VR8104, VR8204, and VR8304

Intermittent Pilot Combination

Gas Controls
INSTALLATION INSTRUCTIONS
These gas controls are available in a range of valve
APPLICATION capacities, see Table 1. (Table 2 provides gas capacity
conversion factors.) The suffix letter indicates
These intermittent pilot gas controls are used in gas-fired temperature range and regulator type, see Table 3.
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. For CE-approved models, the relevant sections of these
They include safety shutoff, a manual valve, two instructions and Table 4 are applicable.
automatic operators, a pressure regulator and a pilot
adjustment.

Table 1. Valve Capacitya

AGA Certified Maximum
AGA Certified Capacity for AGA Certified Minimum Regulation for
Size 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

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 Capacity is reduced by 5 percent when using an outlet screen.
c Valves are guaranteed at only 77 percent of the rating.
d Minimum regulation for LP gas is 15,000 Btuh.
e Minimum regulation for LP gas is 40,000 Btuh.
f Minimum regulation for LP gas is 50,000 Btuh.

Table 2. Gas Capacity Conversion Factor. CE-Only Models

Multiply Listed These gas controls are used in appliances up to 121kW
Gas Specific Gravity Capacity By or 415 kBTUH on natural gas and approved on EN126,
Manufactured 0.60 0.516 which consists of one automatic safety shutoff valve,
Class B or C, one servo-operated shutoff valve, Class D,
Mixed 0.70 0.765 pressure governor, Class C, manually-operated valve,
Propane 1.53 1.62 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
C (-18°C to +79°C) Step-opening
H Slow-opening
Ua Nonregulating
(on-off)
K -40°F to +175°F Slow-opening
M (-40°C to +79°C) 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.

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 VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

Table 6. Flange Adapter Part Numbers.

SPECIFICATIONS
Inlet/Outlet Part Numbera,b
Body Pattern: Straight through; see Table 1 for inlet and Pipe Size Flange Without Hex With Hex
outlet size. (in. NPT) Type Wrench Wrench
Electrical Ratings: 3/8 Straight 393690-1 393690-11
Voltage and Frequency: 24 Vac, 60 Hz. 3/8 Elbow 393690-2 393690-12
Current Draw: 0.5A with both operators energized.
1/2 Straight 393690-6 393690-16
Capacity: See Table 1. 1/2 Elbow 393690-3 393690-13
3/4 Straight 393690-4 393690-14
Conversion: Use conversion factors in Table 2 to con-
vert capacities for other gases. 3/4 Elbow 393690-5 393690-15
a Flange kits include one flange, one O-ring and four
Regulation Range: See Table 1.
mounting screws.
b Do not use flanges on control models with 3/4 in. inlet
Natural-LP Gas Conversion Kits: See Table 5.
and 3/4 in. outlet. On models with 1/2 in. inlet and
Table 5. Natural-LP Gas Conversion Kits. 3/4 in. outlet, use flanges only on the 1/2 in. inlet side.
Model No. Kit to Convert Kit to Convert LP Heavy demands are made on the controls when
Suffix Letter Natural Gas to LP to Natural Gas intermittent pilot systems are used on central heating
equipment in barns, greenhouses, and commercial
H, K, M 393691 394588 properties and on heating appliances such as
P Not field Not field commercial cookers, agricultural equipment, industrial
convertible. convertible. heating equipment and pool heaters.
Q 396021 396025
Special steps may be required to prevent nuisance
R Not required, Not required, shutdowns and control failure due to frequent cycling,
convertible valve. convertible valve. severe environmental conditions related to moisture,
corrosive chemicals, dust or excessive heat. These
Pipe Adapters:
applications require Honeywell Home and Building
Angle and straight adapters available for 3/8-, 1/2- and
Control Engineering review; contact your Honeywell
3/4-in. pipe. See Table 6. Flange kits include one
Sales Representative for assistance.
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
Approvals: specific installation and follow the precautions
American Gas Association Design Certificate: L2025006. suggested.
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
PLANNING THE INSTALLATION cycling rates, the control can wear out more quickly.
Perform a monthly checkout.

