Honeywell Boiler VR8204 User Manual

VR8104, VR8204, and VR8304  
Intermittent Pilot Combination  
Gas Controls  
INSTALLATION INSTRUCTIONS  
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  
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.  
temperature range and regulator type, see Table 3.  
For CE-approved models, the relevant sections of these  
instructions and Table 4 are applicable.  
a
Table 1. Valve Capacity  
AGA Certified Maximum  
Regulation for  
AGA Certified Capacity for  
AGA Certified Minimum  
Regulation for Natural Gas  
Size  
Inlet-Outlet  
Natural Gas  
Natural Gas  
3
3
3
3
3
3
Model  
VR8104  
(in.)  
ft /hr  
m /hr  
ft /hr  
m /hr  
ft /hr  
m /hr  
d
e
f
1/2 x 1/2  
85  
2.3  
4.2  
6.8  
7.6  
8.5  
0.4  
0.6  
0.8  
120  
200  
340  
370  
415  
3.4  
5.7  
9.6  
10  
20  
30  
VR8204  
150  
240  
270  
300  
3
b,c  
b,c  
b,c  
VR8304  
VR8304  
VR8304  
1/2 x 3/4  
3/4 x 3/4  
1.05  
11.8  
a
3
Capacity based on 1000 Btu/ft , 0.64 sp gr natural gas at 1 in. wc pressure drop (37.3 MJ/m , 0.64 sp gr natural gas  
at 0.25 kPa pressure drop).  
b
c
d
e
f
Capacity is reduced by 5 percent when using an outlet screen.  
Valves are guaranteed at only 77 percent of the rating.  
Minimum regulation for LP gas is 15,000 Btuh.  
Minimum regulation for LP gas is 40,000 Btuh.  
Minimum regulation for LP gas is 50,000 Btuh.  
Table 2. Gas Capacity Conversion Factor.  
CE-Only Models  
Multiply Listed  
Capacity By  
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.  
Gas  
Specific Gravity  
Manufactured  
Mixed  
0.60  
0.70  
1.53  
0.516  
0.765  
1.62  
Propane  
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 6. Flange Adapter Part Numbers.  
SPECIFICATIONS  
a,b  
Part Number  
Inlet/Outlet  
Body Pattern: Straight through; see Table 1 for inlet and  
outlet size.  
Pipe Size  
(in. NPT)  
Flange Without Hex  
With Hex  
Wrench  
Type  
Straight  
Elbow  
Wrench  
393690-1  
393690-2  
393690-6  
393690-3  
393690-4  
393690-5  
3/8  
393690-11  
393690-12  
393690-16  
393690-13  
393690-14  
393690-15  
Electrical Ratings:  
Voltage and Frequency: 24 Vac, 60 Hz.  
Current Draw: 0.5A with both operators energized.  
3/8  
1/2  
1/2  
3/4  
3/4  
Straight  
Elbow  
Capacity: See Table 1.  
Straight  
Elbow  
Conversion: Use conversion factors in Table 2 to con-  
vert capacities for other gases.  
a
Flange kits include one flange, one O-ring and four  
mounting screws.  
Regulation Range: See Table 1.  
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.  
Natural-LP Gas Conversion Kits: See Table 5.  
Table 5. Natural-LP Gas Conversion Kits.  
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.  
Model No.  
Suffix Letter Natural Gas to LP  
Kit to Convert  
Kit to Convert LP  
to Natural Gas  
H, K, M  
P
393691  
394588  
Not field  
convertible.  
Not field  
convertible.  
Q
R
396021  
396025  
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.  
Not required,  
convertible valve.  
Not required,  
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.  
Review the following conditions that can apply to your  
specific installation and follow the precautions  
suggested.  
Approvals:  
American Gas Association Design Certificate: L2025006.  
Canadian Gas Association Design Certificate: L2025006.  
Australian Gas Association Design Certificate: 4214.  
Approved for Delta C applications.  
Frequent Cycling  
European Community (CE) Certificate: Pending.  
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.  
PLANNING THE INSTALLATION  
WARNING  
Can cause property damage, severe injury,  
Water or Steam Cleaning  
Fire or Explosion Hazard.  
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.  
or death.  
