Honeywell VR8200 Installation Manual

V8200, VR8200, VR8201 Continuous
Pilot Combination Gas Controls

INSTALLATION INSTRUCTIONS

APPLICATION

These continuous pilot combination gas controls are
used in gas-fired appliances that have up to 200 cfh
capacity of natural gas. They include safety shutoff, a
manual valve, a pressure regulator and pilot adjustment.
The V8200 has a single automatic operator, except for
the V8200F, which, like the VR8200, has two automatic
operators. The VR8201 has two independently controlled
automatic operators. Body pattern is straight-through
with 1/2 in. inlet and 1/2 in. outlet. Some models include
two optional 1/4 in. quick-connect convenience terminals.

See Table 1 for differences between models, and Table 2
for temperature ranges and regulator types. If a 7 follows
the suffix letter in the model number (e.g., V8200A7001),
the unit includes an electrical cut-off (ECO) connector
with two 1/4 in. quick-connect terminals.

Table 1. Continuous Pilot Combination Gas Control Models.

Number of

Model Voltage/Frequency

V8200 24 Vac/60 Hz One OFF-PILOT-ON 0.335

VR8200/V8200F

VR8201 24 Vac/50/60 Hz Two, Independently

a

V8200F is a non-redundant valve due to a step bypass orifice.

Table 2. Model Number Suffix Letter Designation. Table 3. Flange Part Numbers.

Model No.

Suffix Letter

A 0°F to 175°F

C Step-opening

F Unregulated

H Slow-opening

K -40°F to +175°F

M Standard

P Step-opening

a

24 Vac/60 Hz Two OFF-PILOT-ON 0.5

Ambient

Temperature

Range

(-18°C to +79°C)

(-40°C to +79°C)

Standard

step-opening

Automatic

Operators

Controlled

Regulator

Typ e

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

IMPORTANT

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

Controls with standard or slow opening regulators can be
converted from one gas to the other with a conversion kit
(ordered separately). Order conversion kit part no.
393691 to convert from natural (manufactured) to LP
gas; order conversion kit part no. 394588 to convert from
LP to natural (manufactured) gas. Controls with step
opening regulators cannot be converted. Controls with
unregulated step openings (V8200F) are convertible.

Gas Control Knob

Positions

OFF-PILOT-ON 0.5

Inlet/Outlet

Pipe Size

(NPT)

3/8 in. Straight 393690-1 393690-11

1/2 in. Straight 393690-6 399390-16

3/4 in. Straight 393690-4 393690-14

a

Elbow (angle) flanges cannot provide right hand inlet

when the ECO connector is used.

Flange

Typ e

Elbow

Elbow

Elbow

Current Draw

(Amps)

Part Number

With Hex

Wrench

a

393690-2 393690-12

a

393690-3 393690-13

a

393690-5 393690-15

Without Hex

Wrench

69-0234—6

V8200, VR8200, VR8201 CONTINUOUS PILOT COMBINATION GAS CONTROLS

CAUTION

Equipment Damage Hazard.
Improper installation can cause equipment
damage.

The V8200F is not functionally equivalent to other
V8200 models and they should not be used
interchangeably. The V8200F is a non-redundant
valve and is not suitable for applications that
require dual shutoff valves. If the application
requires a redundant shutoff function, a VR8200
Valve should be used. The V8200F includes a
step-opening feature. Use of a valve with non-step
opening characteristics could produce a rough
light-off, resulting in nuisance shutdowns or
possible damage to the appliance.

NOTE: Flange kits include one flange with attached

O-ring and four mounting screws. TRADELINE
kits include a 9/64 in. hex wrench, as noted.

Approvals:

American Gas Association Design Certificate:

UP-70-57A.

Canadian Gas Association Design Certificate:

1029-CC-8375.
Australian Gas Association Design Certificate: 4214.
Approved for Delta C applications.

PLANNING THE INSTALLATION

WARNING

Fire or Explosion Hazard.
Can cause property damage, serious injury or
death.
Follow these warnings exactly:

1. Review the installation as outlined in this
section.

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

When gas controls are used on heating appliances such
as commercial cookers, agricultural equipment, industrial
heating equipment and pool heaters, heavy demands are
made on the controls. Special steps may be required to
prevent nuisance shutdowns and control failure due to
frequent cycling and severe environmental conditions
related to moisture, corrosive chemicals, dust or
excessive heat. These applications require Honeywell
Environmental and Combustion Controls Engineering
review; contact your Honeywell Sales Representative for
assistance.

Review the following conditions that may apply to your
specific installation and take the precautionary steps
suggested.

Frequent Cycling

These controls are designed for use on appliances that
typically cycle only three to four times an hour during the
heating season. In year-round applications with greater
cycling rates, the control can wear out more quickly.
Perform a monthly checkout.

Water or Steam Cleaning

If a gas control gets wet, replace it. If the appliance is
likely to be cleaned with water or steam, protect (cover)
the controls and wiring from water or steam flow. Mount
the controls high enough above the bottom of the cabinet
to avoid getting wet during normal cleaning procedures.
NEMA 4 enclosure is recommended for the ignition
module; see the Electronic Ignition Service Handbook,
form no. 71-97927.

®

High Humidity or Dripping Water

Dripping water can cause the module to fail. Never install
an appliance where water can drip on the controls.

