Page 1
VR4300
Continuous Pilot
Combination Gas Control
Application
These continuous pilot gas controls are used in gas-fired
appliances with capacities up to 300 feet3/hour at one inch wc
pressure drop [5.7 meters3/hour at 0.25 kPa] on natural gas.
They include a manual valve, safety shutoff, two automatic
operators, a pressure regulator, pilot adjustment, and a conduit cover. See Table 1 for temperature ranges and regulator
types.
BODY PATTERN: Straight-through body pattern.
CAPACITY:
Inlet x Outlet Capacity at 1 inch wc Minimum Maximum
Size (In.) Pressure Drop
1/2 X 1/2 180 feet3/hour 30 feet3/hour 225 feet3/hour
1/2 X 3/4 190 feet3/hour 30 feet3/hour 290 feet3/hour
3/4 X 3/4 200 feet3/hour 30 feet3/hour 300 feet3/hour
a
Capacity based on 1000 Btu/feet3, 0.64 specific gravity natural gas at 1 inch wc pressure drop [37.3 MJ/meter3, 0.64 specific
gravity natural gas at 0.25 kPa pressure drop].
[5.1 meter3/hour] [0.8 meter3/hour] [6.4 meter3/hour]
[5.4 meter3/hour] [0.8 meter3/hour] [8.2 meter3/hour]
[5.7 meter3/hour] [0.8 meter3/hour] [8.5 meter3/hour]
a
INLET X OUTLET SIZES AVAILABLE: 1/2 by 3/4 inch
and 3/4 by 3/4 inch.
ADAPTERS: Adapters available for 1/2 and 3/4 inch straight
and angle connections. Refer to Table 2.
ELECTRICAL RATINGS:
Voltage and Frequency: 120 Vac, 60 Hz.
Current Draw: 0.14A.
Use conversion factors in Table 3 to convert capacities for
other gases.
Regulated Capacity Regulated Capacity
TABLE 1—TEMPERATURE RANGES AND
REGULATOR TYPES.
Ambient
Model Temperature Regulator
Number Range Type
VR4300A 0° F to 175° F Standard-opening
[-18° C to +79° C]
VR4300C 0° F to 175° F Step-opening
[-18° C to +79° C]
VR4300H 0° F to 175° F Slow-opening
[-18° C to +79° C]
VR4300M -40° F to 175° F Standard-opening
[-40° C to +79° C]
VR4300P -40° F to 175° F Step-opening
[-40° C to +79° C]
T.H. • Rev. 3-93 • © Honeywell Inc. 1993 • Form Number 69-0683—1
TABLE 2—ADAPTER (FLANGE) PART NUMBERS.
Part Number
Inlet/ Without With
Outlet Flange Hex Hex
Pipe Size Type Wrench Wrench
1/2 inch NPT Straight 393690-6 393690-16
Elbow 393690-3 393690-13
3/4 inch NPT Straight 393690-4 393690-14
Elbow 393690-5 393690-15
NOTE: Flange kits include one flange with attached O-ring
and fan mounting screw.
TABLE 3—GAS CAPACITY CONVERSION
FACTORS.
Specific Multiply Listed
Gas Gravity Capacity By
Manufactured 0.60 0.516
Mixed 0.70 0.765
Propane 1.53 1.62
APPROVALS:
American Gas Association design certificate: UP-70-57A.
Canadian Gas Association design certificate: 1029-CC-8375.
Page 2
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 the instructions and on the
product to assure the product is suitable for your application.
3. Assure installer is a trained, experienced service technician.
4. After installation is complete, use these instructions to
check out 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 the appliance service valve
before starting installation, and perform Gas
Leak Test after completion of installation.
3. Do not bend pilot tubing at gas control or pilot burner
after compression fitting has been tightened because
gas leakage at the connection can result.
4. Always install sediment trap in gas supply line
to prevent contamination of gas control.
