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 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

									AGA Certified Maximum
	Size		AGA Certified Capacity for			AGA Certified Minimum			Regulation for
				Natural Gas		Regulation for Natural Gas			Natural Gas
	Inlet-Outlet
Model	(in.)			ft3/hr	m3/hr	ft3/hr	m3/hr		ft3/hr	m3/hr
VR8104	1/2 x 1/2		85		2.3	10d	0.4		120	3.4
VR8204			150		4.2	20e	0.6		200	5.7
VR8304b,c			240		6.8	30f	0.8		340	9.6
VR8304b,c	1/2 x 3/4		270		7.6				370	1.05
VR8304b,c	3/4 x 3/4		300		8.5				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.

		Multiply Listed
Gas	Specific Gravity	Capacity By
Manufactured	0.60	0.516
Mixed	0.70	0.765
Propane	1.53	1.62

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 models are available CE-approved.

Table 4 shows the additional specifications for the CE-only models.

® U.S. Registered Trademark
Copyright © 2000 Honeywell Inc. • All Rights Reserved	69-1225-4

VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

Table 3. Model Number Suffix Letter Designation.

	Ambient
Model No.	Temperature	Pressure
Suffix Letter	Range	Regulator Type
A	0°F to 175°F	Standard
	(-18°C to +79°C)
C		Step-opening
H		Slow-opening
Ua		Nonregulating
		(on-off)
K	-40°F to +175°F	Slow-opening
	(-40°C to +79°C)
M		Standard
P		Step-opening
Q		Two-Stage
R		Convertible

a Available only on CE VR8204 models.

Table 4. VR8204A,H/VR8304A,H,U CE.

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.
Valve Classification	B + D	C + D
Capacity (1kW = 3.41BTUH)	29 kW at 2.5 mBar	for 1/2 in., 70 kW at 2.5 mBar
	43 kW at 5.0 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	Natural gas: 7.5 to 12.5 mBar (3 to 5 in. wc).
(Except unregulated models)	Natural gas: 12.5 to 17.5 mBar (5 to 7 in. wc).
	LP gas: 20 to 30 mBar (8 to 12 in. wc).
Manually operated valve	10,000 cycles for manual valves; 200,000 cycles for automatic valves.
operations
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 connectiona	M11 x 1 for 6 mm outside diameter tube.
Ground terminala	6.3 mm.
Pressure tapsa	9 mm OD for both inlet and outlet.
Approval	CE-0063AU1215.

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

SPECIFICATIONS

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.

Model No.	Kit to Convert	Kit to Convert LP
Suffix Letter	Natural Gas to LP	to Natural Gas
H, K, M	393691	394588
P	Not field	Not field
	convertible.	convertible.
Q	396021	396025
R	Not required,	Not required,
	convertible valve.	convertible valve.

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.

PLANNING THE INSTALLATION

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.
Inlet/Outlet		Part Numbera,b
Pipe Size	Flange	Without Hex	With Hex
(in. NPT)	Type	Wrench	Wrench
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

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.

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.

3

69-1225—4

VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

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.

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.

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.

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.

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.

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 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

4