Page 1
VR8104, VR8204, and VR8304
Intermittent Pilot Combination
Gas Controls
INSTALLATION INSTRUCTIONS
APPLICATION
These intermittent pilot gas controls are used in gas-fired
appliances with up to 415 ft3/hr capacity at 1 in. wc
pressure drop (8.5 m3/hr at 0.25 kPa) on natural gas.
They include safety shutoff, a manual valve, two
automatic operators, a pressure regula tor and a pilot
adjustment.
Table 1. Valve Capacity
AGA Certified Capacity for
Size
Model
VR8104 1/2 x 1/2 85 2.3
VR8204 150 4.2
VR8304
VR8304
VR8304
a
Capacity 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).
b
Capacity is reduced by 5 percent when using an outle t screen.
c
Valves are guaranteed at only 77 percent of the rating.
d
Minimum regulation for LP gas is 15,000 Btu h.
e
Minimum regulation for LP gas is 40,000 Btu h.
f
Minimum regulation for LP gas is 50,000 Btu h.
Manufactured 0.60 0.516
Mixed 0.70 0.765
Propane 1.53 1.62
Inlet-Outlet
(in.)
b,c
b,c
1/2 x 3/4 270 7.6 370 1.05
b,c
3/4 x 3/4 300 8.5 415 11.8
Table 2. Gas Capacity Conversion Factor.
Gas Specific Gravity
Natural Gas
3
ft
/hr m3/hr ft3/hr m3/hr ft3/hr m3/hr
240 6.8
Multiply Listed
Capacity By
These gas controls are available in a range of valve
capacities, see Table 1. (Table 2 provides gas capacity
conversion factors.) The suffix letter indicates
temperature range and regulator type , see Table 3.
For CE-approved models, the relevant sections of these
instructions and Table 4 are applicable.
a
AGA Certified Minimum
Regulation for Natural Ga s
d
10
e
20
f
30
0.4 120 3.4
0.6 200 5.7
0.8 340 9.6
AGA Certified Maximum
Regulation for
Natural Gas
CE-Only Models
These gas controls are used in appliances up to 121kW
or 415 kBTUH on natural gas and approved on EN126,
which consists of one automatic safety shutoff valve,
Class B or C, one servo-operated shutoff valve, Class D,
pressure governor, Class C, manually-operated valve,
with or without pilot outlet. Only the A, H and U model s
are available CE-approved.
T able 4 shows the additional specifications for the
CE-only models.
® U.S. Registered Trademark
Copyright © 2000 Honeywell Inc. • All Rights Reserved
69- 1225- 4
Page 2
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS
Table 3. Model Number Suffix Letter Designation.
Model No.
Suffix Letter
A 0°F to 175°F
C Step-opening
Ambient
Temperature
Range
(-18°C to +79°C)
Pressure
Regulator Type
Standard
H Slow-opening
a
U
K -40°F to +175°F
M Standard
(-40°C to +79°C)
Nonregulating
(on-off)
Slow-opening
P Step-opening
QTwo-Stage
RConvertible
a
Available only on CE VR8204 models.
Table 4. VR8204A,H/VR8304A,H,U CE.
Specifications VR8204A,H (CE Model Onl y) VR8304A,H (CE Model Onl y)
Main valve connections (If NPT,
the valves must be serviced by
the appliance manufacturer.
1/2 in. ISO, 7/1 internal thread (BSP,
NPT.
1/2 in., 3/4 in. ISO, 7/1 internal thread (BSP,
PL) or 1/2 in., 3/4 in. NPT.
Valve Classification B + D C + D
Capacity (1kW = 3.41BTUH) 29 kW at 2.5 mBar
43 kW at 5.0 mBar
for 1/2 in., 70 kW at 2.5 mBar
99 kW at 5.0 mBar.
For 3/4 in., 87 kW at 2.5 mBar:
121 kW at 5.0 mBar.
Supply Voltage 24 Vac, 50/60 Hz.
Flanges None.
Closing time Less than 1 second.
Opening Time Standard opening (A): less than 2 seconds.
Slow opening (H): less than 6 seconds.
Special fast opening (U): less than 1 second.
Suited for gas families 2H, 2L, and 3.
Outlet Press Range
(Except unregulated models)
Manually operated valve
operations
Natural gas: 7.5 to 12.5 mBar (3 to 5 in. wc).