5. Do not force the gas control knob. Use only your
hand to push down the reset button or turn the
gas control knob. Never use any tools. If the gas
control knob or reset button will not operate by
hand, replace the gas control using a qualified
service technician. Force or attempted repair can
result in fire or explosion.
CAUTION
!
Never apply a jumper across or short the valve coil
terminals. This may burn out the heat anticipator in
the thermostat.
IMPORTANT:
1. These gas controls are shipped with protective seals
over inlet and outlet tappings. Do not remove seals
until ready to connect piping.
2. When a gas control is installed external to the appliance, a conduit cover MUST be installed. Make sure
that conduit cover is placed over the flange before
rotating conduit cover into position.
Follow the appliance manufacturer’s instructions if avail-
able; otherwise, use the instructions provided below.
CONVERTING BETWEEN NATURAL AND LP GAS
To convert a gas control from natural gas to LP gas or
from LP gas to natural gas, contact your Honeywell
representative.
Convert standard- or slow-opening gas controls from
one gas to another with a conversion kit (ordered separately). Order part number 393691 to convert from natural
to LP gas. Order part number 394588 to convert from LP
to natural gas. Step-opening gas controls cannot be converted.
INSTALL ADAPTERS TO CONTROL
If adapters are to be installed on the gas control, mount
them as follows:
Flanges
1. Choose the appropriate flange for your application.
2. Remove seal over gas control inlet or outlet.
3. Assure the O-ring is fitted in the groove of flange. If
the O-ring is not attached or is missing, do not use flange.
4. With O-ring facing gas control, align the screw
holes on the gas control with the holes in the flange. Insert
and tighten the screws provided with the flange. See Fig.
1. Tighten the screws to 25 inch pounds of torque to
provide a gas-tight seal.
Bushings
1. Remove seal over gas control inlet or outlet.
2. Apply moderate amount of good quality pipe compound to bushing, leaving two end threads bare. On LP
installation, use compound resistant to LP gas. Do not use
Teflon tape.
3. Insert bushing in gas control and thread pipe carefully into bushing until tight.
Complete instructions below for piping, installing gas
control, connecting pilot tubing, thermocouple and wiring. Make certain the leak test you perform on the control
after completing the installation includes leak testing the
adapters and screws. If you use a wrench on the valve after
flanges are installed, use the wrench on only the flange,
not on the control.
USING ADAPTERS TO SOLVE SWING RADIUS
PROBLEMS
In some field service applications, it is difficult or
impossible to thread the gas control onto the gas supply
pipe because of space limitations. This problem can be
resolved in many applications by using an adapter. Install
the adapter on the end of the supply pipe in place of the gas
Fig. 1—Install flange to gas control.
6/32 INCH ROUND
SCREWS (1)
CONDUIT
COVER
WARNING
!
FIRE OR EXPLOSION HAZARD CAN
CAUSE PROPERTY DAMAGE, SEVERE
INJURY, OR DEATH
Do not use a gas control set for natural gas on LP gas
or a gas control set for LP gas on natural gas.
VALVE OUTLET
1 DO NOT OVERTIGHTEN SCREWS.
TIGHTEN TO 25 INCH POUNDS.
2
1
FLANGE
9/64 INCH HEX SCREWS (4)
M3098A
Page 3
control by following the same precautions and instructions that are used for installing the gas control. After the
adapter is installed, attach the gas control to the adapter as
outlined above. Note that using an adapter increases the
overall length of the gas control.
LOCATION
Mount the combination gas control in the appliance
vestibule on the gas manifold. If this is a replacement
application, mount the gas control in the same location as
the old control.
Do not locate the gas control where it can be affected by
steam cleaning, high humidity, dripping water, corrosive
chemicals, dust or grease accumulation, or excessive heat.
To assure proper operation, follow these guidelines:
• Locate gas control in a well-ventilated area.
• Mount gas control high enough above the cabinet
bottom to avoid exposure to flooding or splashing
water.
• Assure 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 gas control where exposure to corrosive chemical fumes or dripping water is possible.