Follow these warnings exactly:  
1. Plan the installation as outlined below.  
2. Plan for frequent maintenance as described in  
the Maintenance section.  
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  
CAUTION  
Can burn out valve coil terminals.  
Never apply a jumper across (or short) the valve  
coil terminals, even temporarily.  
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.  
Follow the appliance manufacturers instructions if  
available; otherwise, use these instructions as a guide.  
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.  
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  
Converting Gas Control from Natural Gas  
to LP Gas (or LP Gas to Natural Gas)  
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.  
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  
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.  
(manufactured) gas on LP gas, or a gas control  
set for LP gas on natural (manufactured) gas.  
3. Installer must be a trained, experienced service  
technician.  
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.  
4. After installation is complete, check out product  
operation as provided in these instructions.  
WARNING  
Fire or Explosion Hazard.  
Convertible Pressure Regulators  
Can cause property damage, severe injury  
or death.  
Follow these warnings exactly:  
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.  
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.  
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
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS  
OR  
OTHER SIDE  
OF CAP  
PRESSURE  
REGULATOR  
CAP  
1
VALVE OUTLET  
FLANGE  
M11678  
9/64 INCH HEX SCREWS (4)  
Fig. 1. Top view of convertible  
pressure regulator cap.  
DO NOT OVERTIGHTEN SCREWS. TIGHTEN TO  
25 INCH-POUNDS.  
1
M9046  
Fig. 2. Firmly fasten flange to valve, but  
do not overtighten screws.  
Install Adapters To Control  
If adapters are being installed on the control, mount them  
as follows:  
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 location  
as the old control.  
Flanges  
1. Choose the appropriate flange for your application.  
2. Remove the seal over the gas control inlet or  
outlet.  
3. Make sure that the O-ring is fitted in the groove of  
the flange. If the O-ring is not attached or is  
missing, do not use the flange.  
4. With the O-ring facing the control, align the screw  
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.  
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.  
Cover gas control if appliance is cleaned with water,  
steam, or chemicals or to avoid dust and grease  
accumulation.  
Bushings  
1. Remove the seal over the control inlet or outlet.  
2. Apply a moderate amount of good quality pipe  
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.  
Avoid locating gas control where exposure to  
corrosive chemical fumes or dripping water are likely.  
3. Insert the bushing in the control and carefully  
thread the pipe into the bushing until tight.  
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.  
Complete the instructions below for installing the piping,  
installing the control, connecting the pilot gas tubing and  
the wiring. Make sure the leak test you perform on the  
control after completing the installation includes leak  
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.  
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.  
5
69-1225—4  
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS  
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. 4.  
DROP  
PIPED  
GAS  
SUPPLY  
GAS  
CONTROL  
HORIZONTAL  
5. Remove the seals over the control inlet and outlet if  
RISER  
necessary.  
GAS  
CONTROL  
6. Connect the pipe to the control inlet and outlet. Use  
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 control. Refer to Fig. 5  
and 6.  
PIPED  
GAS  
SUPPLY  
3 IN.  
(76 MM)  
MINIMUM  
2
DROP  
Connect Pilot Gas Tubing  
HORIZONTAL  
3 IN.  
1. Cut tubing to the desired length and bend as  
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.  
2. Square off and remove burrs from the end of the  
tubing.  
(76 MM)  
MINIMUM  
TUBING  
GAS  
SUPPLY  
1
2
GAS  
CONTROL  
RISER  
3 IN.  
(76 MM)  
MINIMUM  
3. Unscrew the brass compression fitting from the  
pilot outlet (Fig. 6). Slip the fitting over the tubing  
and slide out of the way. See Fig. 7.  
2
ALL BENDS IN METALLIC TUBING SHOULD BE SMOOTH.  
1
2
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.  
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.  
M3077  
Fig. 3. Sediment trap installation.  
4. Push the tubing into the pilot gas tapping on the  
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.  
5. Connect the other end of the tubing to the pilot  
burner according to the pilot burner manufacturers  
instructions.  
Install Control  
1. Mounted 0 to 90 degrees in any direction, including  
vertically, from the upright position of the gas  
control knob.  
2. Mount so the gas flow is in the direction of the  
arrow on the bottom of the control.  
