VR8104, VR8204, and VR8304
Intermittent Pilot Combination
Gas Controls
INSTALLATION INSTRUCTIONS
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 regulator and a pilot adjustment.
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.
Table 1. Valve Capacitya
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AGA Certified Maximum |
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Size |
AGA Certified Capacity for |
AGA Certified Minimum |
Regulation for |
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Natural Gas |
Regulation for Natural Gas |
Natural Gas |
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Inlet-Outlet |
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Model |
(in.) |
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ft3/hr |
m3/hr |
ft3/hr |
m3/hr |
ft3/hr |
m3/hr |
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VR8104 |
1/2 x 1/2 |
85 |
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2.3 |
10d |
0.4 |
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120 |
3.4 |
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VR8204 |
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150 |
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4.2 |
20e |
0.6 |
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200 |
5.7 |
VR8304b,c |
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240 |
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6.8 |
30f |
0.8 |
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340 |
9.6 |
VR8304b,c |
1/2 x 3/4 |
270 |
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7.6 |
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370 |
1.05 |
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VR8304b,c |
3/4 x 3/4 |
300 |
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8.5 |
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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.
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Multiply Listed |
Gas |
Specific Gravity |
Capacity By |
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Manufactured |
0.60 |
0.516 |
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Mixed |
0.70 |
0.765 |
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Propane |
1.53 |
1.62 |
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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 models are available CE-approved.
Table 4 shows the additional specifications for the CE-only models.
® U.S. Registered Trademark |
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Copyright © 2000 Honeywell Inc. • All Rights Reserved |
69-1225-4 |
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VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS
Table 3. Model Number Suffix Letter Designation.
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Ambient |
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Model No. |
Temperature |
Pressure |
Suffix Letter |
Range |
Regulator Type |
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A |
0°F to 175°F |
Standard |
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(-18°C to +79°C) |
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C |
Step-opening |
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H |
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Slow-opening |
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Ua |
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Nonregulating |
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(on-off) |
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K |
-40°F to +175°F |
Slow-opening |
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(-40°C to +79°C) |
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M |
Standard |
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P |
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Step-opening |
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Q |
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Two-Stage |
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R |
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Convertible |
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a Available only on CE VR8204 models.
Table 4. VR8204A,H/VR8304A,H,U CE.
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Specifications |
VR8204A,H (CE Model Only) |
VR8304A,H (CE Model Only) |
Main valve connections (If NPT, |
1/2 in. ISO, 7/1 internal thread (BSP, |
1/2 in., 3/4 in. ISO, 7/1 internal thread (BSP, |
the valves must be serviced by |
NPT. |
PL) or 1/2 in., 3/4 in. NPT. |
the appliance manufacturer. |
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Valve Classification |
B + D |
C + D |
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Capacity (1kW = 3.41BTUH) |
29 kW at 2.5 mBar |
for 1/2 in., 70 kW at 2.5 mBar |
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43 kW at 5.0 mBar |
99 kW at 5.0 mBar. |
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For 3/4 in., 87 kW at 2.5 mBar: |
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121 kW at 5.0 mBar. |
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Supply Voltage |
24 Vac, 50/60 Hz. |
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Flanges |
None. |
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Closing time |
Less than 1 second. |
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Opening Time |
Standard opening (A): less than 2 seconds. |
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Slow opening (H): less than 6 seconds. |
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Special fast opening (U): less than 1 second. |
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Suited for gas families |
2H, 2L, and 3. |
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Outlet Press Range |
Natural gas: 7.5 to 12.5 mBar (3 to 5 in. wc). |
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(Except unregulated models) |
Natural gas: 12.5 to 17.5 mBar (5 to 7 in. wc). |
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LP gas: 20 to 30 mBar (8 to 12 in. wc). |
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Manually operated valve |
10,000 cycles for manual valves; 200,000 cycles for automatic valves. |
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operations |
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Ambient temperature range |
-20°C to +70°C (-4°F to +158°F). |
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Maximum inlet pressure |
60 mBar (24 in. wc). |
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Screen |
Fine mesh on inlet. |
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Pilot connectiona |
M11 x 1 for 6 mm outside diameter tube. |
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Ground terminala |
6.3 mm. |
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Pressure tapsa |
9 mm OD for both inlet and outlet. |
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Approval |
CE-0063AU1215. |
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a The VR8204U uses standard U.S. construction. Inlet 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 |
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS
Body Pattern: Straight through; see Table 1 for inlet and outlet size.
Electrical Ratings:
Voltage and Frequency: 24 Vac, 60 Hz.
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 5.
Table 5. Natural-LP Gas Conversion Kits.
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Model No. |
Kit to Convert |
Kit to Convert LP |
Suffix Letter |
Natural Gas to LP |
to Natural Gas |
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H, K, M |
393691 |
394588 |
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P |
Not field |
Not field |
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convertible. |
convertible. |
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Q |
396021 |
396025 |
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R |
Not required, |
Not required, |
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convertible valve. |
convertible valve. |
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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 Certificate: 4214.
Approved for Delta C applications.
European Community (CE) Certificate: Pending.
WARNING
Fire or Explosion Hazard.
Can cause property damage, severe injury, 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. |
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Inlet/Outlet |
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Part Numbera,b |
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Pipe Size |
Flange |
Without Hex |
With Hex |
(in. NPT) |
Type |
Wrench |
Wrench |
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3/8 |
Straight |
393690-1 |
393690-11 |
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3/8 |
Elbow |
393690-2 |
393690-12 |
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1/2 |
Straight |
393690-6 |
393690-16 |
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1/2 |
Elbow |
393690-3 |
393690-13 |
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3/4 |
Straight |
393690-4 |
393690-14 |
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3/4 |
Elbow |
393690-5 |
393690-15 |
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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.
Heavy demands are made on the controls when intermittent pilot 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 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 your specific installation and follow the precautions suggested.
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 checkout.
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.
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.
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69-1225—4 |
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS
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.
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.
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.
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.
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.
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.
69-1225—4 |
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