Install Piping to Gas Control
All piping must comply with local codes and ordinances or with the National Fuel Gas Code (ANSI Z223.1
NFPA No. 54), whichever applies. Tubing installation
must comply with approved standards and practices.
1. Use new, properly reamed pipe free from chips. If
tubing is used, assure the ends are square, deburred and
clean. All tubing bends must be smooth and without
deformation.
2. Run pipe or tubing to the gas control. If tubing is
used, obtain a tube-to-pipe coupling to connect the tubing
to the gas control.
3. Install sediment trap in the supply line to the gas
control. See Fig. 2.
Install Gas Control
1. Mount the gas control 0-90 degrees, in any direction
including vertically, from the upright position of the gas
control knob.
2. Mount the gas control so gas flow is in the direction
of the arrow on the bottom of the gas control.
3. Thread pipe the amount shown in Table 4 for insertion into gas control. Do not thread pipe too far. Valve
distortion or malfunction may result if the pipe is inserted
too deeply into the gas control. See Fig. 3.
TABLE 4—NPT PIPE THREAD LENGTH IN in.
Maximum Depth
Pipe Can Be
Pipe Thread Pipe Inserted Into
Size This Amount Control
3/8 9/16 3/8
1/2 3/4 1/2
3/4 13/16 3/4
4. Apply a moderate amount of good quality pipe
compound (do not use Teflon tape) to pipe only, leaving
two end threads bare. On LP installations, use compound
resistant to LP gas.
5. Remove seals over gas control inlet and outlet if
necessary.
6. Connect pipe to gas control inlet and outlet. Use
wrench on the square ends of the gas control. If an adapter
is used, place wrench on adapter rather than gas control.
Refer to Figs. 4 and 5.
Fig. 2—Sediment trap installation.
DROP
HORIZONTAL
3 INCHES
[76]
MINIMUM
HORIZONTAL
RISER
3 INCHES
[76]
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.
PIPED
GAS
SUPPLY
GAS
CONTROL
2
DROP
TUBING
1
GAS
SUPPLY
2
GAS
CONTROL
2
Fig. 3—Use moderate amount of pipe compound.
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).
Fig. 4—Top view of gas control.
PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)
INLET
PRESSURE TAP
INLET
PILOT ADJUSTMENT
GAS
(UNDER CAP SCREW)
CONTROL
KNOBRED RESET BUTTON
RISER
PIPED
GAS
SUPPLY
3 INCHES
[76]
MINIMUM
WIRING
TERMINALS (3)
OUTLET
PRESSURE
TAP
OUTLET
PILOT OUTLET
GAS
CONTROL
M3077
M3075
M1639C
3 69-0683—1
Page 4
Fig. 5—Proper use of wrench on gas control.
WHEN FLANGE IS NOT USED
APPLY WRENCH
FROM TOP OR
BOTTOM OF GAS
CONTROL TO
EITHER SHADED AREA
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 the tubing. Do not bend tubing at gas control or
pilot burner after compression fitting has been tightened,
because this can result in gas leakage at the connection.
2. Square off and remove burrs from end of tubing.
3. Unscrew compression fitting from the pilot outlet.
See Fig. 4. Slip the compression fitting over the tubing and
slide out of the way.
Fig. 6—Always use new compression fitting.
GAS CONTROL
TIGHTEN NUT ONE TURN
BEYOND FINGER TIGHT
FITTING BREAKS OFF AND CLINCHES
TUBING AS NUT IS TIGHTENED
TO PILOT
BURNER
M3076
NOTE: When replacing a gas control, cut off old compres-
sion fitting and replace with the new compression
fitting provided on the gas control. Never use the old
compression fitting because it may not provide a gastight seal.
4. Push tubing into the pilot gas tapping on the outlet
end of the control until it bottoms. While holding tubing all
the way in, slide compression fitting into place, engage
threads and turn until finger tight. Then tighten one more
turn with wrench. Do not overtighten. Refer to Fig. 6.