Natural gas: 12.5 to 17.5 mBar (5 to 7 in. wc).
LP gas: 20 to 30 mBar (8 to 12 in. wc).
10,000 cycles for manual valves; 200,000 cycles for automatic valves.
Ambient temperature range -20°C to +70°C (-4°F to +158°F).
Maximum inlet pressure 60 mBar (24 in. wc).
Screen Fine mesh on inlet.
Pilot connection
Ground terminal
Pressure taps
a
a
a
M11 x 1 for 6 mm outside diameter tube.
6.3 mm.
9 mm OD for both inlet and outlet.
Approval CE-0063AU1215.
a The VR8204U uses standard U.S. constru cti on. Inl et and outlet ports are 1/2 in. NPT, and the pilot connection is the
standard 7/16 in. thread for a 1/4 in. pilot tube. European-style inlet and outlet pressure taps are available.
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.
69-1225—4 2
Page 3
VR8104, VR8204 AND VR8304 INT ERMITTENT PILOT COMBINATION GAS CONTROL S
SPECIFICATIONS
Body Pattern:
outlet size.
Electrical Ratings:
Voltage and Frequency: 24 Vac, 60 Hz.
Current Draw: 0.5A with both operators energized.
Capacity:
Conversion:
vert capacities for other gases.
Regulation Range:
Natural-LP Gas Conversion Kits:
Model No.
Suffix Letter
H, K, M 393691 394588
P Not field
Q 396021 396025
R Not required,
Pipe Adapters:
Angle and straight adapters available for 3/ 8- , 1/2- and
3/4-in. pipe. See Table 6. 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 Certi fi cat e: 4214.
Approved for Delta C applications.
European Community (CE) Cert if icate: Pending.
Straight through; see Table 1 for inlet and
See Table 1.
Use conversion factors in Table 2 to con-
See Table 1.
See Table 5.
Table 5. Natural-LP Gas Conversion Kits.
Kit to Convert
Natural Gas to LP
convertible.
convertible valve.
Kit to Convert LP
to Natural Gas
Not field
convertible.
Not required,
convertible valve.
PLANNING THE INSTALLATION
WARNING
Fire or Explosion Hazard.
Can cause property damage, sev er e inj ury,
or death.
Follow these warnings exactly:
1. Plan the installation as outlined below.
2. Plan for frequent maintenance as described in
the Maintenance section.
Table 6. Flange Adapter Part Numbers.
Inlet/Outlet
Pipe Size
(in. NPT)
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
a
Flange kits include one flange, one O-ring and four
mounting screws.
b
Do 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.
Heavy demands are made on the controls when
intermittent pilot systems are used on central heating
equipment in barns, greenhouses, and comme rci al
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 failure due to frequent cycling ,
severe environmental conditions related to moisture,
corrosive chemicals, dust or excessive heat. These
applications require Honeywell Home and Building
Control Engineering review; contact your Honeywell
Sales Representative for assistance.
Review the following conditions that can apply to you r
specific installation and follow the precautions
suggested.
Flange
Type
Part Number
Without Hex
Wrench
a,b
With Hex
Wrench
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 applicat ions with greater
cycling rates, the control can wear out more quickly.
Perform a monthly checkout.
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 proced ure s.
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 th e 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, reg ularly
check out the system.
3 69-1225—4
Page 4
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS
Corrosive Chemicals
Corrosive chemicals can attack the control, eventual ly
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 con trol 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 cont ro l.
Make sure the maximum ambient temperature at the
control does not exceed the rating of the control. If the
appliance operates at very high temperatur es, use
insulation, shielding, and air circulation, as necessary, to
protect the control. Proper insulation or shiel ding should
be provided by the appliance manufacturer; verify proper
air circulation is maintained when the appliance is
installed.
INSTALLATION
When Installing this Product...
Read these instructions carefully. Failure to follow
1.
them could damage the product or cause a
hazardous condition.
Check the ratings given in the instructions and on
2.
the product to make sure the product is suitable for
your application.
Installer must be a trained, experienced service
3.
technician.
After installation is complete, check out product
4.
operation as provided in these instructions.
WARNING
Fire or Explosion Hazard.
