Honeywell VR8104, VR8204 Installation Manual

VR8104, VR8204, AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

Corrosive Chemicals

Corrosive chemicals can attack the control, eventually causing a failure. If chemicals are used for routine cleaning, avoid contact with the control. Where chemicals are suspended in air, as in some industrial or agricultural applications, protect the control with an enclosure.

Dust or Grease Accumulation

Heavy accumulations of dust or grease can cause the control to malfunction. Where dust or grease can be a problem, provide covers for the control to limit contamination.

Heat

Excessively high temperatures can damage the control. Make sure the maximum ambient temperature at the control does not exceed the rating of the control. If the appliance operates at very high temperatures, use insulation, shielding, and air circulation, as necessary, to protect the control. Proper insulation or shielding should be provided by the appliance manufacturer; verify proper air circulation is maintained when the appliance is installed.

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 make sure the product is suitable for your application.

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

4. After installation is complete, check out product operation as provided in these instructions.

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 the gas supply at the appliance service valve before starting installation, and perform Gas Leak Test after installation is complete.

3. Do not bend pilot tubing at gas control or pilot burner after compression fitting is tightened, or gas leakage at the connection can result.

4. Always install a sediment trap in the gas supply line to prevent contamination of the gas control.

5. Do not force the gas control knob. Use only your hand to 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 fire or explosion.

CAUTION

Equipment Damage. Can burn out valve coil terminals.

Never apply a jumper across (or short) the valve coil terminals, even temporarily.

Follow the appliance manufacturers instructions if available; otherwise, use these instructions as a guide.

IMPORTANT

These gas controls are shipped with protective seals over the inlet and outlet tappings. Do not remove the seals until ready to install adapters or connect the piping.

Converting Gas Control from Natural Gas to LP Gas (or LP Gas to Natural Gas)

WARNING

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

1. Do not attempt to convert step-opening models (suffix letter P).

2. Always change the main and pilot burner orifices when converting from natural to LP gas or from LP to natural gas. Carefully follow appliance manufacturer specifications and instructions to assure proper appliance conversion.

3. Gas controls are factory-set for natural (and manufactured) or LP gas. Do not attempt to use a gas control set for natural (manufactured) gas on LP gas, or a gas control set for LP gas on natural (manufactured) gas.

Controls with standard, slow-opening, and two-stage regulators (model numbers with suffix H, K, M, or Q) can be converted from one gas to the other with a conversion kit (ordered separately). See Table 4 for the correct conversion kit.

Convertible Pressure Regulators

Controls with suffix letter R are convertible pressure regulator models. They can be converted from natural gas to LP gas or from LP gas to natural gas without a conversion kit.

Before converting the control from one gas to another, check the control label and the appliance manufacturer’s rating plate to determine if the pressure regulator setting (factory set) will meet the appliance manifold requirements after conversion.

NOTE: Convertible pressure regulator models (suffix

letter R) do not have field-adjustable regulators.

If the factory pressure regulator setting meets the appliance manifold requirement, convert the control as follows:

1. Remove the pressure regulator cap, Fig. 1.

2. Invert the cap so that the letters appear that

represent the gas type appropriate for the appliance. NAT for natural manufactured gas, LP for liquid petroleum gas.

3. Replace the cap and tighten firmly.

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VR8104, VR8204, AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

PRESSURE REGULATOR CAP

Fig. 1. Top view of convertible

pressure regulator cap.

OTHER SIDE OF CAP

M11678

Install Adapters To Control

If adapters are being installed on the control, mount them as follows:

Flanges

1. Choose the appropriate flange for your application.

2. Remove the seal over the gas control inlet or outlet.

3. Make sure that the O-ring is fitted in the groove of

the flange. If the O-ring is not attached or is missing, do not use the flange.

4. With the O-ring facing the 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. 2. Tighten the screws to 25 inch-pounds of torque to provide a gas-tight seal.