5. Connect other end of tubing to pilot burner according
to pilot burner manufacturer’s instructions.
WHEN FLANGE IS USED
APPLY WRENCH
TO FLANGE ONLY
M3083
Connect Thermocouple
Connect thermocouple lead as shown in Fig. 7. Refer to
Tables 5 and 6 for maximum leadwire lengths. This 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. Do not overtighten.
WIRING
Follow the wiring instructions furnished by the appliance manufacturer, if available, or use the general instructions provided below.
All wiring must comply with applicable electrical codes
and ordinances, including insulated quick connect terminals.
Disconnect power supply before making wiring connections to prevent electrical shock or equipment damage.
1. Check the power supply rating on the gas control and
assure it matches the available supply. Install thermostat
and other controls as required.
2. When the gas control is installed external to the
appliance, install the conduit cover on the conduit fitting.
Do not secure conduit cover at this time.
3. Connect control circuit to gas control terminals. See
Figs. 4 and 8.
NOTE: Use leadwires with insulated terminals.
4. Make sure conduit cover is in position and secured to
the gas control with the screw provided. See Fig. 1.
5. Adjust thermostat heat anticipator as instructed in
appliance manual (i.e., usually 0.1A).
4
Page 5
Fig. 7—Installing thermocouple to the power unit. Fig. 8—Wiring connections for 120 volt control.
THERMOCOUPLE
LEAD
1
1
THIS IS AN ELECTRICAL CONECTION AND MUST BE CLEAN
AND DRY. DO NOT USE PIPE COMPOUND.
M3096
120V
THERMOSTAT
2
GAS CONTROL TERMINALS
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
DO NOT JUMPER THESE TERMINALS. THIS
2
SHORTS VALVE COIL AND MAY BURN OUT
ANTICIPATOR IN THERMOSTAT.
OPTIONAL HIGH LIMIT.
3
3
L1
L2
HIGH LIMIT
CONTROLLER
1
L1
(HOT)
L2
M3092A
TABLE 5—MAXIMUM 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
Inches Meters Inches Meters Inches Meters Inches Meters
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 6—MAXIMUM LENGTH OF SUPPLEMENTARY LIMIT LEADWIRES WHEN USING Q309A
THERMOCOUPLE.
Thermocouple Maximum Leadwire Length x 2 (Wires)
Length AWG No. 14 AWG No. 16 AWG No. 18
Inches Meters Inches Meters Inches Meters Inches Meters
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.
5 69-0683—1
Page 6
Start-up and Checkout
WARNING
!
FIRE OR EXPLOSION HAZARD CAN
CAUSE PROPERTY DAMAGE, SEVERE
INJURY, OR DEATH
1. Do not force the gas control knob. Use only your
hand to push down the reset button or turn the
gas control knob. Never use any tools.
2. If the gas control knob or reset button will not
operate by hand, or if the reset button stays
depressed after it is released, the gas control
should be replaced by a qualified service technician.
GAS CONTROL KNOB SETTINGS
The gas control knob has three settings:
OFF: Prevents pilot and main burner gas flow.
PILOT: Permits pilot gas flow only. Gas control knob must be
held depressed or thermocouple must be heated sufficiently
to hold the safety control valve open.
ON: Permits main burner and pilot gas flow. Gas control
and thermostat control main burner gas flow.
NOTE: Gas controls are shipped with the gas control knob in
the ON position.
PERFORM GAS LEAK TEST
ADJUST THE PILOT BURNER FLAME
The pilot flame should envelop 3/8 to 1/2 inch [10 to
13 millimeters] of the thermocouple tip. Refer to Fig. 9. To
adjust the pilot flame:
1. Remove the pilot adjustment cover screw. Refer to
Fig. 5.
2. Turn the inner adjustment screw clockwise to
decrease or counterclockwise to increase the pilot flame.
3. Always replace the cover screw after adjustment and
tighten firmly to assure proper operation.
Fig. 9—Proper flame adjustment.