WARNING Water or Steam Cleaning

Fire or Explosion Hazard.
Can cause property damage, severe injury, If a control gets wet, replace it. If the appliance is likely to
or death. be cleaned with water or steam, protect (cover) the
Follow these warnings exactly: control and wiring from water or steam flow. Mount the
1. Plan the installation as outlined below. control high enough above the bottom of the cabinet so it
2. Plan for frequent maintenance as described in does not get wet during normal cleaning procedures.
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.

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VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

Corrosive Chemicals
Corrosive chemicals can attack the control, eventually CAUTION
causing a failure. If chemicals are used for routine Equipment Damage.
cleaning, avoid contact with the control. Where Can burn out valve coil terminals.
chemicals are suspended in air, as in some industrial or Never apply a jumper across (or short) the valve
agricultural applications, protect the control with an coil terminals, even temporarily.
enclosure.
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 IMPORTANT
control to malfunction. Where dust or grease can be a These gas controls are shipped with protective
problem, provide covers for the control to limit seals over the inlet and outlet tappings. Do not
contamination. remove the seals until ready to install adapters
or connect the piping.
Heat
Excessively high temperatures can damage the control. Converting Gas Control from Natural Gas
Make sure the maximum ambient temperature at the to LP Gas (or LP Gas to Natural Gas)
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
WARNING
Fire Or Explosion Hazard.
air circulation is maintained when the appliance is Can cause property damage, severe injury
installed. or death.
1. Do not attempt to convert step-opening models
(suffix letter P).
INSTALLATION 2. Always change the main and pilot burner
orifices when converting from natural to LP gas
or from LP to natural gas. Carefully follow
When Installing this Product... appliance manufacturer specifications and
1. Read these instructions carefully. Failure to follow instructions to assure proper appliance
them could damage the product or cause a conversion.
hazardous condition. 3. Gas controls are factory-set for natural (and
2. Check the ratings given in the instructions and on manufactured) or LP gas. Do not attempt to
the product to make sure the product is suitable for use a gas control set for natural
your application. (manufactured) gas on LP gas, or a gas control
3. Installer must be a trained, experienced service set for LP gas on natural (manufactured) gas.
technician.
4. After installation is complete, check out product Controls with standard, slow-opening, and two-stage
operation as provided in these instructions. 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.
WARNING
Fire or Explosion Hazard. Convertible Pressure Regulators
Can cause property damage, severe injury
or death. Controls with suffix letter R are convertible pressure
Follow these warnings exactly: regulator models. They can be converted from natural
1. Disconnect power supply before wiring to gas to LP gas or from LP gas to natural gas without a
prevent electrical shock or equipment damage. conversion kit.
2. To avoid dangerous accumulation of fuel gas,
turn off the gas supply at the appliance service Before converting the control from one gas to another,
valve before starting installation, and perform check the control label and the appliance manufacturer’s
Gas Leak Test after installation is complete. rating plate to determine if the pressure regulator setting
3. Do not bend pilot tubing at gas control or pilot (factory set) will meet the appliance manifold
burner after compression fitting is tightened, or requirements after conversion.
gas leakage at the connection can result.
4. Always install a sediment trap in the gas NOTE: Convertible pressure regulator models (suffix
supply line to prevent contamination of the gas letter R) do not have field-adjustable regulators.
control.
5. Do not force the gas control knob. Use only If the factory pressure regulator setting meets the
your hand to turn the gas control knob. Never appliance manifold requirement, convert the control as
use any tools. If the gas control knob will not follows:
operate by hand, the gas control should be 1. Remove the pressure regulator cap, Fig. 1.
replaced by a qualified service technician. 2. Invert the cap so that the letters appear that
Force or attempted repair may result in fire or represent the gas type appropriate for the
explosion. appliance. NAT for natural manufactured gas, LP
for liquid petroleum gas.
3. Replace the cap and tighten firmly.

