Honeywell 393691, 394588 Installation Instructions Manual

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69-0244EF-01

393691 LP Gas and 394588

WARNING

Natural Gas Conversion Kits

FOR VR8200/VR8300/SV9500/SV9600 FAMILY OF COMBINATION GAS CONTROLS

INSTALLATION INSTRUCTIONS

APPLICATION

The 393691 LP Conversion Kit changes VR8200/VR8300/SV9500/SV9600 family combination gas controls from regulated natural gas to regulated LP gas. The 394588 Natural Gas Conversion Kit changes VR8200/VR8300/SV9500/SV9600 family combination gas controls from regulated LP gas to regulated natural gas. Kits include a new cap screw, pressure regulator adjustment screw, spring and conversion label.

To use this kit, assure gas control is equipped with a standard or slow opening pressure regulator.

NOTE: Step regulator valves cannot be converted.

INSTALLATION

When Installing this Product…

1. Read these instructions carefully. Failure to

follow instructions can damage product or cause a hazardous condition.

2. Check ratings given in instructions and on

product to make sure product is suitable for your application.

3. The installer must be a trained, experienced

service technician.

4. After installation is complete, use these instruc-

tions to check out product operation.

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

Follow these warnings exactly:

1. Disconnect power supply before wiring to prevent electrical shock or equipment damage.

2. To avoid dangerous accumulation of fuel gas, turn off gas supply at appliance service valve before starting installation and perform Gas Leak Test after completion of installation.

3. Use only y our ha nd to turn g as con trol k nob. Never use any tools. If gas control knob will not operate by hand, then a qualified technician should replace the gas control. Force or attempted repair may result in fire or explosion.

4. Change main and pilot burner orifices to meet appliance manufacturer specifications.

To convert from one gas to another:

1. Turn off gas supply at the appliance service

valve.

2. Remove regulator cap screw and pressure

regulator adjusting screw. Refer to Fig. 1.

3. Remove the existing spring.

4. Insert the replacement spring. Refer to Fig. 2.

PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW)

INLET PRESSURE TAP

INLET

1 THERMOCOUPLE CONNECTION

THERMOCOUPLE CONNECTION AND RED RESET BUTTON ON STANDING PILOT MODELS ONLY.

Fig. 1. Top view of VR8200 combination gas control.

RED RESET BUTTON

CONVENIENCE TERMINALS (2) (OPTIONAL)

GAS CONTROL KNOB

WIRING TERMINALS (2)

OUTLET PRESSURE TAP

OUTLET

PILOT OUTLET

PILOT ADJUSTMENT (UNDER CAP SCREW)

M8084

393691 LP GAS AND 394588 NATURAL GAS CONVERSION KITS

WARNING

COLOR CODE FOR LP

GAS

NATURAL GAS

CAP SCREW BLACK

BLACK BLACK

SILVER

PRESSURE REGULATOR ADJUSTING SCREW

BLACK BLACK

SPRING

RED

STAINLESS STEEL

PRESSURE REGULATOR HOUSING

M7780B

O RING

Perform Gas Leak Test

Gas Leak Test

1. Paint pipe connections upstream of gas control

2. If gas leak is detected, tighten all pipe connec-

3. Stand clear of main burner while lighting to pre-

4. With main burner operating, paint pipe joints

5. If another gas leak is detected, tighten adapter

Fig. 2. Conversion kit installation in regulator.

5. Install the new plastic pressure regulator

adjustment screw. Assure that the screw top is flush with the regulator top.

6. Turn pressure regulator adjustment screw

clockwise eleven complete turns. The preliminary pressure setting is approximately

10.0 in. wc (2.5 kPa) for LP gas regulator (393691) and 3.5 in. wc (0.9 kPa) for natural gas regulator (394588).

7. Check the regulator setting using a manometer

or by clocking the gas meter. See Check and Adjust Gas Input and Burner Ignition section.

8. Install the new cap screw and O ring.

9. Mount conversion label on the gas control.

10. Install the gas control and appliance according

to appliance manufacturer instructions.

START-UP

Gas Control Knob Settings

OFF: Prevents pilot and main burner gas flow.

PILOT (On standing pilot controls only): Permits pilot burner gas flow when red knob is held down or thermocouple current is above power unit dropout value.

ON: Permits gas flow into gas control. Pilot burner gas is controlled as in the PILOT position for standing pilot and intermittent pilot systems. Main burner gas flow is controlled by thermostat and automatic valve operators.

6. Replace part if gas leak can not be stopped.

Light Pilot (Standing Pilot Models)

1. Turn gas control knob clockwise to OFF.

2. Turn gas control knob counterclockwise

3. Hold down the gas control knob about one min-

Turn on System (Intermittent and Direct Ignition Systems)

Rotate the gas control kno b counterclockwise to ON.

Turn on Main Burner

Follow appliance manufacturer instructions or adjust thermostat setting to call for heat.