PROPER FLAME
ADJUSTMENT
LIGHT MAIN BURNER
Follow the appliance manufacturer’s instructions or place
the thermostat setting above room temperature to call for
heat.
CHECK AND ADJUST GAS INPUT TO MAIN
BURNER
3/8 TO 1/2 INCH
10 TO 13 mm
THERMOCOUPLE
M3086
WARNING
!
FIRE OR EXPLOSION HAZARD CAN
CAUSE PROPERTY DAMAGE, SEVERE
INJURY, OR DEATH
Check for gas leaks with rich soap and water
solution any time work is done on a gas control.
GAS LEAK TEST
1. Paint all pipe connections upstream of the gas control
with a rich soap and water solution. Bubbles indicate a gas
leak.
2. If a gas leak is detected, tighten the pipe connection.
3. Stand clear while lighting main burner to prevent
injury caused from hidden gas leaks that could cause flashback in the appliance vestibule. Light the main burner.
4. With the main burner in operation, paint all pipe joints
(including adapters) and gas control inlet and outlet with rich
soap and water solution.
5. If another gas leak is detected, tighten adapter screws,
joints, and pipe connections.
6. Replace the part if gas leak cannot be stopped.
LIGHT THE PILOT BURNER FLAME
1. Turn the gas control knob clockwise to OFF. Wait
five minutes to dissipate any unburned gas. Sniff around the
appliance near the floor. Do not relight the pilot flame if you
smell gas.
2. Turn the gas control knob counterclockwise to
PILOT. Push down and hold the gas control knob while
lighting the pilot flame.
3. Hold the gas control knob down about one minute, then
release.
• If the pilot flame goes out, turn the gas control knob
clockwise to OFF and repeat steps 1 through 3.
• If pilot flame remains lit, turn the gas control knob
counterclockwise to ON.
CAUTION
!
1. Do not exceed the input rating stamped on the
appliance nameplate, or manufacturer’s recommended burner orifice pressure for the size
orifice(s) used. Assure the main burner primary
air supply is properly adjusted for complete
combustion (refer to the appliance
manufacturer’s instructions).
2. IF CHECKING GAS INPUT BY CLOCKING
THE GAS METER:
• Assure that the only gas flow through the
meter is that of the appliance being tested.
• Assure that other appliances are turned off
and that their pilot burners are extinguished
(or deduct their gas consumptions from the
meter reading).
• Convert the flow rate to Btuh as described in
the Gas Controls Handbook (form 70-2602)
and compare to the Btuh input rating on the
appliance nameplate.
3. IF CHECKING GAS INPUT WITH A MANOMETER (PRESSURE GAUGE):
• Assure the gas control knob is in the PILOT
position before removing the outlet pressure
tap plug to connect the manometer.
• Turn the gas control knob back to PILOT
when removing the manometer and replacing outlet pressure tap plug.
• Shut off the 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 the manometer and
replacing the outlet pressure tap plug.
• Perform the Gas Leak Test at the inlet pres-
sure tap plug.
6
Page 7
Standard-Opening and Slow-Opening Pressure Regulator
1. The gas control outlet pressure should match the
manifold pressure listed on the appliance nameplate.
2. With the main burner operating, check the gas control
flow rate using the meter clocking method or check the gas
pressure using a manometer connected to the gas control
outlet pressure tap. Refer to Fig. 4.
3. If necessary, adjust the pressure regulator to match the
appliance rating. Refer to Table 7 or 8 for the factory set
nominal outlet pressures and adjustment ranges.
a. Remove the pressure regulator adjustment cap and
screw.
b. Using a screwdriver, turn the inner adjustment
screw clockwise to increase or counterclockwise to decrease the main burner gas pressure.
c. Always replace the cap screw and tighten firmly to
assure proper operation.
4. If the desired outlet gas pressure or gas flow rate cannot
be achieved by adjusting the gas control, check the gas
control inlet pressure using a manometer at the inlet pressure
tap. If the inlet pressure is in the normal range (refer to Table
7 or 8), replace the gas control. Otherwise, take the necessary
steps to provide proper gas pressure to the gas control.
