Honeywell V804B, V404B Installation Manual

Honeywell
V400 AND V800
COMBINATION GAS CONTROLS
APPLICATION
V400 and V800 are used on gas fired standing pilot appliances with 30 mV thermocouple. These gas controls include a manual gas valve, safety shutoff, single millivolt­age automatic operator, and pressure regulator, pilot gas filter and flow adjustment, pressure tapping, and thermo­couple connector.
V400 is used on 120V systems. V800 is used on 24V systems. Refer to Table 1 for more specifications. Refer to Table 2 for available gas capacities.
V800 gas controls are available with 1/4 x 1/4 inch or 3/ 16 x 1/4 inch energy cut-off (ECO) quick-connects. With the connector, an ECO high limit can be connected into the power circuit. When the temperature at the ECO exceeds the high limit, a switch opens and de-energizes the power
TABLE 1—MODEL SPECIFICATIONS.
MODEL NUMBER AMBIENT PRESSURE PRESSURE
SUFFIX LETTER TEMPERATURE RANGE REGULATOR TYPE REGULATOR MODEL
A32° F to 175° F Standard-Opening V5306A C32° F to 175° F Step-Opening V5307A M-40° F to 175° F Standard-Opening V5306B P-40° F to 175° F Step-Opening V5307B
PIPE SIZE CAPACITY
(INLET x 1 INCH WCPD CAPACITY CAPACITY
OUTLET) ft
1/2" x 3/8" 110 3.1 110 3.1 11 0.3
1/2" x 1/2" 225 6.4 225 6.4 23 0.7
1/2" x 3/4" 250 7.1 290 8.2 23 0.7
3/4" x 3/4" 335 9.5 425 12.0 34 1.0
a
Capacity is based on 1000 Btu/ft3, 0.64 specific gravity natural gas at 1 inch wc pressure drop [37.3 MJ/m3, 0.64 specific
gravity natural gas at 0.25 kPa pressure drop]. Use conversion factors to convert to other gases.
[0° C to 79° C]
[0° C to 79° C] [-40° C to 79° C] [-40° C to 79° C]
TABLE 2—GAS CONTROL CAPACITIES.
GAS CONTROL MAXIMUM MINIMUM
3
/hr m3/hr ft3/hr m3/hr ft3/hr m3/hr
a
AT REGULATION REGULATION
unit and shuts off main burner and pilot gas flow. To restart system, pilot flame must be relit and gas control must be reset manually.
Power for the gas control and the control system is provided by a 30 mV thermocouple. We recommend the Q340 Thermocouple.
Replacement parts:
1. Energy cut off (ECO) connector: 392451-1
2. Pressure Regulators: Standard opening pressure regulator: V5306A,B. Step opening pressure regulator: V5307A,B.
3. Valve Operators: Line Voltage Operator: V404B. Low Voltage Operator: V804B.
TYPE OF GAS SPECIFIC GRAVITY MULTIPLY LISTED CAPACITY BY: Manufactured 0.60 0.516
Mixed 0.70 0.765 Propane 1.53 1.62
INSTALLATION
WHEN INSTALLING THIS PRODUCT…
1. Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition.
2. Check the ratings given in these instructions and on the product to ensure the product is suitable for your application.
J.A. Form Number 95-6996—10 Rev. 6-91 ©Honeywell Inc. 1991
3. Ensure installer is a trained, experienced service
technician.
4. After completing installation, use these instructions to
check product operation.
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE, SEVERE IN­JURY, OR DEATH
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 following installation.
3. Do not bend pilot gas tubing at control or at pilot
burner after compression fitting is tightened. Gas leakage at the connection may result.
4. Always install sediment trap in gas supply line to
prevent contamination of gas control.
5. Do not force gas control knob. Use only your hand
to turn gas control knob. If the knob will not operate by hand, the control should be replaced by a qualified service technician. Force or attempted repair may result in fire or explosion.
Never apply a jumper across (or short) gas control coil terminals. This may burn out thermostat heat anticipator.