Adjust Pilot Flame

The pilot flame should envelop 3/8 to 1/2 in. (10 to 13 mm) of the thermocouple or igniter-sensor tip. Refer to Fig. 3. To adjust pilot flame:

1. Remove pilot adjustment cap screw. Refer to

2. Turn inner adjustment screw clockwise to

3. Always replace cap screw after adjustment and

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

Check for gas leaks with soap and water solution any time work is done on a gas system.

with rich soap and water solution. Bubbles indicate gas leak.

tions.

vent injury caused from hidden leaks that could cause flashback in the appliance vestibule. Light main burner.

(including adapters) and control inlet and outlet with rich soap and water solution.

screws, joints, and pipe connections.

Wait five minutes to dissipate any unburned gas. Smell for gas around the appliance near the floor. Do not relight pilot flame if you smell gas.

to PILOT. Push down and hold the knob while lighting the pilot flame.

ute, then release. a. If pilot flame goes out, turn gas control knob

clockwise to OFF and repeat steps 1 through 3.

b. If pilot flame remains lit, turn gas control

knob counterclockwise to ON.

Fig. 1.

decrease or counterclockwise to increase pilot flame.

tighten firmly to safeguard proper operation.

69-0244EF—01 2

393691 LP GAS AND 394588 NATURAL GAS CONVERSION KITS

CAUTION

PROPER FLAME ADJUSTMENT

Fig. 3. Proper flame adjustment.

3/8 TO 1/2 IN. (10 TO 13 MM)

THERMOCOUPLE

M3086B

Check and Adjust Gas Input and Burner Ignition

Equipment Damage Hazard. Exceeding input ratings can damage the equipment.

1. Do not exceed input rating stamped on appliance nameplate, or manufacturer recommended burner orifice pressure for size orifice(s) used. Make certain primary air supply to main burner is properly adjusted for complete combustion. Follow appliance manufacturer instructions.

2. IF CHECKING GAS INPUT BY CLOCKING GAS METER:

a. Make sure that the only gas flowing

through the meter is for the appliance being checked.

b. Make certain that other appliances are

turned off with their pilot flames extinguished (or deduct their gas consumption from the meter reading).

c. Convert flow rate to Btuh as described in

form 70-2602, Gas Controls Handbook, and compare to Btuh input rating on appliance nameplate.

3. IF CHECKING GAS INPUT WITH MANOMETER:

a. Be sure the gas control knob is in the

PILOT position before removing outlet pressure tap plug to connect manometer (pressure gauge).

b. Turn the gas control knob back to PILOT

when removing gauge and replacing plug.

c. Shut off gas supply at the appliance

service valve, or for LP gas, at the gas tank, before removing the outlet pressure tap plug and before disconnecting manometer and replacing outlet pressure tap plug.

d. Perform Gas Leak Test at outlet pressure

tap plug.

Checking Gas Pressure Using a Manometer (Pressure Gauge)

1. Turn gas control knob to PILOT (standing pilot

systems) or OFF (intermittent and direct ignition systems).

2. Remove outlet pressure tap plug from gas con-

trol and connect pressure gauge. Refer to Fig. 1.

3. Turn gas control knob to ON position.

4. To obtain an accurate outlet pressure reading,

main burner must be cycled on and off several times to stabilize the pressure regulator diaphragm.

5. Light main burner and read pressure gauge.

6. If necessary, adjust pressure regulator to match

appliance rating. (On step-opening regulators, match the full rate outlet pressure.) a. Remove pressure regulator adjustment cap

screw.

b. Using a screwdriver, turn inner adjustment

screw clockwise to increase or counterclockwise to decrease gas pressure to main burner.

c. Always replace cap screw and tighten firmly

to prevent gas leakage.

7. Turn gas control knob to PILOT (standing pilot

system) or OFF (intermittent and direct ignition systems).

8. Remove pressure gauge and replace outlet

pressure tap plug and pressure regulator cap screw.

9. Proceed to Checkout section.

Checking Gas Pressure Using Meter Clocking Method

NOTE: Use this method when manometer is not

available or when manifold pressure is not specified in in. wc (kPa) by the burner manufacturer.

1. Make sure that the only gas flowing through the

meter is for the appliance being checked.

2. Make certain that other appliances are turned

off with their pilot flames extinguished (or deduct their gas consumption from the meter reading).

3. Turn gas control knob or switch to ON position.

4. To obtain an accurate outlet pressure reading,

cycle main burner on and off several times to stabilize the pressure regulator diaphragm.

5. Using a watch with a second hand, carefully

clock the gas meter to determine the time per revolution. Use Table 1 to determine the exact main burner gas flow rate in cubic feet per hour (cfh). a. For one ft

use Table 1 directly.

b. For 1/2 ft

(1) Determine time for two dial revolutions (2) Use Table 1 directly.

c. For two ft

(1) Determine time for one complete dial

(2) Divide time by two. (3) Use Table 1 directly.

6. Compare actual input with burner manufacturer

recommended input (stamped on burner nameplate). To convert Btuh rating to cfh

/hr) use the following formula:

Input Rating in Btuh = (cfh) x (the BTU content of the gas)

7. If necessary, adjust pressure regulator to match