Step-Opening Pressure Regulator
1. The gas control outlet pressure should match the
manifold pressure listed on the appliance nameplate.
2. With main burner operating, check the gas control
flow rate using the meter clocking method or check the gas
TABLE 5—PRESSURE REGULATOR SPECIFICATION PRESSURES IN in.
Nominal Inlet Setting Setting Range
Type of Pressure Full Full
Model Gas Range Step Rate Step Rate
Standard-, Natural 5.0 - 7.0 — 3.5 — 3.0 - 5.0
Slow-opening LP 12.0 - 14.0 — 10.0 — 8.0 - 12.0
Step- Natural 5.0 - 7.0 0.9 3.5 — 3.0 - 5.0
opening LP 12.0 - 14.0 2.2 10.0 — 8.0 - 12.0
pressure using a manometer connected to the gas control
outlet pressure tap. Refer to Fig. 4.
3. If necessary, adjust the pressure regulator to match
the appliance rating. Refer to Table 7 or 8 for factory set
nominal outlet pressures and adjustment ranges.
a. Remove the pressure regulator adjustment cap screw.
b. Using a screwdriver, turn the inner adjustment screw
clockwise to increase or counterclockwise
to decrease the main burner gas pressure.
c. Always replace the cap screw and tighten firmly to
assure proper operation.
4. If desired outlet pressure or flow rate cannot be
achieved by adjusting the gas control, check the inlet
pressure using a manometer at inlet pressure tap or upstream of the gas control. If the inlet pressure is in the
normal range (refer to Table 7 or 8), replace the existing gas
control. Otherwise, take the necessary steps to provide
proper gas pressure to the gas control.
5. Carefully check main burner lightoff at the step
pressure. Assure the main burner lights smoothly and
without flashback to the orifice and that all ports remain lit.
Cycle the main burner several times, allowing at least 30
seconds between cycles for the regulator to resume the step
function. Repeat after allowing main burner to cool.
Readjust the full rate outlet pressure if necessary to improve lightoff characteristics.
Outlet Pressure
Nominal Factory
TABLE 6—PRESSURE REGULATOR SPECIFICATION PRESSURES IN kPa.
Model Gas Range Step Rate Step Rate
Standard-, Natural 1.2 - 1.7 — 0.9 — 0.7 - 1.2
Slow-opening LP 2.9 - 3.9 — 2.7 — 2.0 - 3.0
Step- Natural 1.2 - 1.7 0.2 0.9 — 0.7 - 1.2
opening LP 2.9 - 3.9 0.9 2.7 — 2.0 - 3.0
CHECK SAFETY SHUTDOWN PERFORMANCE
WARNING
!
FIRE OR EXPLOSION HAZARD CAN
CAUSE PROPERTY DAMAGE, SEVERE
INJURY, OR DEATH
Perform the safety shutdown test any time work is
done on a gas system.
Type of Pressure Full Full
Nominal Inlet Setting Setting Range
Nominal Factory
1. Place gas control knob in PILOT position. Main
burner should go off and pilot should remain lit.
2. Extinguish pilot flame. Pilot gas flow should stop
within 2-1/2 minutes. Safety shutoff of pilot gas proves
complete shutdown since safety shutoff valve prevents
main burner and pilot gas flow.
3. Relight pilot burner and operate system through one
complete cycle to assure all controls operate properly.
7 69-0683—1
Outlet Pressure
Page 8
Maintenance
WARNING
!
FIRE OR EXPLOSION HAZARD CAN
CAUSE PROPERTY DAMAGE, SEVERE
INJURY, OR DEATH
Improper cleaning or reassembly may cause gas
leakage. When cleaning, assure that control is
reassembled properly and perform gas leak test.