Bushings

1. Remove the seal over the control inlet or outlet.

2. Apply a moderate amount of good quality pipe

compound to the bushing, leaving two end threads bare. On an LP installation, use compound that is resistant to LP gas. Do not use Teflon tape.

3. Insert the bushing in the control and carefully thread the pipe into the bushing until tight.

Complete the instructions below for installing the piping, installing the control, connecting the pilot gas tubing and the wiring. Make sure 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 the flanges are installed, use the wrench only on the flange, not on the control. See Fig. 5.

VALVE OUTLET

FLANGE

9/64 INCH HEX SCREWS (4)

DO NOT OVERTIGHTEN SCREWS. TIGHTEN TO

25 INCH-POUNDS.

Fig. 2. Firmly fasten flange to valve, but

do not overtighten screws.

M9046

Location

The combination gas control is mounted 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.

Locate the combination gas control where it cannot be affected by steam cleaning, high humidity, or 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 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 are likely.

Install Piping to 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 that is free from chips. If tubing is used, make sure the 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 the tubing to the control.

3. Install a sediment trap in the supply line to the control. See Fig. 3.

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VR8104, VR8204, AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

4. Apply a moderate amount of good quality pipe

DROP

3 IN.

PIPED GAS SUPPLY

GAS CONTROL

DROP

TUBING

GAS SUPPLY

GAS CONTROL

HORIZONTAL

3 IN.

(76 MM)

MINIMUM

HORIZONTAL

RISER

(76 MM)

MINIMUM

ALL BENDS IN METALLIC TUBING SHOULD BE SMOOTH.

CAUTION: SHUT OFF THE MAIN GAS SUPPLY BEFORE REMOVING 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. 3. Sediment trap installation.

Install Control

1. Mounted 0 to 90 degrees in any direction, including vertically, from the upright position of the gas control knob.

2. Mount so the gas flow is in the direction of the arrow on the bottom of the control.

3. Thread the pipe the amount shown in Table 7 for insertion into control or adapters. Do not thread pipe too far. Valve distortion or malfunction can result if the pipe is inserted too deeply.

Table 7. NPT Pipe Thread Length (in.).

Pipe Size

Thread Pipe this Amount

Maximum Depth Pipe can

be Inserted into Control

compound (do not use Teflon tape) only to the pipe, leaving two end threads bare. On LP installations, use a compound resistant to LP gas. See Fig. 4.

5. Remove the seals over the control inlet and outlet if necessary.

6. Connect the pipe to the control inlet and outlet. Use a wrench on the square ends of the control. If a flange is used, place the wrench on the flange rather than on the gas control. Refer to Fig. 5 and 6.

Connect Pilot Gas Tubing

1. Cut tubing to the desired length and bend as necessary for routing to the pilot burner. Do not make sharp bends or deform the tubing. Do not bend the tubing at the gas control after the compression nut is tightened, because this can result in gas leakage at the connection.

2. Square off and remove burrs from the end of the tubing.

3. Unscrew the brass compression fitting from the pilot outlet (Fig. 6). Slip the fitting over the tubing and slide out of the way. See Fig. 7.

NOTE: When replacing a control, cut off the old

compression fitting and replace with the compression fitting provided on the combination gas control. Never use the old compression fitting because it may not provide a gas-tight seal.

4. Push the tubing into the pilot gas tapping on the outlet end of the control until it bottoms. While holding the tubing all the way in, slide the fitting into place and engage the threads; then turn until finger tight. Tighten one more turn with a wrench, but do not overtighten.

5. Connect the other end of the tubing to the pilot burner according to the pilot burner manufacturer’s instructions.

TWO IMPERFECT THREADS

THREAD PIPE THE AMOUNT SHOWN IN TABLE FOR INSERTION INTO GAS CONTROL

GAS CONTROL

PIPE

3/8 9/16 3/8

1/2 3/4 1/2

Fig. 4. Use moderate amount of pipe compound.

3/4 13/16 3/4

APPLY A MODERATE AMOUNT OF PIPE COMPOUND TO PIPE ONLY (LEAVE TWO END THREADS BARE).

M3075B

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