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 VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

T OR P

NA

L
NA

L
T P

OTHER SIDE
PRESSURE
OF CAP
REGULATOR
CAP

T
NA
NA
T

1
VALVE OUTLET

FLANGE
M11678

9/64 INCH HEX SCREWS (4)

Fig. 1. Top view of convertible
pressure regulator cap. 1 DO NOT OVERTIGHTEN SCREWS. TIGHTEN TO
25 INCH-POUNDS. M9046

Install Adapters To Control Fig. 2. Firmly fasten flange to valve, but

do not overtighten screws.
If adapters are being installed on the control, mount them
as follows:
Location
Flanges The combination gas control is mounted in the appliance
vestibule on the gas manifold. If this is a replacement
1. Choose the appropriate flange for your application.
application, mount the gas control in the same location
2. Remove the seal over the gas control inlet or
as the old control.
outlet.
3. Make sure that the O-ring is fitted in the groove of
Locate the combination gas control where it cannot be
the flange. If the O-ring is not attached or is
affected by steam cleaning, high humidity, or dripping
missing, do not use the flange.
water, corrosive chemicals, dust or grease accumulation
4. With the O-ring facing the control, align the screw
or excessive heat. To assure proper operation, follow
holes on the gas control with the holes in the
these guidelines:
flange. Insert and tighten the screws provided with
• Locate gas control in a well-ventilated area.
the flange. See Fig. 2. Tighten the screws to 25
• Mount gas control high enough above cabinet bottom
inch-pounds of torque to provide a gas-tight seal.
to avoid exposure to flooding or splashing water.
• Assure the ambient temperature does not exceed the
Bushings ambient temperature ratings for each component.
1. Remove the seal over the control inlet or outlet. • Cover gas control if appliance is cleaned with water,
2. Apply a moderate amount of good quality pipe steam, or chemicals or to avoid dust and grease
compound to the bushing, leaving two end threads accumulation.
bare. On an LP installation, use compound that is • Avoid locating gas control where exposure to
resistant to LP gas. Do not use Teflon tape. 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
Complete the instructions below for installing the piping, All piping must comply with local codes and ordinances
installing the control, connecting the pilot gas tubing and or with the National Fuel Gas Code (ANSI Z223.1,
the wiring. Make sure the leak test you perform on the NFPA No. 54), whichever applies. Tubing installation
control after completing the installation includes leak must comply with approved standards and practices.
testing the adapters and screws. If you use a wrench on
the valve after the flanges are installed, use the wrench 1. Use new, properly reamed pipe that is free from
only on the flange, not on the control. See Fig. 5. 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.

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VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

4. Apply a moderate amount of good quality pipe

DROP compound (do not use Teflon tape) only to the
PIPED GAS pipe, leaving two end threads bare. On LP
HORIZONTAL GAS CONTROL installations, use a compound resistant to LP gas.
SUPPLY See Fig. 4.
5. Remove the seals over the control inlet and outlet if
RISER
necessary.
GAS 6. Connect the pipe to the control inlet and outlet. Use
CONTROL PIPED a wrench on the square ends of the control. If a
3 IN. GAS
SUPPLY
flange is used, place the wrench on the flange
(76 MM)
MINIMUM rather than on the gas control. Refer to Fig. 5
and 6.
2

DROP Connect Pilot Gas Tubing

HORIZONTAL 3 IN. 1. Cut tubing to the desired length and bend as
TUBING (76 MM)
MINIMUM necessary for routing to the pilot burner. Do not
GAS
1
SUPPLY
make sharp bends or deform the tubing. Do not
2
bend the tubing at the gas control after the
compression nut is tightened, because this can
GAS result in gas leakage at the connection.
CONTROL
RISER 2. Square off and remove burrs from the end of the
3 IN. tubing.
(76 MM) 3. Unscrew the brass compression fitting from the
MINIMUM
pilot outlet (Fig. 6). Slip the fitting over the tubing
2
and slide out of the way. See Fig. 7.
1 ALL BENDS IN METALLIC TUBING SHOULD BE SMOOTH.
NOTE: When replacing a control, cut off the old
2 CAUTION: SHUT OFF THE MAIN GAS SUPPLY BEFORE REMOVING compression fitting and replace with the
END CAP TO PREVENT GAS FROM FILLING THE WORK AREA. TEST compression fitting provided on the combination
FOR GAS LEAKAGE WHEN INSTALLATION IS COMPLETE. M3077
gas control. Never use the old compression
fitting because it may not provide a gas-tight
Fig. 3. Sediment trap installation. seal.

