Honeywell VR8215S, VR8215T Installation Manual

VR8215S,T Direct Ignition Combination Gas Controls
INSTALLATION INSTRUCTIONS

APPLICATION

The Trade VR8215S,T Direct Ignition Combination Gas Controls are used in gas-fired appliances with up to
3
150 ft
applications and include a switch and a pressure regulator.
• Valve capacities are shown in Table 1.
• Table 2 provides gas capacity conversion factors.
• For suffix letter designation, see Table 3.
Table 1. Valve Capacity.
Size
Inlet x
Model
VR8215 1/2 x 1/2 150 4.25
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
Minimum regulation for LP gas is 30,000 Btu/h (0.85 m3/hr).
Table 2. Gas Capacity Conversion Factor. Table 3. Model Number Suffix Letter Designation.
Gas Specific Gravity
Manufactured 0.60 0.516 Mixed 0.70 0.765 Propane 1.53 1.62
Outlet (in.
NPT)
AGA Certified Capacity
for Natural Gas
3
ft
/hr m3/hr ft3/hr m3/hr ft3/hr m3/hr
Multiply Listed
Capacity By
a
AGA Certified
Minimum
Regulation for
Natural Gas
b
15
Model Number Suffix
Letter
SStandard TSlow Opening
AGA Certified Maximum
Regulation for Natural
0.42 200 5.66
Gas
Pressure Regulator
Type
34-00006EF-03
VR8215S,T 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, 50/60 Hz. Current Draw: 0.5A.
Field Wiring:
2-1/4 in. spade quick-connect terminals.
Capacity: See Table 1.
Conversion:
Use conversion factors in Table 2 to convert capacities
for other gases.
Table 4. Natural-LP Gas Conversion Kits.
Model Number Suffix Letter Kit to Convert Natural Gas to LP Kit to Convert LP to Natural Gas
S, T 396221 396222
Table 5. Replacement Part Cross-Reference.
Trade Replacements
(Double-Check Specifications
Before Replacement) Competitive Replacement
Universal
Service Part
VR8215 VR8215S1503 VR8205S2262, VR8205S2270,
Direct Service
Part
Replacement Resideo White-Rogers Robertshaw
VR8205S2296, VR8205S2338, VR8205S2353, VR8205S2361, VR8205S2379, VR8205S2395, VR8205S2437, VR8205S2858, VR8205S2882, VR8205S5802, VR8205S5828, VR8205S5836, VR8205S5844, VR8215S1222, VR8215S1263, VR8215S5207, VR8215S5215, VR8205A2008, VR8205A2016, VR8205A2024, VR8205A2065, VR8205A2081, VR8205A2131, VR8205A2263, VR8205A2800, VR8205M1080, VR8205M1106, VR8205M1122, VR8205M1130, VR8205M1148, VR8205M1155, VR8205M1163, VR8205M2310, VR8205M2401, VR8205M2476, VR8205M2484, VR8205M2831, VR8205M2864, VR8205M2872, VR8205M2880, VR8205M5024, VR8205M5032
VR8215T1502 VR8205H1003, VR8205H1011,
VR8205H2605, VR8205H2621, VR8205K1157, VR8205K1173, VR8205K2247, VR8205K2593, VR8205K2619, VR8205T5801, VR8215T1205, VR8215T1239, VR8215T5206, VR8215T5214
Regulation Range: See Table 7.
Natural-LP Gas Conversion Kits: See Table 4.
Approvals:
CSA Design Certificate #112395.
(-40 °F to +175 °F; -40 °C to +79 °C)
Australian Gas Association Certificate #7960.
(-20 °C to +79 °C only)
Outlet: Class 2, Grade 20 pressure regulator
Auto shutoff valve function: Class 3
36G22-214, 36J22-214, 36G22-207
34-00006EF—03 2
VR8215S,T DIRECT IGNITION COMBINATION GAS CONTROLS
WARNING
WARNING
CAUTION

PLANNING THE INSTALLATION

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.
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 failure due to frequent cycling, severe environmental conditions related to moisture, corrosive chemicals, dust or excessive heat. These applications require Resideo Engineering review; contact your Resideo 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 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 procedures.

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.

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.

