Honeywell VR8105, VR8205, VR8305 Installation Manual

VR8105, VR8205, and VR8305

Direct Ignition Combination

Gas Controls

					INSTALLATION INSTRUCTIONS
APPLICATION				capacities; see Table 1. (Table 2 provides gas capacity
				These gas controls are available in a range of valve
These direct ignition gas controls are used in gas-fired				conversion factors.) The suffix letter indicates
				temperature range and regulator type; see Table 3.
appliances with up to 415 ft3/hr capacity at 1 in. wc
pressure drop (8.5 m3/hr at 0.24 kPa) on natural gas.
They include a manual valve, two automatic operators
and a pressure regulator.
			Table 1. Valve Capacity.a
		AGA Certified		AGA Certified Minimum		AGA Certified Maximum
		Capacity for		Regulation for		Regulation for Natural
	Size Inlet-	Natural Gas		Natural Gas			Gas
Model	Outlet (in.)	ft3/hr	m3/hr	ft3/hr	m3/hr	ft3/hr		m3/hr
VR8105	1/2 x 1/2	85	2.3	10d	0.4	120		3.4
VR8205		150	4.2	20e	0.6	200		5.7
VR8305b,c		240	6.8	30f	0.8	340		9.6
VR8305b,c	1/2 x 3/4	270	7.6			370		10.5
VR8305b,c	3/4 x 3/4	300	8.5			415		11.8

aCapacity based on 1000 Btu/ft3, 0.64 sp gr natural gas at 1 in. wc pressure drop (37.3 MJ/m3, 0.64 sp gr natural gas at 0.25 kPa pressure drop).

bCapacity is reduced by 5 percent when using an outlet screen.

cValves are guaranteed at only 77 percent of the rating.

dMinimum regulation for LP gas is 15,000 Btuh.

eMinimum regulation for LP gas is 40,000 Btuh.

fMinimum regulation for LP gas is 50,000 Btuh.

Table 2. Gas Capacity Conversion Factor.

		Multiply Listed
Gas	Specific Gravity	Capacity By
Manufactured	0.60	0.516
Mixed	0.70	0.765
Propane	1.53	1.62

Table 3. Model Number Suffix Letter Designation.

	Model No.
	Suffix	Ambient	Pressure
	Letter	Temperature Range	Regulator Type
	A	0°F t0 175° F	Standard
		(-18°C to +79°C)
	C		Step-opening
	H		Slow-opening
	K	-40°F to +175°F
		(-40°C to +79°C)
	M		Standard
	P		Step-opening
	Q		Two-stage
	R		Convertible

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VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

SPECIFICATIONS

Body Pattern: Straight through; See Table 1 for inlet and outlet size.

Electrical Ratings:

Voltage and Frequency: 24 Vac, 60 Hz or 50/60 Hz depending on model.

Current Draw: 0.5A with both operators energized.

Capacity: See Table 1.

Conversion:

Use conversion factors in Table 2 to convert capacities for other gases.

Regulation Range: See Table 1.

Natural-LP Gas Conversion Kits: See Table 4.

Pipe Adapters:

Angle and straight adapters available for 3/8-, 1/2- and 3/4-in. pipe. See Table 5. Flange kits include one flange with attached O-ring, four mounting screws, a 9/64 in. hex wrench and instructions.

Approvals:

American Gas Association Design Certificate: L2025006. Canadian Gas Association Design Certificate: L2025006. Australian Gas Association Design Certificate: 4214.

Approved for Delta C applications.

European Community (CE) Certificate: Pending.

PLANNING THE INSTALLATION

WARNING

Fire or Explosion Hazard.

Can cause severe injury, death or property damage.

Follow these warnings exactly:

1.Plan the installation as outlined below.

2.Plan for frequent maintenance as described in the Maintenance section.

Heavy demands are made on the controls when direct ignition systems are used on central heating equipment in barns, greenhouses, and commercial properties and on heating appliances such as commercial cookers, agricultural equipment, industrial heating equipment and pool heaters.

Special steps may be required to prevent nuisance shutdowns and control failures due to frequent cycling, severe environmental conditions related to moisture, corrosive chemicals, dust or excessive heat. These applications require Honeywell Engineering review; contact your Honeywell Sales Representative for assistance.

Review the following conditions that can apply to your specific installation and follow the precautions suggested.