3. Thread the pipe the amount shown in Table 7 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.  
TWO IMPERFECT  
GAS CONTROL  
THREADS  
Table 7. NPT Pipe Thread Length (in.).  
PIPE  
Pipe  
Size  
Thread Pipe Maximum Depth Pipe can  
this Amount  
be Inserted into 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).  
3/8  
9/16  
3/8  
1/2  
3/4  
3/4  
1/2  
3/4  
M3075B  
13/16  
Fig. 4. Use moderate amount of pipe compound.  
69-12254  
6
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS  
WHEN FLANGE IS USED  
WHEN FLANGE IS NOT USED  
APPLY WRENCH  
FROM TOP OR  
BOTTOM OF GAS  
CONTROL TO  
APPLY WRENCH  
TO FLANGE ONLY  
EITHER SHADED AREA  
M3079  
Fig. 5. Proper use of wrench on gas control with and without flanges.  
HI-LO  
ADJUSTMENT SCREWS  
(UNDER CAP)  
PRESSURE REGULATOR  
ADJUSTMENT  
(UNDER CAP SCREW)  
WIRING  
TERMINALS (3)  
REGULATOR  
VENT COVER  
OUTLET  
PRESSURE  
TAP  
INLET  
PRESSURE TAP  
LO  
HI  
OUTLET  
INLET  
TWO-STAGE  
PRESSURE  
REGULATOR  
MODEL  
PILOT OUTLET  
INLET  
GAS  
PILOT ADJUSTMENT  
CONTROL  
KNOB  
(UNDER CAP SCREW)  
M10968A  
Fig. 6. Top view of gas control.  
All wiring must comply with applicable electrical codes  
and ordinances.  
GAS CONTROL  
TIGHTEN NUT ONE TURN  
BEYOND FINGER TIGHT.  
Disconnect power supply before making wiring  
connections to prevent electrical shock or equipment  
damage.  
TO PILOT  
BURNER  
FITTING BREAKS OFF AND CLINCHES  
TUBING AS NUT IS TIGHTENED.  
1. Check the power supply rating on the gas control  
and make sure it matches the available supply.  
Install a transformer, thermostat and other controls  
as required.  
M3076A  
Fig. 7. Always use new compression fitting.  
2. Connect control circuit to the gas control terminals.  
See Fig. 8.  
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.  
7
69-12254  
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS  
Turn On Main Burner  
S8600  
Follow appliance manufacturer instructions or turn up  
VENT  
DAMPER  
PLUG  
thermostat to call for heat.  
5
GND  
TH-W  
(OPT)  
24V  
24V  
GND  
(BURNER)  
(OPT)  
MV MV/PV PV  
SENSE SPARK  
Perform Gas Leak Test  
3
5
WARNING  
PV  
Fire or Explosion Hazard.  
Can cause property damage, severe injury  
or death.  
2
PV/MV  
MV  
4
Perform Gas Leak Test every time work is done  
on a gas system.  
THERMOSTAT  
GAS CONTROL  
TERMINALS  
IMPORTANT  
LIMIT  
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.  
CONTROLLER  
Q345, Q346,  
Q348, Q362, Q381  
PILOT BURNER/  
IGNITER-SENSOR  
GROUND  
L1 L2  
(HOT)  
PILOT GAS  
SUPPLY  
1
Gas Leak Test  
1. Paint pipe connections upstream of the gas control  
with rich soap and water solution. Bubbles indicate  
a gas leak.  
2. If a leak is detected, tighten the pipe connections.  
3. Light the main burner. Stand clear of the main  
burner while lighting to prevent injury caused from  
hidden leaks that could cause flashback in the  
appliance vestibule.  
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS  
AND OVERLOAD PROTECTION AS REQUIRED.  
2
3
4
ALTERNATE LIMIT CONTROLLER LOCATION.  
MAXIMUM WIRE LENGTH 3 ft [.9 m].  
CONTROLS IN 24V CIRCUIT MUST NOT BE IN  
GROUND LEG TO TRANSFORMER.  
5
FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER  
PLUG, CONNECT THERMOSTAT TO TH-W. LEAVE  
24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.  