4. Push the tubing into the pilot gas tapping on the

Install Control outlet end of the control until it bottoms. While
1. Mounted 0 to 90 degrees in any direction, including holding the tubing all the way in, slide the fitting
vertically, from the upright position of the gas into place and engage the threads; then turn until
control knob. finger tight. Tighten one more turn with a wrench,
2. Mount so the gas flow is in the direction of the but do not overtighten.
arrow on the bottom of the control. 5. Connect the other end of the tubing to the pilot
3. Thread the pipe the amount shown in Table 7 for burner according to the pilot burner manufacturer’s
insertion into control or adapters. Do not thread instructions.
pipe too far. Valve distortion or malfunction can
result if the pipe is inserted too deeply. TWO IMPERFECT
THREADS GAS CONTROL

Table 7. NPT Pipe Thread Length (in.).

Pipe Thread Pipe Maximum Depth Pipe can PIPE
Size this Amount be Inserted into Control
3/8 9/16 3/8 THREAD PIPE THE AMOUNT APPLY A MODERATE AMOUNT OF
SHOWN IN TABLE FOR PIPE COMPOUND TO PIPE ONLY
1/2 3/4 1/2 INSERTION INTO GAS CONTROL (LEAVE TWO END THREADS BARE).
M3075B
3/4 13/16 3/4
Fig. 4. Use moderate amount of pipe compound.

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 VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

WHEN FLANGE IS NOT USED WHEN FLANGE IS USED

APPLY WRENCH
FROM TOP OR APPLY WRENCH
BOTTOM OF GAS TO FLANGE ONLY
CONTROL TO
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 WIRING
REGULATOR ADJUSTMENT TERMINALS (3)
VENT COVER (UNDER CAP SCREW)
OUTLET
PRESSURE
INLET TAP
PRESSURE TAP

LO
HI

OUTLET
TWO-STAGE INLET
PRESSURE
REGULATOR
PILOT OUTLET
INLET MODEL
GAS PILOT ADJUSTMENT
CONTROL (UNDER CAP SCREW)
KNOB M10968A

Fig. 6. Top view of gas control.

All wiring must comply with applicable electrical codes

GAS CONTROL and ordinances.
TIGHTEN NUT ONE TURN
BEYOND FINGER TIGHT. TO PILOT Disconnect power supply before making wiring
BURNER connections to prevent electrical shock or equipment
damage.

FITTING BREAKS OFF AND CLINCHES 1. Check the power supply rating on the gas control
TUBING AS NUT IS TIGHTENED. M3076A
and make sure it matches the available supply.
Install a transformer, thermostat and other controls
Fig. 7. Always use new compression fitting. as required.
2. Connect control circuit to the gas control terminals.
Wiring See Fig. 8.
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.

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VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

Turn On Main Burner

S8600
Follow appliance manufacturer instructions or turn up
VENT
DAMPER 5 thermostat to call for heat.
GND 24V TH-W PLUG
MV MV/PV PV (BURNER) GND 24V (OPT) (OPT) SENSE SPARK
Perform Gas Leak Test

PV
5 3
WARNING
2 Fire or Explosion Hazard.
PV/MV 4 Can cause property damage, severe injury
MV or death.
GAS CONTROL THERMOSTAT Perform Gas Leak Test every time work is done
TERMINALS on a gas system.