Can cause property damage, sev er e inj ury
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 instr ucti ons i f
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 specification s 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 anothe r,
check the control label and the appliance manufacturer’s
rating plate to determine if the pressure regulat or setting
(factory set) will meet the appliance manifo ld
requirements after conversion.
NOTE: Convertible pressure regulator models ( suffix
letter R) do not have field-adjustable regulat or s.
If the factory pressure regulator setting meets the
appliance manifold requirement, con vert the control as
follows:
Remove the pressure regulator cap, Fig. 1.
1.
Invert the cap so that the letters appear that
2.
represent the gas type appropriate for the
appliance. NAT for natural manufactured gas, LP
for liquid petroleum gas.
Replace the cap and tighten firmly.
3.
69-1225—4 4
Page 5
VR8104, VR8204 AND VR8304 INT ERMITTENT PILOT COMBINATION GAS CONTROL S
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
M11678
L
Install Adapters To Control
If adapters are being installed on the control, mount them
as follows:
Flanges
Choose the appropriate flange for your applic at ion .
1.
Remove the seal over the gas control inlet or
2.
outlet.
Make sure that the O-ring is fitted in the groove of
3.
the flange. If the O-ring is not attached or is
missing, do not use the flange.
With the O-ring facing the control, align the screw
4.
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
Remove the seal over the control inlet or outlet.
1.
Apply a moderate amount of good quality pipe
2.
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.
Insert the bushing in the control and carefully
3.
thread the pipe into the bushing until tight.
Complete the instructions below for installing th e pipi ng,
installing the control, connecting the pil ot ga s tubi ng and
the wiring. Make sure the leak test you perform on the
control after completing the installation includ es lea k
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
1
25 INCH-POUNDS.
Fig. 2. Firmly fasten flange to valve, but
do not overtighten screws.
1
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 locati on
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 g a s c o n trol 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 ordinance s
or with the National Fuel Gas Code (ANSI Z223.1,
NFPA No. 54), whichever applies. Tubing installation
must comply with approved standards and practices.
Use new, properly reamed pipe that is free from
1.
chips. If tubing is used, make sure the ends are
square, deburred and clean. All tubing bends must
be smooth and without deformation.
Run pipe or tubing to the control. If tubing is used,
2.
obtain a tube-to-pipe coupling to connect the
tubing to the control.
Install a sediment trap in the supply line to the
3.
control. See Fig. 3.
5 69-1225—4
Page 6
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS
Apply a moderate amount of good quality pipe
4.
DROP
3 IN.
PIPED
GAS
SUPPLY
GAS
CONTROL
2
DROP
TUBING
1
GAS
SUPPLY
2
GAS
CONTROL
RISER
PIPED
GAS
SUPPLY
3 IN.
(76 MM)
MINIMUM
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.
Fig. 3. Sediment trap installation.
Install Control
Mounted 0 to 90 degrees in any direction, including
1.
vertically, from the upright position of the gas
control knob.
Mount so the gas flow is in the direction of the
2.
arrow on the bottom of the control.
Thread the pipe the amount shown in Table 7 for
3.
insertion into control or adapters. Do not thread
pipe too far. Valve distortion or malfunction can
result if the pipe is inserted too deeply.
GAS
CONTROL
M3077
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.
Remove the seals over the control inlet and outlet if
5.
necessary.
Connect the pipe to the control inlet and outlet. Use
6.
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 contro l. Re fe r to Fi g. 5
and 6.
Connect Pilot Gas Tubing
Cut tubing to the desired length and bend as
1.
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.
Square off and remove burrs from the end of the
2.
tubing.
Unscrew the brass compression fitting from the
3.
pilot outlet (Fig. 6). Slip the fitting over th e tubi ng
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.
Push the tubing into the pilot gas tapping on the
4.
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.
Connect the other end of the tubing to the pilot
5.
burner according to the pilot burner manufacturer’s
instructions.
TWO IMPERFECT
THREADS
GAS CONTROL
Table 7. NPT Pipe Thread Length (in.).
Pipe
Thread Pipe
Size
this Amount
3/8 9/16 3/8
1/2 3/4 1/2
Maximum Depth Pipe can
be Inserted into Control
THREAD PIPE THE AMOUNT
SHOWN IN TABLE FOR
INSERTION INTO GAS CONTROL
PIPE
3/4 13/16 3/4
Fig. 4. Use moderate amount of pi pe compound.
