with Shut-Off Ball Dimensions, in. (mm) Size A B C D E F G H J T (max) L (max) Weight, lb (kg) (9) -/4 (32) 2.02 2.67 (68) 2.69 (68) 0.4 (0) 0.66 (7) 0.88 (22) 2.53 (64) 2.76 (70) 2.76 (70) 4.58 (6) 5.05 (28) 5.05 (28) 3.54 (90) 3.79 (96) 4.4 (05) 3.38 (86) 3.50 (89) 4.00 (02).03 (26).45 (37).43 (36) 0.90 (23).4 (29).4 (29).8 (46) 2.28 (58) 2.28 (58).55 (39).55 (39) 2.00 3.97 (0) 5.08 (29) 5.57 (4).6 (.09).9 (86) 2.9 (32) 2 PP Series Piping Packages for VG000 Series Ball s Product Bulletin
Motorized Control s The VG000 Series Ball is a motorized control valve (Figure 4). Refer to the VG000 Series Forged Brass Ball s Product Bulletin (LIT-97732) for more details. All threaded ball valves are compatible with the piping packages. For more information on the electric valve actuators as well as available models, refer to the following documents: VA904-xGA-2S, -3S Series Electric Non-Spring Return Actuators Product Bulletin (LIT-20050) M906-xGx-2 Series Electric Non-Spring Return Actuators Product Bulletin (LIT-26823) VA9203 Series Electric Spring Return Actuator Product Bulletin (LIT-20702) Installation The PP Series Piping Package allows for a simple installation to the VAV box. Use the following steps and Figure 5 to install the piping package. Figure 4: Motorized Control s Figure 5: Piping Package Return and Supply Sides. Verify that the pressure in the pipe is above the ambient pressure on the gauge. Note: Pipes are tested in production at 00 psig (689 kpa) for 24 hours and brought down to 40 psig (276 kpa) prior to shipping. 2. Measure the length of pipe needed on the supply side and on the return side to match the length needed for the installation. 3. Cut the pipe at the location measured. 4. Sweat or press the supply side of the pipe. 5. Measure the length of pipe needed on the bypass (for the three-way valve models). 6. Sweat or press the return side of the pipe. For the three-way valve models: PP Series Piping Packages for VG000 Series Ball s Product Bulletin 3
7. Screw the bypass pipe into the Y-strainer with a union end ball valve on the supply line. 8. Sweat the pipe provided to the ball valve on the bypass pipe. Repair Information If the PP Series Piping Package fails to operate within its specifications, replace the unit. For a replacement piping package, contact the nearest Johnson Controls representative. Technical Specifications Y-Strainer with a Union End Ball Product Code Body Ball Ball Seal Stem O-Rings Filter Screen Maximum Seat Pressure Rating Operating Temperature Union Connection Product Code Body O-Ring Maximum Pressure Maximum Operating Temperature UBY Forged brass C37000 Full port chrome plated Teflon Explosion-proof Ethylene propylene diene monomer (EPDM) 20 mesh, stainless steel 400 psig (2,758 kpa) -4 to 250 F (20 to 2 C) UA Forged brass C37000 EPDM 400 psig -4 to 250 F (20 to 2 C) Combination Commissioning and Automatic Flow Limiting Product Code AC Body Brass C3770 Ball Chrome plated brass C3770 Ball Seat Teflon O-Ring EPDM Diaphragm Reinforced EPDM Spring Stainless steel Tail Piece, Nut Brass Stem Blowout-proof Maximum Seat Pressure Rating 400 psig (2,758 kpa) Operating Temperature -4 to 250 F (20 to 2 C) Flow Rate Accuracy ±5% Cartridge (Included in Combination Commissioning and Automatic Flow Limiting ) Body Spring Diaphragm and O-Ring Orifice Brass C36000 or equivalent 304 stainless steel EPDM Brass C36000 or equivalent 4 PP Series Piping Packages for VG000 Series Ball s Product Bulletin
Calibrated Manual Balancing with Shut-Off Ball Product Code MC Body Brass ASTM B584-844 Ball Brass ASTM B6 C36000 Ball Seal Glass and carbon-filled Teflon Stem O-Ring EPDM Maximum Working Pressure 300 psig (2,069 kpa) Operating Temperature -4 to 250 F (20 to 2 C) Pressure Gauge Case Black painted steel Dial Black figures on white background Tube and Sprocket Bronze Accuracy ASME B40.00, Grade B, ±3.75% (0 to 25 psig [0 to 72 kpa]: 3%, 25 to 75 psig [72 to 57 kpa]: 2%, 75 to 00 psig [57 to 689 kpa]: 3%) Operating Temperature -40 to 50 F (-40 to 65 C) Ball (Three-Way Models) Product Code Body Handle Ball Ball Seal O-Ring Union Seal Stem Maximum Seat Pressure Rating Operating Temperature Pipe Copper Pipe UBV Brass C37000 Chrome plated steel with plastic cover Chrome plated Teflon EPDM Viton O-ring Explosion-proof 400 psig (2,758 kpa) -4 to 250 F (20 to 2 C) Type L The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these specifications, consult the local Johnson Controls office. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication or misuse of its products. Building Efficiency 507 E. Michigan Street, Milwaukee, WI 53202 Metasys and Johnson Controls are registered trademarks of Johnson Controls, Inc. All other marks herein are the marks of their respective owners. 204 Johnson Controls, Inc. PP Series Piping Packages for VG000 Series Ball s Product Bulletin 5 Published in U.S.A. www.johnsoncontrols.com