Regular preventive maintenance is important in applications that place a heavy load on system controls, such as
in the commercial cooking and agricultural and industrial
industries because:
• In many such applications, particularly commercial
cooking, the equipment operates 100,000-200,000
cycles per year. Such heavy cycling can wear out the
gas control in one to two years.
• Exposure to water, dirt, chemicals and heat can
damage the gas control and shut down the control
system.
The maintenance program should include regular checkout of the gas control as described in the Start-up and
Checkout section, and the control system as described in
the appliance manufacturer’s literature.
Maintenance frequency must be determined individually for each application. Some considerations are:
• Cycling frequency. Appliances that may cycle
100,000 times annually should be checked monthly.
• Intermittent use. Appliances that are used seasonally
should be checked before shutdown and again before
the next use.
• Consequence of unexpected shutdown. Where the
cost of an unexpected shutdown would be high, the
system should be checked more often.
• Dusty, wet, or corrosive environment. Since these
environments can cause the gas control to deteriorate
more rapidly, the system should be checked more
often.
The gas control should be replaced if:
• It does not perform properly during checkout or
troubleshooting.
• The gas control knob is hard to turn or push down, or
it fails to pop back up when released.
• The gas control is likely to have operated for more
than 200,000 cycles.
Service
WARNING
!
FIRE OR EXPLOSION HAZARD CAN
CAUSE PROPERTY DAMAGE, SEVERE
INJURY OR DEATH
Do not disassemble the gas control; it contains no
replaceable components. Attempted disassembly
or repair may damage the gas control.
CAUTION
!
Do not apply a jumper across or short the valve
coil terminals. This may burn out the heat anticipator in the thermostat.
IMPORTANT: Allow 60 seconds after shutdown before
re-energizing step-opening model to assure lightoff
at step pressure.
IF THE PILOT BURNER FLAME WILL NOT LIGHT
1. Assure the main gas supply valve is open and the
pilot gas supply line is purged of air.
2. Attempt to light pilot burner flame following procedures in Light the Pilot Burner Flame, page 6. If pilot
burner flame still will not light:
a. Check the pilot gas adjustment screw. If closed,
readjust the pilot flame.
b. Perform the Gas Leak Test at the compression fit-
ting. If a gas leak is detected, replace the old compression fitting or tighten the newly installed one.
Refer to Fig. 4.
c. Assure that the pilot burner tubing or pilot burner
orifice is not clogged.
IF THE PILOT BURNER FLAME GOES OUT WHEN
THE GAS CONTROL KNOB IS RELEASED
1. Assure the gas control knob is held in at least one
minute to allow the thermocouple time to heat.
2. Check the pilot burner flame adjustment. Refer to
Adjust the Pilot Burner Flame, page 6.
3. Check the wiring between the thermocouple and the
gas control valve operator.
4. Assure thermocouple connection to the power unit is
tightened one-fourth turn beyond finger tight.
5. If pilot burner flame still goes out, measure the open
and closed thermocouple output voltage. Compare it to the
acceptable range charts in the thermocouple specifications
or in the Gas Controls Handbook. Replace the thermocouple if voltages are outside the acceptable range.
6. Check the power unit resistance. If above 11 ohms,
replace the gas control.
IF THE MAIN BURNER WILL NOT COME ON
WITH A CALL FOR HEAT
1. Assure the gas control knob is in the ON position.
2. Adjust the thermostat several degrees above room
temperature.
3. Use an ac voltmeter to measure the voltage across
terminals L1 and L2:
a. If no voltage is present, check the control circuit for
proper operation.
b. If voltage is present, but first operator did not click
open, check for excessive inlet gas pressure. If inlet
gas pressure is correct, replace the gas control.
4. Measure the open and closed thermocouple output
voltages and compare to the acceptable range charts in the
thermocouple specifications or in the Gas Controls Handbook. Replace the thermocouple if voltages are outside the
acceptable range.
IF THE MAIN BURNER IS OVERFIRING
Adjust the gas control pressure regulator to the correct
pressure. If the regulator cannot be adjusted and supply
pressure is in the normal range, replace the gas control.