APPLY A MODERATE AMOUNT OF
PIPE COMPOUND TO PIPE ONLY
(LEAVE TWO END THREADS BARE).
M3075B
69-1225—46
Page 7
VR8104, VR8204 AND VR8304 INT ERMITTENT PILOT COMBINATION GAS CONTROL S
WHEN FLANGE IS NOT USED
APPLY WRENCH
FROM TOP OR
BOTTOM OF GAS
CONTROL TO
EITHER SHADED AREA
Fig. 5. Proper use of wrench on gas cont r ol wi th and without flanges.
HI-LO
ADJUSTMENT SCREWS
(UNDER CAP)
REGULATOR
VENT COVER
INLET
HI
LO
TWO-STAGE
PRESSURE
REGULATOR
MODEL
PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)
INLET
PRESSURE TAP
INLET
Fig. 6. Top view of gas control.
GAS CONTROL
TIGHTEN NUT ONE TURN
BEYOND FINGER TIGHT.
FITTING BREAKS OFF AND CLINCHES
TUBING AS NUT IS TIGHTENED.
TO PILOT
BURNER
M3076A
Fig. 7. Always use new compressio n fitting.
Wiring
Follow the wiring instructions furnished by the appl iance
manufacturer, if available, or use the general instructions
provided below. When these instructions differ from the
appliance manufacturer, follow the appliance
manufacturer instructions.
WHEN FLANGE IS USED
APPLY WRENCH
TO FLANGE ONLY
M3079
WIRING
TERMINALS (3)
OUTLET
PRESSURE
TAP
OUTLET
PILOT OUTLET
GAS
CONTROL
KNOB
All wiring must comply with applicable electrical codes
and ordinances.
Disconnect power supply before making wiring
connections to prevent electrical shock or equipment
damage.
Check the power supply rating on the gas control
1.
and make sure it matches the available supply.
Install a transformer, thermostat and other controls
as required.
Connect control circuit to the gas control terminals.
2.
See Fig. 8.
PILOT ADJUSTMENT
(UNDER CAP SCREW)
M10968A
7 69-1225—4
Page 8
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS
PROPER FLAME
ADJUSTMENT
IGNITERSENSOR
M3080A
3/8 TO 1/2 INCH
(10 TO 13 mm)
S8600
GND
24V
(BURNER)
MV MV/PV PV
PV
PV/MV
MV
GAS CONTROL
TERMINALS
Q345, Q346,
Q348, Q362, Q381
PILOT BURNER/
IGNITER-SENSOR
POWER SUPPLY. PROVIDE DISCONNECT MEANS
1
AND OVERLOAD PROTECTION AS REQUIRED.
2
ALTERNATE LIMIT CONTROLLER LOCATION.
MAXIMUM WIRE LENGTH 3 ft [.9 m].
3
CONTROLS IN 24V CIRCUIT MUST NOT BE IN
4
GROUND LEG TO TRANSFORMER.
FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER
5
PLUG, CONNECT THERMOSTAT TO TH-W. LEAVE
24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.
Fig. 8. Typical wiring connections for 24 volt control
in intermittent ignition system wi t h S8600.
GND
THERMOSTAT
PILOT GAS
SUPPLY
24V
TH-W
(OPT)
5
GROUND
VENT
DAMPER
PLUG
(OPT)
2
4
LIMIT
CONTROLLER
5
SENSE
L1
(HOT)
SPARK
3
L2
1
M9056
Turn On Main Burner
Follow appliance manufacturer instr uct ion s or turn up
thermostat to call for heat.
Perform Gas Leak Test
WARNING
Fire or Explosion Hazard.
Can cause property damage, severe injury
or death.
Perform Gas Leak Test every time work is done
on a gas system.
IMPORTANT
Do not spray soap and water solution on the
gas control. Do not use an excessive amount of
soap and water solution to perform the gas leak
test. These can damage the control.
Gas Leak Test
Paint pipe connections upstream of the gas control
1.
with rich soap and water solution. Bubbles indicate
a gas leak.
If a leak is detected, tighten the pipe connections.
2.
Light the main burner. Stand clear of the main
3.
burner while lighting to prevent injury caused from
hidden leaks that could cause flashback in the
appliance vestibule.