4. With the main burner in operation, paint the pipe  
joints (including adapters) and the control inlet and  
outlet with rich soap and water solution.  
M9056  
5. If another leak is detected, tighten the adapter  
screws, joints, and pipe connections.  
6. Replace the part if a leak cannot be stopped.  
Fig. 8. Typical wiring connections for 24 volt control  
in intermittent ignition system with S8600.  
Check and Adjust Pilot Flame  
STARTUP AND CHECKOUT  
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:  
WARNING  
Fire or Explosion Hazard.  
Can cause property damage, severe injury  
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.  
1. Remove pilot adjustment cover screw. See Fig. 6.  
2. The pilot adjustment is shipped at the full pilot gas  
flow rate. Turn the inner adjustment screw  
clockwise  
if the inlet pressure is too high.  
Turn the inner adjustment screw clockwise  
Gas Control Knob Settings  
to decrease or counterclockwise  
pilot flame.  
to increase  
Gas control knob settings are as follows:  
OFF: Prevents pilot and main gas flow through the  
control.  
3. Replace the cover screw after the adjustment to  
prevent gas leakage.  
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.  
PROPER FLAME  
ADJUSTMENT  
3/8 TO 1/2 INCH  
(10 TO 13 mm)  
NOTE: Controls are shipped with the gas control knob  
in the ON position.  
IGNITER-  
SENSOR  
Turn On System  
Rotate the gas control knob counterclockwise  
ON.  
to  
M3080A  
Fig. 9. Proper flame adjustment.  
69-12254  
8
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS  
NOTE: If the burner firing rate is above 150,000 Btuh  
Check and Adjust Gas Input  
and Burner Ignition  
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. Take whatever steps  
are required to correct the situation.  
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.  
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 adjustable.  
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.  
1. Carefully check the main burner lightoff. Make sure  
that the main burner lights smoothly and that all  
ports remain lit.  
2. Check the full rate manifold pressure listed on the  
appliance nameplate. Gas control full rate outlet  
pressure should match this rating.  
3. With main burner operating, check the gas control  
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.  
4. If necessary, adjust the pressure regulator to  
match the appliance rating. See Tables 8A and 8B  
for factory-set nominal outlet pressure and  
adjustment range.  
3. IF CHECKING GAS INPUT WITH  
MANOMETER: Make sure the gas control knob  
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 removing  
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.  
a. Remove the pressure regulator adjustment cap  
screw.  
Using a screwdriver, turn the inner adjustment screw  
(Fig. 6) clockwise  
counterclockwise  
to the burner.  
to increase or  
to decrease the gas pressure  
b. Always replace the cap screw and tighten  
firmly to prevent gas leakage.  
5. If the desired outlet pressure or flow rate cannot be  
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.  
6. Carefully check the burner lightoff at step pressure.  
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.  
NOTE: Check the inlet pressure before adjusting the  
pressure regulator.  
Standard and Slow-Opening  
(H, K and M) Models  
1. Carefully check the main burner lightoff. Make sure  
that the main burner lights smoothly and that all  
ports remain lit.  
2. Check the full rate manifold pressure listed on the  
appliance nameplate. Gas control full rate outlet  
pressure should match this rating.  
3. With main burner operating, check the control flow  
rate using the meter clocking method or check  
pressure using a manometer connected to the  
outlet pressure tap on the control. See Fig. 6.  
4. If necessary, adjust the pressure regulator to  
match the appliance rating. See Tables 8A and 8B  
for factory-set nominal outlet pressure and  
adjustment range.  
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 adjustment procedure  
for the appliance in which the control is installed.  
a. Remove the pressure regulator adjustment cap  
screw.  
b. Using a screwdriver, turn the inner adjustment  
screw (Fig. 6) clockwise  
counterclockwise  
to increase or  
to decrease the gas  
pressure to the burner.  
c. Always replace the cap screw and tighten  
firmly to prevent gas leakage.  
1. Set appliance to operate on high.  
2. Carefully check the main burner lightoff. Make sure  
that the main burner lights smoothly and that all  
ports remain lit.  
3. Check the full rate (high) manifold pressure listed  
on the appliance nameplate for high pressure. The  
gas control full rate outlet pressure should match  
this rating.  
5. If the desired outlet pressure or flow rate cannot  
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.  