These gas controls are shipped with protective seals over inlet and outlet tappings. Do not remove seals until ready to connect piping.
Follow the appliance manufacturer’s instructions if avail­able; otherwise, use the instructions provided below as a guide.
CHOOSE LOCATION
Do not locate the combination gas control where it may be affected by steam cleaning, high humidity, dripping water, corrosive chemicals, dust or grease accumulation, or excessive heat. To ensure proper operation, follow these guidelines.
• Locate in a well ventilated area.
• Mount high enough above the cabinet bottom to avoid exposure to flooding or splashing water.
• Ensure the ambient temperature does not exceed the ambient temperature ratings for each component.
• Cover gas control if appliance is cleaned with water, steam, or chemicals or to avoid dust and grease accumulation.
• Avoid locating where exposure to corrosive chemical fumes or dripping water are likely.
Mount combination gas control in the appliance vesti­bule on the gas manifold. In replacement applications, mount gas control in the same location as the old control.
INSTALL PIPING TO CONTROL
All piping must comply with local codes and ordinances or with National Fuel Gas Code (ANSI Z223.1 NFPA No.
1. Use new, properly reamed pipe free from chips. If tubing is used, make sure ends are square, deburred, and clean. All tubing bends must be smooth and without defor­mation.
2. Run pipe or tubing to the control. If tubing is used, obtain a tube-to-pipe coupling to connect tubing to the
CAUTION
IMPORTANT
control.
3. Install sediment trap in gas supply line. Refer to Fig. 1.
INSTALL CONTROL
1. This control can be mounted 0-90 degrees, in any direction, from the upright position of the gas control knob, including vertically.
2. Mount the control so gas flow is in direction of arrow on bottom of control.
3. Thread pipe the amount shown in Table 3 for insertion into control. DO NOT THREAD PIPE TOO FAR. Valve distortion or malfunction may result if pipe is inserted too deeply.
DROP
3 IN.
PIPED GAS SUPPLY
GAS CONTROL
2
DROP
TUBING
1
GAS SUPPLY
2
GAS CONTROL
2
HORIZONTAL
3 IN.
(76 MM)
MINIMUM
HORIZONTAL
RISER
(76 MM)
MINIMUM
ALL BENDS IN METALLIC TUBING SHOULD BE SMOOTH.
1
CAUTION: SHUT OFF THE MAIN GAS SUPPLY BEFORE REMOVING
2
END CAP TO PREVENT GAS FROM FILLING THE WORK AREA. TEST FOR GAS LEAKAGE WHEN INSTALLATION IS COMPLETE.
RISER
PIPED GAS SUPPLY
3 IN.
(76 MM)
MINIMUM
GAS CONTROL
M3077
Fig. 1Install sediment trap.
TABLE 3—NPT PIPE THREAD LENGTH (IN.).
PIPE THREAD CAN BE INSERTED SIZE LENGTH INTO CONTROL
OVERALL MAXIMUM DEPTH PIPE
3/8 9/16 3/8 1/2 3/4 1/2 3/4 13/16 3/4
19/16 1
4. Apply moderate amount of good quality pipe com­pound to adapter, leaving two end threads bare. Refer to Fig. 2. (On LP gas installations, use compound resistant to LP gas.) Do not use Teflon tape.
5. Remove seals over control inlet and outlet, if neces­sary.
6. Connect pipe to control inlet and outlet. To tighten inlet and outlet connections, use wrench on projecting wrench boss. Refer to Figs. 3 and 4.
2
3. Unscrew brass compression fitting from pilot gas
TWO IMPERFECT THREADS
THREAD PIPE THE AMOUNT SHOWN IN TABLE FOR INSERTION INTO GAS CONTROL
GAS CONTROL
PIPE
APPLY A MODERATE AMOUNT OF PIPE COMPOUND TO PIPE ONLY (LEAVE TWO END THREADS BARE).
M3075B
Fig. 2Use moderate amount of pipe compound.