With the main burner in operation, paint the pipe
4.
joints (including adapters) and the control inlet and
outlet with rich soap and water solution.
If another leak is detected, tighten the adap ter
5.
screws, joints, and pipe connections.
Replace the part if a leak cannot be stopped.
6.
STARTUP AND CHECKOUT
WARNING
Fire or Explosion Hazard.
Can cause property damage, sev er e inj ury
or death.
1. Do not force the gas control knob on the
appliance. Use only your hand to turn the gas
control knob. Never use any tools.
2. If the knob does not operate by hand, the
control should be replaced by a qualified
service technician.
Gas Control Knob Settings
Gas control knob settings are as follows:
OFF: Prevents pilot and main gas flow through the
control.
ON: Permits gas to flow into the control body. Under
control of the thermostat and intermittent pilot module,
gas can flow to the pilot and main burners.
NOTE: Controls are shipped with the gas control knob
in the ON position.
Turn On System
Rotate the gas control knob counterclockwise to
ON.
Check and Adjust Pilot Flame
The pilot flame should envelop 3/8 to 1/2 in. (10 to 13
mm) of the tip of the igniter-sensor. See Fig. 9. If the pilot
flame is small or lazy, the inlet gas pressure may be too
low, or the pilot orifice may be partially clogged. Check
and repair as necessary. If the pilot flame is hard and
noisy, the inlet gas pressure may be too high. The gas
control has a pilot adjustment mechanism to reduce the
pilot flow if necessary. If pilot adjustment is necessary,
proceed as follows:
Remove pilot adjustment cover screw. See Fig. 6.
1.
The pilot adjustment is shipped at the full pilot gas
2.
flow rate. Turn the inner adjustment screw
clockwise if the inlet pressure is too high.
Turn the inner adjustment screw clockwise
to decrease or counterclockwise to increase
pilot flame.
Replace the cover screw after the adjustment to
3.
prevent gas leakage.
Fig. 9. Proper flame adjustment.
69-1225—48
Page 9
VR8104, VR8204 AND VR8304 INT ERMITTENT PILOT COMBINATION GAS CONTROL S
Check and Adjust Gas Input and Burner Ignition
IMPORTANT
1. Do not exceed input rating stamped on
appliance nameplate, or manufacturer’s
recommended burner orifice pressure for size
orifice(s) used. Make certain primary air supply
to main burner is properly adjusted for complete
combustion. Follow appliance manufacturer
instructions.
2. IF CHECKING GAS INPUT BY CLOCKING
GAS METER: Make certain there is no gas flow
through the meter other than to the appliance
being checked. Other appliances must remain
off with the pilots extinguished (or deduct their
consumption from the meter reading). Convert
flow rate to Btuh as described in form 70-2602,
Gas Controls Handbook, and compare to Btuh
input rating on appliance nameplate.
3. IF CHECKING GAS INPUT WITH
MANOMETER: Make s u re th e g a s c o nt ro l k nob
is in the OFF position before removing outlet
pressure tap plug to connect manometer
(pressure gauge). Also move the gas control
knob to the OFF position when removing the
gauge and replacing the plug. Before remo ving
inlet pressure tap plug, shut off gas supply at
the manual valve in the gas piping to the
appliance or, for LP, at the tank. Also shut off
gas supply before disconnecting manometer
and replacing plug. Repeat Gas Leak Test at
plug with main burner operating.
NOTE: Check the inlet pressure before adjusting the
pressure regulator.
Standard and Slow-Opening
(H, K and M) Models
Carefully check the main burner lightoff. Make sure
1.
that the main burner lights smoothly and that all
ports remain lit.
Check the full rate manifold pressure listed on the
2.
appliance nameplate. Gas control full rate outl et
pressure should match this rating.
With main burner operating, check the control flow
3.
rate using the meter clocking method or check
pressure using a manometer connected to the
outlet pressure tap on the control. See Fig. 6.
If necessary, adjust the pressure regulator to
4.
match the appliance rating. See Tables 8A and 8B
for factory-set nominal outlet pressure and
adjustment range.
a. Remove the pressure regulator adjustment cap
screw.
b. Using a screwdriver, turn the inner adjustment
screw (Fig. 6) clockwise to increase or
counterclockwise to decrease the gas
pressure to the burner.
c. Always replace the cap screw and tighten
firmly to prevent gas leakage.