9
69-12254  
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS  
4. With main burner operating, check the gas control  
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.  
5. If necessary, adjust the high pressure regulator to  
match the appliance rating. See Tables 8A and 8B  
for factory-set nominal outlet pressure and  
adjustment range.  
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.  
a. Remove the pressure regulator adjustment cap  
(Fig. 6).  
b. Using a screwdriver, turn the inner adjustment  
Check Safety Shutdown Performance  
screw for HI pressure clockwise  
increase or counterclockwise  
to  
to  
WARNING  
Can cause property damage, severe injury  
or death.  
Perform the safety shutdown test any time work  
is done on a gas system.  
decrease the gas pressure to the burner.  
6. After high pressure has been checked, check low  
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 regulator setting.  
7. Check the low rate manifold pressure listed on the  
appliance nameplate. Gas control low rate outlet  
pressure should match this rating.  
8. With main burner operating, check the gas control  
flow rate as before (using the meter clocking  
method or check pressure using a manometer  
connected to the outlet pressure tap on the  
control).  
Fire or Explosion Hazard.  
NOTE: Read steps 1 through 7 before starting, and  
compare to the safety shutdown or safety  
lockout tests recommended for the intermittent  
pilot (IP) ignition module. Where different, use  
the procedure recommended for the module.  
1. Turn off gas supply.  
2. Set thermostat or controller above room  
temperature to call for heat.  
3. Watch for ignition spark or for glow at hot surface  
igniter either immediately or following prepurge.  
See IP module specifications.  
9. If necessary, adjust the low pressure regulator to  
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  
4. Time the length of the spark operation. See the IP  
module specifications.  
5. After the module locks out, open the manual gas  
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.  
LO pressure clockwise  
counterclockwise  
the burner.  
to increase or  
to decrease the gas pressure to  
6. Set the thermostat below room temperature and  
wait one minute.  
7. Operate system through one complete cycle to  
make sure all controls operate properly.  
10. Once high and low pressure have been checked  
and adjusted, replace pressure regulator  
adjustment cap. If the desired outlet pressure or  
Table 8A. Pressure Regulator Specification Pressures (in. wc).  
Factory Set Nominal Outlet  
Pressure  
Setting Range  
Full Rate  
Type of Nominal Inlet  
Model Type  
Gas  
Pressure Range  
Step  
Full Rate  
3.5  
Step  
Standard,  
Slow  
NAT  
5.0 to 7.0  
3.0 to 5.0  
LP  
12.0 to 14.0  
5.0 to 7.0  
10.0  
3.5  
8.0 to 12.0  
0.7 to 1.7  
1.4 to 5.5  
Step  
NAT  
LP  
0.9  
2.2  
None  
None  
12.0 to 14.0  
5.0 to 7.0  
10.0  
a
Two-Stage  
NAT  
1.7 Low  
3.5 High  
0.9 to 3.0 Low  
3.0 to 5.0 High  
LP  
121.0 to 14.0  
4.9 Low  
3.5 to 5.5 Low  
10.0 High  
8.0 to 11.0 High  
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.  
69-12254  
10  
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS  
Table 8B. Pressure Regulator Specification Pressures (kPa).  
Factory Set Nominal Outlet  
Pressure  
Setting Range  
Type of  
Gas  
Nominal Inlet  
Pressure Range  
Model Type  
Step  
Full Rate  
Step  
Full Rate  
Standard,  
Slow  
NAT  
1.2 to 1.7  
0.9  
0.7 to 1.2  
LP  
2.9 to 3.9  
1.2 to 1.7  
2.9 to 3.9  
1.2 to 1.7  
2.5  
0.9  
2.5  
2.0 to 3.0  
Step  
NAT  
LP  
0.2  
0.5  
None  
None  
0.17 to 0.48  
1.4 to 1.37  
a
Two-stage  
NAT  
0.48 Low  
0.9 High  
0.22 to 0.75 Low  
0.75 to 1.2 High  
LP  
2.9 to 3.9  
1.2 Low  
2.5 High  
0.9 to 1.4 Low  
2.0 to 2.5 High  
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.  
Dusty, wet, or corrosive environments. Since these  
environments can cause the gas control to deteriorate  
more rapidly, the system should be checked more  
often.  