8
Page 9
INSTRUCTIONS TO THE HOMEOWNER
WARNING
!
FIRE OR EXPLOSION HAZARD CAN
CAUSE PROPERTY DAMAGE, SEVERE
INJURY, OR DEATH
Follow these warnings exactly:
1. Pilot burner flame must be lit manually. Follow
these instructions exactly.
2. Before lighting pilot burner flame, smell around
the appliance for gas. Be sure to smell next to
floor because LP gas is heavier than air.
3. IF YOU SMELL GAS:
• Turn off the gas supply at the appliance
service valve. On LP gas systems, turn off
gas supply at the gas tank.
• Do not light any appliances in the house.
• Do not touch electrical switches or use the
phone.
• Leave the building and use a neighbor’s
phone to call your gas supplier.
• If you cannot reach your gas supplier, call the
fire department.
4. Do not force the gas control knob. Use only your
hand to push down or turn the gas control knob.
Never use any tools. If the gas control knob will
not operate by hand, the gas control should be
replaced by a qualified service technician. Force
or attempted repair may result in a fire or explosion.
5. The gas control must be replaced in case of any
physical damage, tampering, bent terminals,
missing or broken parts, stripped threads, or
evidence of exposure to heat.
IMPORTANT: Follow the operating instructions provided
by the manufacturer of your heating appliance. The
information below will help you in a typical gas control
application, but the specific controls used and the
procedures outlined by the manufacturer or your
appliance may differ, requiring special instructions.
LIGHTING THE PILOT BURNER FLAME
STOP: Read the Warnings Above.
The pilot burner flame must be lit manually. If the pilot
burner flame has gone out, follow these instructions exactly:
1. Set the thermostat to its lowest setting.
2. Disconnect all electric power to the appliance.
3. Remove the gas control access panel.
4. Push in the gas control knob slightly and turn clock-
wise to OFF.
NOTE: The gas control knob cannot be turned from
PILOT to OFF unless it is pushed in slightly. Do not
force the gas control knob.
5. Wait five minutes to clear out any unburned gas. If
you then smell gas, STOP! Follow step 3 in the Warnings
above. If you do not smell gas, continue with the next step.
6. Remove the pilot burner access panel located below
and behind the gas control.
7. Find the pilot burner by following the metal tube
from the gas control. The pilot burner is between the two
burner tubes behind the pilot burner access panel.
8. Turn the gas control knob counterclockwise to
PILOT.
9. Push and hold the gas control knob all the way in.
Immediately light the pilot burner flame with a match and
continue holding the gas control knob in for one minute
after the pilot burner flame is lit.
10. Release the gas control knob and it will pop back up.
The pilot burner flame should remain lit. If pilot burner
flame goes out, repeat steps 1 through 10.
• If the gas control knob does not pop up when
released, stop immediately and call your service
technician or gas supplier.
• If the pilot flame will not stay lit after several tries,
turn the gas control knob to OFF and call your
service technician or gas supplier.
11. Turn the gas control knob counterclockwise
to ON.
12. Replace the pilot burner access panel.
13. Replace the gas control access panel.
14. Reconnect all electric power to the appliance.
15. Set the thermostat to the desired setting.
TURNING OFF THE APPLIANCE
VACATION SHUTDOWN—Set the thermostat to the
desired room temperature while you are away.
COMPLETE SHUTDOWN—Push the gas control knob
in slightly and turn clockwise to OFF. Do not
force. Appliance will completely shut off. Follow Lighting the Pilot Burner Flame procedure above to resume
normal operation.
9 69-0683—1
Page 10
Home and Building Control Home and Building Control Helping You Control Your World
Honeywell Inc. Honeywell Limited—Honeywell Limitée
1985 Douglas Drive North 740 Ellesmere Road
Golden Valley, Minnesota 55422 Scarborough, Ontario
M1P 2V9
Printed in U.S.A.
QUALITY IS KEY
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