If the desired outlet pressure or flow rate cannot
5.
be achieved by adjusting the gas control, check the
gas control inlet pressure using a manometer at
the inlet pressure tap of the gas control. If the inlet
pressure is in the nominal range (see Tables 8A
and 8B), replace the gas control. Otherwise, take
the necessary steps to provide proper gas
pressure to the control.
NOTE: If the burner firing rate is above 150,000 Btuh
on VR8304 models (see Table 1 for VR8304
capacities), it may not be possible to deliver the
desired outlet pressure. This is an application
issue, not a control failure. T ake whatever steps
are required to correct the situation.
Step-Opening (P ) Models
Step-opening models require that you check and adjust
the full-rate pressure first and then check the step
pressure. The step pressure is not field adjustabl e.
Carefully check the main burner lightoff. Make sure
1.
that the main burner lights smoothly and that all
ports remain lit.
Check the full rate manifold pressure listed on the
2.
appliance nameplate. Gas control full rate outlet
pressure should match this rating.
With main burner operating, check the gas control
3.
flow rat e us i n g th e me te r c loc ki n g m et h od o r che c k
pressure using a manometer connected to the
outlet pressure tap on the gas control. See Fig. 6.
If necessary, adjust the pressure regulator to
4.
match the appliance rating. See Tables 8A and 8B
for factory-set nominal outlet pressure and
adjustment range.
a. Remove the pressure regulator adjustment cap
screw.
Using a screwdriver, turn the inner adjustment screw
(Fig. 6) clockwise to increase or
counterclockwise to decrease the gas pressure
to the burner.
b. Always replace the cap screw and tighten
firmly to prevent gas leakage.
If the desired outlet pressure or flow rate cannot be
5.
achieved by adjusting the gas control, check the
gas control inlet pressure using a manometer at
the inlet pressure tap of the control. If the inlet
pressure is in the nominal range (see Tables 8A
and 8B), replace the control. Otherwise, take the
necessary steps to provide proper gas pressure to
the control.
Carefully check the burner lightoff at step pressure.
6.
Make sure the burner lights smoothly and without
flashback to the orifice. Make sure all ports remain
lit. Cycle the burner several times, allowing at least
60 seconds between cycles for the regulator to
resume the step function. Repeat after allowing the
burner to cool. Readjust the full rate outlet
pressure, if necessary, to improve lightoff
characteristics.
Two-Stage (Q) Models
Two-stage models require that you check and adjust both
high and low pressure regulator settings. Two-stage
appliance operating sequences vary. Consult the
appliance manufacturer instructions for the specific
operating sequence and regulator adjus tment pr ocedure
for the appliance in which the control is installed.
Set appliance to operate on high.
1.
Carefully check the main burner lightoff. Make sure
2.
that the main burner lights smoothly and that all
ports remain lit.
Check the full rate (high) manifold pressure listed
3.
on the appliance nameplate for high pressure. The
gas control full rate outlet pressure should match
this rating.
9 69-1225—4
Page 10
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS
With main burner operating, check the gas control
4.
flow rate using the meter clocking method or check
pressure using a manometer connected to the
outlet pressure tap on the gas control. See Fig. 6.
If necessary, adjust the high pressure regulator to
5.
match the appliance rating. See Tables 8A and 8B
for factory-set nominal outlet pressure and
adjustment range.
a. Remove the pressure regulator adjustment cap
(Fig. 6).
b. Using a screwdriver, turn the inner adjustment
screw for HI pressure clockwise to
increase or counterclockwise to
decrease the gas pressure to the burner.
After high pressure has been checked, check low
6.
pressure regulation. Two-stage appliance
operating sequences vary. Consult the appliance
manufacturers instructions for the specific
operating sequence and regulator adjustment
procedure for the appliance in which the control is
installed and for instructions on how to prevent the
control from moving to high stage while checking
the low pressure regul at o r setting.
Check the l ow rate manifold press ure listed on the
7.
appliance nameplate. Gas control low rate outlet
pressure should match this rating.
With main burner operating, check the gas control
8.
flow rate as before (using the meter clocking
method or check pressure using a manometer
connected to the outlet pressure tap on the
control).
If necessary, adjust the low pressure regulator to
9.
match the appliance rating. See Tables 8A and 8B
for factory-set nominal outlet pressure and
adjustment range.
a. Remove the pressure regulator adjustment cap
(Fig. 6).