In addition, high ambient humidity can cause the gas
control to corrode and fail.

If the appliance is in a humid atmosphere, make sure air
circulation around the controls is adequate to prevent
condensation. Also, regularly check out the system.
NEMA 4 enclosure is recommended for the ignition
module; see the Electronic Ignition Service Handbook,
form no. 71-97927.

Corrosive Chemicals

Corrosive chemicals can attack the module and gas
control, eventually causing a failure. If chemicals are used
for routine cleaning, avoid contact with the controls.
Where chemicals are suspended in air, as in some
industrial or agricultural applications, NEMA 4 enclosure
is recommended for the ignition module; see the
Electronic Ignition Service Handbook, form no. 71-97927.

Dust or Grease Accumulation

Heavy accumulations of dust or grease can cause
controls to malfunction. Where dust or grease can be a
problem, provide covers for the module and the gas
control to limit contamination. NEMA 4 enclosure is
recommended for the ignition module; see the Electronic
Ignition Service Handbook, form no. 71-97927.

Heat

Excessively high temperatures can damage controls.
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 controls. Proper insulation or shielding should
be provided by the appliance manufacturer; verify proper
air circulation is maintained when the appliance is
installed.

69-0234—6 2

V8200, VR8200, VR8201 CONTINUOUS PILOT COMBINATION GAS CONTROLS

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 the product
operation as provided in these instructions.

WARNING

Fire or Explosion Hazard.
Can cause property damage, serious 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 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 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, have a qualified service technician
replace the control. Force or attempted repair
may result in fire or explosion.

CAUTION

Equipment Damage Hazard.
Can cause property damage.

Never apply a jumper across or short the valve
coil terminals. This can burn out the heat
anticipator in the thermostat.

IMPORTANT

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 instructions if
available; otherwise, use the instructions provided.

Converting Between Natural and LP Gas

WARNING

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

1. Use a gas control set for natural (manufactured)
gas only on a natural (manufactured) gas
system. Use a gas control set for LP gas only
on an LP gas system.

2. When making conversions, be sure main and
pilot burner orifices are changed to meet
appliance manufacturer specifications.

Gas controls with standard or delayed opening regulators
can be converted between LP and natural gas. Gas
controls with step opening regulators cannot be
converted. Refer to appliance manufacturer instructions
for orifice specifications and conversion procedures. Gas
controls are factory-set for natural (manufactured) or LP
gas. Do not attempt to use a control set for natural
(manufactured) gas on a LP gas control, or a control set
for LP gas on a natural (manufactured) gas control. Gas
controls with step opening regulators cannot be
converted.

Models Requiring Conversion Kit

Models with slotted pressure regulator cap, (see Fig. 5),
require a conversion kit. Gas controls with standard or
slow opening regulators can be converted from one gas to
the other with a conversion kit (ordered separately). Order
part no. 393691 to convert from natural (manufactured) to
LP gas; order part no. 394588 to convert from LP to
natural (manufactured) gas. Follow instructions provided
with kit. Gas controls with step opening regulators cannot
be converted.

Models with Convertible Pressure Regulators

Models with NAT or LP stamped on the pressure regulator
cap (see Fig.1), are convertible pressure regulator
models.

To convert between natural and LP gas:

1. Check valve label and appliance manufacturer’s
rating plate to determine if the factory pressure
regulator setting meets the appliance manifold
requirement.

2. Check for letters NAT (natural manufactured gas) or
LP (liquid petroleum gas) on the pressure regulator
cap.

3. If the appropriate letters are not visible, remove the
cap.

4. Invert cap until letters appear that represent the gas
type selected.

5. Replace and tighten 1/4 turn past finger tight.

NOTE: Convertible pressure regulator models do

not have field-adjustable regulators.

3 69-0234—6

V8200, VR8200, VR8201 CONTINUOUS PILOT COMBINATION GAS CONTROLS

.

T

N

A

A

N

T

PRESSURE
REGULATOR
CAP

T

N

A

A

N

T

Fig. 1. Top view of convertible pressure

regulator cap.

P

OR

L

P

OTHER SIDE
OF CAP

M11678A

L

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.

NOTE: A right angle inlet flange cannot be used

with the ECO connected.

2. Remove seal over gas control inlet or outlet.

3. ensure 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 O-ring facing the valve, align the screw holes
on the control with the holes in the flange. Insert
and tighten the screws provided with the flange.
(See Fig. 2). Tighten the screws to 25 in. pounds
(2.82 n·m) 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 into control and thread pipe carefully
until tight.

Complete instructions below for installing piping, installing
gas control, connecting pilot gas tubing, connecting
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 gas control after flanges are installed,
use the wrench only on the flange, not on the control.

GAS CONTROL OUTLET

FLANGE

1

DO NOT OVERTIGHTEN SCREWS.
TIGHTEN TO 25 INCH-POUNDS.

Fig. 2. Fasten flange to valve firmly, but do not

9/64 INCH HEX SCREWS (4)

overtighten screws.

1

M2913A

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.

Do not locate the 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 gas control in a well-ventilated area.

• Mount gas control 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 to avoid dust and grease
accumulation.

• Avoid locating gas control where exposure to corrosive
chemical fumes or dripping water is likely.

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, ensure 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 sediment trap in the supply line to the gas
control. (See Fig. 3).

69-0234—6 4