		Frequent Cycling
		this control is designed for use on appliances that typically
		cycle three to four times an hour only during the heating
		season. In year-around applications with greater cycling
		rates, the control can wear out more quickly. Perform a
		monthly check.
	Table 4. Natural-LP Gas Conversion Kits.
Model No. Suffix Letter		Kit to Convert Natural Gas to LP	Kit to Convert LP to Natural Gas
H, K, M		393691	394588
P		Not field convertible.	Not field convertible.
Q		396021	396025
R		Not required, convertible valve.	Not required, convertible valve.

Table 5. Flange Adapter Part Numbers.

Inlet/Outlet Pipe		Part Numbera,b
Size (in. NPT)	Flange Type	Without Hex Wrench	With Hex Wrench
3/8	Straight	393690-1	393690-11
3/8	Elbow	393690-2	393690-12
1/2	Straight	393690-6	393690-16
1/2	Elbow	393690-3	393690-13
3/4	Straight	393690-4	393690-14
3/4	Elbow	393690-5	393690-15

aFlange kits include one flange, one O-ring and four mounting screws.

bDo not use flanges on control models with 3/4 in. inlet and 3/4 in. outlet. On models with 1/2 in. inlet and 3/4 in. outlet, use flanges only on the 1/2 in. inlet side.

Table 6 shows additional specifications for the CE-only models.

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VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

Table 6. VR8205A,H/VR8305A,H CE Models.

Specification	VR8205A,H (CE Model Only)	VR8305A,H (CE Model Only)
Main Valve Connection	1/2 in. ISO, 7/1 internal thread (BSP.PL)	1/2 in., 3/4 in. ISO, 7/1 internal thread
		(BSP.PL).

Ambient Temperature Range -20°C to +70°C (-4°F to +158°F)

Maximum Inlet Pressure	60 mBar (24 in. wc).
Pressure Regulation	Servo regulator with adjustable outlet pressure; in accordance with EN 88 Class C.
	Natural gas: 9mBar, typical; LP: 20 mBar, typical.
Regulator Adjustment	For natural gas, 7.5 mBar to 12.5 mBar, field adjustable.
	For LP gas, 20 mBar to 30 mBar, field adjustable.
Ground Terminal	6.3 mm
Pressure Taps	9 mm OD
Valve Classification	B+D	C+D

CAUTION

Equipment Damage Hazard. Improper use can damage equipment.

Read the instructions before use. This control must be installed in accordance with the rules in force.

Water or Steam Cleaning

If a control gets wet, replace it. If the appliance is likely to be cleaned with water or steam, protect (cover) the control and wiring from water or steam flow. Mount the control high enough above the bottom of the cabinet so it does not get wet during normal cleaning procedures.

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.

High Humidity or Dripping Water

Dripping water can cause the control to fail. Never install an appliance where water can drip on the control. In addition, high ambient humidity can cause the control to corrode and fail. If the appliance is in a humid atmosphere, make sure air circulation around the control is adequate to prevent condensation. Also, regularly check out the system.

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.

WARNING

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

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

4.Do not force the gas control knob. Never use any tools. If the gas control knob does 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 manufacturer 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.

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VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

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

WARNING

Fire or Explosion Hazard.

Can cause severe injury, death or property damage.

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 specification and instructions to assure proper appliance conversion.

3.Gas controls are factory-set for natural (and manufactured) gas 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 letters 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 the other, check the control label and the appliance manufacturer rating plate to determine of 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.

A	T		OR	L	P
			N
N					L
			A
		T			P

PRESSURE

OTHER SIDE

REGULATOR

CAP

OF CAP

A	T
		N
N
	T	A

M11678

Fig. 1. Top view of convertible pressure regulator cap.

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. Remove the seal over the ignition system control inlet or outlet.

2.Make sure 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.

3.With the O-ring facing the gas control, align the screw holes on the control with the holes in the flange.

4.Insert and tighten the screws provided with the flange. See Fig. 2. Tighten the screws to 25 inchpounds of torque to provide a gas-tight seal.

1

VALVE OUTLET

FLANGE
9/64 INCH HEX SCREWS (4)
1 DO NOT OVERTIGHTEN SCREWS. TIGHTEN TO
25 INCH-POUNDS.	M9046

Fig. 2. Firmly fasten flange to valve, but do not overtighten screws.

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.

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