Using a screwdriver, turn the inner adjustment screw for
LO pressure clockwise to increase or
counterclockwise to decrease the gas pressure to
the burner.
Once high and low pressure have been checked
10.
and adjusted, replace pressure regulator
adjustm ent cap. If the desired outlet pre ss ure or
Table 8A. Pressure Regulator Specification Pressures (in. wc).
Factory Set Nominal Outlet
Model Type
Standard,
Slow
Step NAT 5.0 to 7.0 0.9 3.5 None 0.7 to 1.7
Two-Stage NAT 5.0 to 7.0 — 1.7 Low
a
Low Fire setting range for VR8304Q 1/2 in. by 1/2 in. and 1/ 2 in. by 3.4 in . is 1.5 to 3.0 in . wc .
Type of
NAT 5.0 to 7.0 — 3.5 — 3.0 to 5.0
LP 12.0 to 14.0 — 10.0 — 8.0 to 12.0
LP 12. 0 to 14. 0 2.2 10.0 None 1.4 to 5.5
LP 121. 0 to 14.0 — 4.9 Low
Gas
Nominal Inlet
Pressure Range
Pressure Se tt i ng Range
Step Full Rate Step Full Rate
flow rate cannot be achieved by adjusting the gas
control, check the control inlet pressure using a
manometer at the inlet pressure tap of the control.
If the inlet pressure is in the nominal range
(see Tables 8A and 8B), replace the gas control.
Otherwise, take the necessary steps to provide
proper gas pressure to the control.
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 .
NOTE: Read steps 1 through 7 before starting, and
compare to the safety shutdown or safe ty
lockout tests recommended for the intermittent
pilot (IP) ignition module. Where different, use
the procedure recommended for the modul e.
Turn off gas supply.
1.
Set thermostat or controller above room
2.
temperature to call for heat.
Watch for ignition spark or for glow at hot surface
3.
igniter either immediately or following pr epur ge.
See IP module specifications.
Time the length of the spark operation. See the IP
4.
module specifications.
After the module locks out, open the manual gas
5.
cock and make sure no gas is flowing to the pilot or
main burner. With modules that continue to spark
until the pilot lights or the system shuts down
manually, the pilot should light when the manual
gas control knob is opened.
Set the thermostat below room temperatu re and
6.
wait one minute.
Operate system through one complete cycle to
7.
make sure all controls operate properly.
3.5 High
10.0 High
—
— 3.5 to 5.5 Low
0.9 to 3.0 Low
3.0 to 5.0 High
8.0 to 11.0 High
a
69-1225—410
Page 11
VR8104, VR8204 AND VR8304 INT ERMITTENT PILOT COMBINATION GAS CONTROL S
Table 8B. Pressure Regulator Specification Pressures (kPa).
Factory Se t Nominal Outl e t
Model Type
Standard,
Slow
Step NAT 1.2 to 1.7 0.2 0.9 None 0.17 to 0.48
Two-stage NAT 1.2 to 1.7 — 0.48 Low
a
Low Fire setting range for VR8304Q 1/2 in. by 1/2 in. and 1/ 2 in. by 3.4 in . is 0.37 to 0.75 kPa.
Type of
NAT 1.2 to 1.7 — 0.9 — 0.7 to 1.2
LP 2.9 to 3.9 — 2.5 — 2.0 to 3.0
LP 2.9 to 3.9 0.5 2.5 None 1.4 to 1.37
LP 2.9 to 3.9 — 1.2 Low
Gas
Nominal Inlet
Pressure Range
Pressure Setting Range
Step Full Rate Step Full Rate
0.9 High
2.5 High
—
— 0. 9 to 1.4 Low
0.22 to 0.75 Low
0.75 to 1.2 High
2.0 to 2.5 High
a
Non-Regulating On-Off (U) Models
Non-regulating VR8204U Valves are designed for
application in various parts of Europe where a separate,
distinct, pressure regulator is required. The V R8204U is
similar to the VR8204A in all other aspects and should be
installed accordingly.
MAINTENANCE
WARNING
Fire or Explosion Hazard.
Can cause property damage, sev er e inj ury,
or death.