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 VR8204U is  
similar to the VR8204A in all other aspects and should be  
installed accordingly.  
The system should be replaced if:  
It does not perform properly on checkout or  
troubleshooting.  
The gas control is likely to have operated for more  
than 200,000 cycles.  
MAINTENANCE  
The control is wet or looks as if it has been wet.  
WARNING  
Can cause property damage, severe injury,  
or death.  
SERVICE  
Fire or Explosion Hazard.  
Do not disassemble the gas control; it contains  
no replaceable components. Attempted  
disassembly, repair, or cleaning can damage the  
control, resulting in gas leakage.  
WARNING  
Can cause property damage, severe injury  
or death.  
Fire or Explosion Hazard.  
Do not disassemble the control; it contains no  
replaceable components. Attempted  
disassembly, repair, or cleaning can damage  
the gas control, resulting in gas leakage.  
Regular preventive maintenance is important 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.  
CAUTION  
Can burn out valve coil terminals.  
Never apply a jumper across (or short) the valve  
coil terminals, even temporarily.  
Equipment Damage.  
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.  
After servicing, verify proper system operation.  
If Main Burner Does Not Come  
On With Call For Heat  
Maintenance frequency must be determined individually  
for each application. Some considerations are:  
1. Confirm the gas control knob is in the ON position.  
2. Adjust thermostat several degrees above room  
temperature.  
Cycling frequency. Appliances that may cycle 20,000  
times annually should be checked monthly.  
Intermittent use. Appliances that are used seasonally  
should be checked before shutdown and again before  
the next use.  
3. Using ac voltmeter, check for 24V at gas control:  
If pilot lights, measure across MV/PV and MV.  
If pilot does not light, measure across MV/PV  
and PV before safety lockout occurs.  
Consequence of unexpected shutdown. Where the  
cost of an unexpected shutdown would be high, the  
system should be checked more often.  
4. If voltage is incorrect or not present, check control  
circuit for proper operation.  
5. If 24V is present, replace gas control.  
11  
69-12254  
VR8104, VR8204 AND VR 8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS  
STOP: Read the Warnings Above Before  
INSTRUCTIONS TO THE  
HOMEOWNER  
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 instructions:  
1. Set the thermostat to its lowest setting to reset the  
safety control.  
WARNING  
Fire or Explosion Hazard.  
2. Disconnect all electric power to the appliance.  
3. Remove the burner access panel if provided on  
your appliance.  
Can cause property damage, severe injury,  
or death.  
Follow these warnings exactly:  
4. Turn the gas control knob clockwise  
to the  
1. Pilot flame is lit automatically. Do not light the  
pilot flame manually.  
OFF position.  
5. Wait five minutes to clear out any unburned gas.  
Then if you smell gas, STOP! Follow Step 2 in the  
Warning above. If you do not smell gas, continue  
with the next step.  
2. Before lighting the pilot burner flame, smell  
around the appliance for gas. Be sure to smell  
next to the floor because LP gas is heavier  
than air. If you smell gas:  
6. Turn the gas control knob counterclockwise  
to the ON position.  
7. Replace the burner access panel.  
8. Reconnect all electric power to the appliance.  
9. Set the thermostat to the desired setting.  
10. If the appliance does not turn on, turn the gas  
control knob to the OFF position and contact a  
qualified service technician for assistance.  
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 neighbors  
phone to call your gas supplier.  
If you cannot reach your gas supplier, call  
the fire department.  
Turning Off the Appliance  
Vacation Shutdown  
Set the thermostat to the desired room temperature while  
you are away.  
3. Replace the gas control in the event 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 instructions.  
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 procedure  
in the Instructions to the Homeowner section above to  
resume normal operation.  
Home and Building Control  
Home and Building Control  
Honeywell Inc.  
1985 Douglas Drive North  
Golden Valley, Minnesota 55422  
Honeywell Limited-Honeywell Limitée  
35 Dynamic Drive  
Scarborough, Ontario  
M1V 4Z9  
Printed in U.S.A. on recycled  
paper containing at least 10%  
post-consumer paper fibers.  
69-12254 G.R. Rev. 9-00  

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