PRESSURE REGULATOR ADJUSTMENT (BENEATH COVER SCREW)
MANUAL GAS CONTROL KNOB
WRENCH BOSS
PILOTSTAT POWER UNIT
GAS INLET
OFF
INLET
PILOT
STANDARD PRESSURE
ON
PILOT FLOW ADJ. SCREW (BENEATH COVER SCREW)
REGULATOR ("A" MODEL)
STEP OPENING REGULATOR ("C" MODEL)
INSTALL LONG SCREW IN OUTSIDE CORNER
PILOT GAS OUTLET. PRESSURE TAPPING DIRECTLY BENEATH
M17845
Fig. 3Top view of standard capacity gas control.
CONNECT PILOT GAS TUBING
1. Cut tubing to desired length and bend as necessary for routing to pilot burner. Do not make sharp bends or deform tubing. Do not bend tubing at control after compres­sion nut has been tightened, as this may result in gas leakage at connection.
2. Square off and remove burrs from end of tubing.
outlet. Refer to Fig. 4. Slip fitting over tubing and slide out of way.
NOTE: When replacing a control, cut off old compression
fitting and replace with new compression fitting provided on new combination gas control. Never use old com­pression fitting as it may not provide a gas-tight seal. Refer to Fig. 4.
4. Push tubing into pilot gas tapping on outlet end of the control until it bottoms. While holding tubing all the way in, slide fitting into place and engage threads. Turn until finger tight. Then tighten one more turn with wrench. Do not overtighten.
5. Connect other end of tubing to pilot burner according to pilot burner manufacturers instructions.
GAS CONTROL
TIGHTEN NUT ONE TURN BEYOND FINGER TIGHT.
FITTING BREAKS OFF AND CLINCHES TUBING AS NUT IS TIGHTENED.
TO PILOT BURNER
M3076A
Fig. 4Always use new compression fitting.
CONNECT THERMOCOUPLE
The thermocouple connection to the power unit or ECO connector (Fig. 3) is an electrical connection and must be clean and dry. Never use pipe compound. Tighten only 1/4 turn beyond finger tight to give good electrical continuity.
CONNECT ECO (Standard-Capacity models only)
If the ECO is provided, the leadwires must be equipped with insulated 1/4 in. female quick-connect terminals. Leadwire lengths must not exceed the lengths shown in Tables 4 and 5. Connect high limit or ECO leadwires to the two terminals on the thermocouple.
If ECO is not provided, connect a Q313B Thermopile Generator in place of the thermocouple to act as the high­limit for the system.
TABLE 4MAXIMUM LENGTH OF SUPPLEMENTARY LIMIT LEADWIRES WHEN USING Q340A THERMOCOUPLE.
THERMOCOUPLE MAXIMUM LEADWIRE LENGTH X 2 (wires)
LENGTH AWG NO. 14 AWG NO. 16 AWG NO. 18 in. m in. m in. m in. m 18 0.5 35 0.9 22 0.6 13 0.3 24 0.6 29 0.7 18 0.5 11 0.3 30 0.8 23 0.6 15 0.4 9 0.2 36 0.9 17 0.4 11 0.3 6 0.2 48 1.2 DO NOT USE. 60 1.5
TABLE 5MAXIMUM LENGTH OF SUPPLEMENTARY LIMIT LEADWIRE WHEN USING Q309A THERMOCOUPLE.
THERMOCOUPLE MAXIMUM LEADWIRE LENGTH X 2 (wires)
LENGTH AWG NO. 14 AWG NO. 16 AWG NO. 18 in. m in. m in. m in. m 12 0.3 47 1.2 30 0.8 18 0.5 18 0.5 41 1.0 26 0.7 16 0.4 24 0.6 35 0.9 22 0.6 14 0.4 30 0.8 29 0.8 18 0.5 11 0.3 36 0.9 23 0.6 15 0.4 9 0.2 40 1.0 19 0.5 12 0.3 7 0.2 48 1.2 11 0.3 7 0.2 60 1.5 DO NOT USE.
3 95-699610
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