Do not disassemble the gas control; it contains
no replaceable components. Attempted
disassembly, repair, or cleaning can damage the
control, resulting in gas leakage.
Regular preventive maintenance is importan t for
applications in the commercial cooking and agricultural
and industrial industries that place a heavy load on
system controls because:
• In many such applications, particularly commercial
cooking, the equipment operates 100,000 to 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 control as outlined in the Startup and
Checkout section, and the control system as described in
the appliance manufacturer literature .
Maintenance frequency must be determined indi vid uall y
for each application. Some considerations are:
• Cycling frequency. Appliances that may cycle 20,000
times annually should be checked monthly.
• Intermittent use. Appliances tha t 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 environments. Since these
environments can cause the gas control to deteriorate
more rapidly, the system should be checked more
often.
The system should be replaced if:
• It does not perform properly on checkout or
troubleshooting.
• The gas control is likely to have operated fo r mor e
than 200,000 cycles.
• The control is wet or looks as if it has been wet.
SERVICE
WARNING
Fire or Explosion Hazard.
Can cause property damage, severe injury
or death.
Do not disassemble the control; it contains no
replaceable components. Attempte d
disassembly, repair, or cleaning can damage
the gas control, resulting in gas leakage.
CAUTION
Equipment Damage.
Can burn out valve coil terminals.
Never apply a jumper across (or short) the valve
coil terminals, even temporarily.
After servicing, verify proper system operation .
If Main Burner Does Not Come On With Call For Heat
Confirm the gas control knob is in the ON position.
1.
Adjust thermostat several degrees above room
2.
temperature.
Using ac voltmeter, check for 24V at gas control:
3.
• If pilot lights, measure across MV/PV and MV.
• If pilot does not light, measure across MV/PV
and PV before safety lockout occurs.
If voltage is incorrect or not present, check control
4.
circuit for proper operation.
If 24V is present, replace gas control.
5.
11 69-1225—4
Page 12
VR8104, VR8204 AND VR 8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS
INSTRUCTIONS TO THE HOMEOWNER
WARNING
Fire or Explosion Hazard.
Can cause property damage, sev er e inj ury,
or death.
Follow these warnings exactly:
1. Pilot flame is lit automatically. Do not light the
pilot flame manually.
2. Before lighting the pilot burner flame, smel l
around the appliance for gas. Be sure to smell
next to the floor because LP gas is heavier
than air. If you smell gas:
• Turn off the gas supply at the appliance
service valve. On LP gas systems, turn off
the 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.
3. Replace the gas control in the ev ent 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 heating appliance manufacturer. The
information below describes a typical control
application, but the specific controls used and
the procedures outlined in your appliance
manufacturer instructions can differ, requiring
special instr uctions.
STOP: Read the Warnings Above Before Proceeding.
The pilot flame is lit automatically. If the appliance does
not turn on when the thermostat is set several degrees
above room temperature, follow these instr uct ion s:
Set the thermostat to its lowest setting to reset the
1.
safety control.
Disconnect all electric power to the appliance.
2.
Remove the burner access panel if provided on
3.
your appliance.
Turn the gas control knob clockwise to the
4.
OFF position.
Wait five minutes to clear out any unburned gas.
5.
Then if you smell gas, STOP! Follow Step 2 in the
Warning above. If you do not smell gas, continue
with the next step.
Turn the gas control knob counterclockwise
6.
to the ON position.
Replace the burner access panel.
7.
Reconnect all electric power to the applianc e.
8.
Set the thermostat to the desired setting.
9.
If the appliance does not turn on, turn the gas
10.
control knob to the OFF position and contact a
qualified service technician for assistance .
Turning Off the Appliance
Vacation Shutdown
Set the thermostat to the desired room temperature while
you are away.
Complete Shutdown
Turn off power to the appliance. Turn off the gas supply
to the appliance. Turn the gas control knob to OFF. The
appliance will completely shut off. Follow the proced ur e
in the Instructions to the Homeowner section above to
resume normal operation.
Home and Building Control Home and Building Control
Honeywell Inc. Honeywell Limited-Honeywell Limitée
1985 Douglas Drive North 35 Dynamic Drive
Golden Valley, Minnesota 55422 Scarborough, Ontario
69-1225—4 G.R. Rev. 9-00 www.honeywell.com
M1V 4Z9
Printed in U.S.A. on recycled
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