Honeywell VR8204, VR8304 User Manual

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

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).

Capacity is reduced by 5 percent when using an outle t screen.

Valves are guaranteed at only 77 percent of the rating.

Minimum regulation for LP gas is 15,000 Btu h.

Minimum regulation for LP gas is 40,000 Btu h.

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

/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.

AGA Certified Minimum

Regulation for Natural Ga s

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.

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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

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

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

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.

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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

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

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.

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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

them could damage the product or cause a hazardous condition. Check the ratings given in the instructions and on

the product to make sure the product is suitable for your application. Installer must be a trained, experienced service

technician. After installation is complete, check out product

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.

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. Replace the cap and tighten firmly.

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