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.
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 gas supply at the appliance service valve before star ting 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 on-off switch. Use only your fingers to operate the on-off switch. Never use any tools. If the electronic on-off switch 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.
5. Gas will leak if installed backwards.

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.
Equipment Damage Hazard. Can burn out thermostat or transformer.
Applying a jumper across (or shorting) the valve coil terminals, even temporarily, can burn out the thermostat or transformer.
Follow the appliance manufacturers instructions if available; otherwise use these instructions as a guide.
3 34-00006EF—03
VR8215S,T DIRECT IGNITION COMBINATION GAS CONTROLS
WARNING
COLOR CODE FOR
LP GAS
NATURAL GAS
PRESSURE REGULATOR ADJUSTING SCREW
BLACK BLACK
SPRING
RED
STAINLESS STEEL
PRESSURE REGULATOR HOUSING
M20046B
REUSE EXISTING METAL CAP SCREW.
1
1
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)

Fire Or Explosion Hazard. Can cause property damage, severe injury or death.
1. Always change the main 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.
2. 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 and slow-opening regulators (model numbers with suffix S or T) can be converted from one gas to the other with a conversion kit. See Table 4 for the conversion kit part number.
1. Turn off gas supply at the appliance service
valve.
2. Remove regulator cap screw and save. See Fig. 5.
3. Remove the pressure regulator adjusting screw.
See Fig. 1.
4. Remove the existing spring.
5. Insert the replacement spring. See Fig. 1.
6. Install the new plastic pressure regulator adjust-
ment screw.
7. Check the regulator setting using a manometer
or by clocking the gas meter. See “Check and Adjust Gas Input and Burner Ignition” on page 7.
8. Reinstall the regulator cap screw.
9. Mount conversion label on the gas control.

Install Bushings To Control

If bushings are being installed on the control, mount them as follows:
Bushings
1. Remove the seal over the control inlet or outlet.
2. Apply a moderate amount of good quality pipe
NOTE: Do not use Teflon tape.
3. Insert the bushing in the control and carefully
Complete the instructions below for installing the piping, installing the control, connecting the wiring. Make sure the leak test you perform on the control after completing the installation includes leak testing the bushings.
Fig. 1. Converting between LP and natural gas.
compound to the bushing, leaving two end threads bare. On an LP installation, use compound that is resistant to LP gas. See Fig. 2.
thread the pipe into the bushing until tight.
34-00006EF—03 4

Location

The gas controls are 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.
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 gas control 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.
VR8215S,T DIRECT IGNITION COMBINATION GAS CONTROLS
TWO IMPERFECT THREADS
GAS CONTROL
THREAD PIPE THE AMOUNT SHOWN IN TABLE FOR INSERTION INTO GAS CONTROL
APPLY A MODERATE AMOUNT OF PIPE COMPOUND TO PIPE ONLY (LEAVE TWO END THREADS BARE).
M3075B
PIPE
GAS CONTROL
GAS CONTROL
HORIZONTAL
DROP
PIPED GAS SUPPLY
PIPED GAS SUPPLY
3 IN.
(76 MM)
MINIMUM
3 IN.
(76 MM)
MINIMUM
RISER
GAS CONTROL
TUBING GAS SUPPLY
HORIZONTAL
DROP
3 IN.
(76 MM)
MINIMUM
RISER
M3077
2
1
2
2
1
2
ALL BENDS IN METALLIC TUBING SHOULD BE SMOOTH.
CAUTION: SHUT OFF THE MAIN GAS SUPPLY BEFORE REMOVING END CAP TO PREVENT GAS FROM FILLING THE WORK AREA. TEST FOR GAS LEAKAGE WHEN INSTALLATION IS COMPLETE.
M27670B
ON
OFF
PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW)
INLET
INLET PRESSURE TAP 1/8 IN. NPT
OUTLET
OUTLET PRESSURE TAP 1/8 IN. NPT
ON/OFF SWITCH
• 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 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 that is free from
chips. If tubing is used, make sure 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 a sediment trap in the supply line to the
control. See Fig. 3.

Install Control

1. Can be mounted in any direction.
2. Mount so the gas flow is in the direction of the
arrow on the bottom of the control.
NOTE: Gas valve will leak if installed backwards.
3. Thread the pipe the amount shown in Table 6 for
insertion into control or adapters. Do not thread pipe too far. Valve distortion or malfunction can result if the pipe is inserted too deeply.
4. Apply a moderate amount of good quality pipe
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. 2.
5. Remove the seals over the control inlet and out-
let if necessary.
6. Connect the pipe to the control inlet and outlet.
Use a wrench on the hex end of the control. See Fig. 4.
Fig. 3. Sediment trap installation.
Table 6. NPT Pipe Thread Length.
Pipe
Thread Pipe
Size
this Amount
b
3/8 1/2 3/4 (19) 1/2 (13)
a
All dimensions are in inches (mm).
b
OK when bushings are used.
9/16 (14) 3/8 (9)
Maximum Depth Pipe
can be inserted into
Fig. 2. Use moderate amount of pipe compound.
Control
a
M27669A
Fig. 4. Proper use of wrench on gas control.
Fig. 5. Top view of gas control.
5 34-00006EF—03
VR8215S,T DIRECT IGNITION COMBINATION GAS CONTROLS
WARNING
WARNING

Wiring

Follow the wiring instructions furnished by the appliance manufacturer, if available, or use the general instructions provided below. When these instructions differ from the appliance manufacturer, follow the appliance manufacturer instructions.
IMPORTANT
All wiring must comply with applicable electri­cal codes and ordinances.
Electrical Shock Hazard or Equipment Damage Hazard. Can cause serious injury, death or equipment damage.
Disconnect power supply before making wiring connections to prevent electrical shock or equipment damage.
1. Check the power supply rating on the gas control
and make sure it matches the available supply. Install a transformer and other controls as required.
2. Connect the control circuit to the gas control
terminals. See Fig. 6 and 7.
3. Adjust thermostat heat anticipator to 0.50A rat-
ing stamped on valve label.
L1
BURNER
(HOT)
M27697
L2
1
2
S87B CONTROL MODULE
ALARM
VALV E VALV E
4
IGNITER-SENSOR AND BURNER GROUND
3
5
GND
24V (GND)
24V
TEMPERATURE CONTROLLER
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
2
ALTERNATE LIMIT CONTROLLER LOCATION.
3
MAXIMUM IGNITER-SENSOR CABLE LENGTH: 3 ft. (0.9 m) OR LESS.
4
3A REPLACEABLE FUSE.
5
ALARM TERMINAL PROVIDED ON SOME MODELS.
Fig. 6. Typical wiring connections for 24 volt
control in S87 Direct Ignition System.
ALARM, IF USED
DUAL VALVE COMBINATION GAS CONTROL
Q347 IGNITER-SENSOR
DUAL VALVE COMBINATION GAS CONTROL
THERMOSTAT OR CONTROLLER
1
2
3
S89C,G,J/S890C,G,J HOT SURFACE IGNITION CONTROL
VALV E VALVE (GND)
24V TH-W 24V (GND)
GND (BURNER) VENT DAMPER PLUG
BURNER GROUND
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. MAKE SURE L1 AND L2 ARE NOT REVERSED; THIS WOULD PREVENT FLAME DETECTION.
ALTERNATE LIMIT CONTROLLER LOCATION.
SEN TERMINAL AND Q354 FLAME SENSOR ON D MODELS ONLY.
Fig. 7. Typical wiring connections with 24 volt
control in S89 Direct Ignition System.
L2
HSI
L1
HSI
SEN
3
2
WHITE BLUE BLACK BLUE
HOT SURFACE IGNITER­SENSOR
Q354 FLAME SENSOR
LIMIT CONTROLLER
(HOT)
1
M27628
L1
L2

STARTUP AND CHECKOUT

On-Off Switch
The on-off switch settings are as follows:
• OFF: Prevents main gas flow through the control.
• ON: Permits gas to flow into the control body. Under control of the thermostat and direct ignition module, gas can flow to the main burners.
NOTE: Controls are shipped with the electronic on-
off switch in the ON position.

Perform Gas Leak Test

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. This can damage the control. Do not use an excessive amount of soap and water solution to perform the gas leak test. Apply only to pipe thread areas.
Gas Leak Test
1. Paint pipe connections upstream of the gas con-
trol with rich soap and water solution. Bubbles indicate a gas leak.
2. If a leak is detected, tighten the pipe connec-
tions.
34-00006EF—03 6
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