LIMIT
IMPORTANT
CONTROLLER Do not spray soap and water solution on the
Q345, Q346, gas control. Do not use an excessive amount of
Q348, Q362, Q381 soap and water solution to perform the gas leak
PILOT BURNER/ GROUND L1 L2
IGNITER-SENSOR (HOT) test. These can damage the control.
PILOT GAS 1
SUPPLY
Gas Leak Test
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS
1. Paint pipe connections upstream of the gas control
AND OVERLOAD PROTECTION AS REQUIRED. with rich soap and water solution. Bubbles indicate
a gas leak.
2 ALTERNATE LIMIT CONTROLLER LOCATION.
2. If a leak is detected, tighten the pipe connections.
3 MAXIMUM WIRE LENGTH 3 ft [.9 m]. 3. Light the main burner. Stand clear of the main
4 CONTROLS IN 24V CIRCUIT MUST NOT BE IN
burner while lighting to prevent injury caused from
GROUND LEG TO TRANSFORMER. hidden leaks that could cause flashback in the
5 FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER
appliance vestibule.
PLUG, CONNECT THERMOSTAT TO TH-W. LEAVE 4. With the main burner in operation, paint the pipe
24V OPEN. DO NOT REMOVE VENT DAMPER PLUG. M9056 joints (including adapters) and the control inlet and
outlet with rich soap and water solution.
5. If another leak is detected, tighten the adapter
Fig. 8. Typical wiring connections for 24 volt control screws, joints, and pipe connections.
in intermittent ignition system with S8600. 6. Replace the part if a leak cannot be stopped.

STARTUP AND CHECKOUT Check and Adjust Pilot Flame

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
WARNING flame is small or lazy, the inlet gas pressure may be too
low, or the pilot orifice may be partially clogged. Check
Fire or Explosion Hazard. and repair as necessary. If the pilot flame is hard and
Can cause property damage, severe injury noisy, the inlet gas pressure may be too high. The gas
or death. control has a pilot adjustment mechanism to reduce the
1. Do not force the gas control knob on the pilot flow if necessary. If pilot adjustment is necessary,
appliance. Use only your hand to turn the gas proceed as follows:
control knob. Never use any tools. 1. Remove pilot adjustment cover screw. See Fig. 6.
2. If the knob does not operate by hand, the 2. The pilot adjustment is shipped at the full pilot gas
control should be replaced by a qualified flow rate. Turn the inner adjustment screw
service technician. clockwise if the inlet pressure is too high.
Turn the inner adjustment screw clockwise
Gas Control Knob Settings to decrease or counterclockwise to increase
Gas control knob settings are as follows: pilot flame.
OFF: Prevents pilot and main gas flow through the 3. Replace the cover screw after the adjustment to
control. prevent gas leakage.
ON: Permits gas to flow into the control body. Under
control of the thermostat and intermittent pilot module,
PROPER FLAME
gas can flow to the pilot and main burners. 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 to
ON. M3080A

Fig. 9. Proper flame adjustment.

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 VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

Check and Adjust Gas Input NOTE: If the burner firing rate is above 150,000 Btuh
on VR8304 models (see Table 1 for VR8304
and Burner Ignition capacities), it may not be possible to deliver the
desired outlet pressure. This is an application
IMPORTANT issue, not a control failure. Take whatever steps
1. Do not exceed input rating stamped on are required to correct the situation.
appliance nameplate, or manufacturer’s
recommended burner orifice pressure for size Step-Opening (P) Models
orifice(s) used. Make certain primary air supply Step-opening models require that you check and adjust
to main burner is properly adjusted for complete the full-rate pressure first and then check the step
combustion. Follow appliance manufacturer pressure. The step pressure is not field adjustable.
instructions.
2. IF CHECKING GAS INPUT BY CLOCKING 1. Carefully check the main burner lightoff. Make sure
GAS METER: Make certain there is no gas flow that the main burner lights smoothly and that all
through the meter other than to the appliance ports remain lit.
being checked. Other appliances must remain 2. Check the full rate manifold pressure listed on the
off with the pilots extinguished (or deduct their appliance nameplate. Gas control full rate outlet
consumption from the meter reading). Convert pressure should match this rating.
flow rate to Btuh as described in form 70-2602, 3. With main burner operating, check the gas control
Gas Controls Handbook, and compare to Btuh flow rate using the meter clocking method or check
input rating on appliance nameplate. pressure using a manometer connected to the
3. IF CHECKING GAS INPUT WITH outlet pressure tap on the gas control. See Fig. 6.
MANOMETER: Make sure the gas control knob 4. If necessary, adjust the pressure regulator to
is in the OFF position before removing outlet match the appliance rating. See Tables 8A and 8B
pressure tap plug to connect manometer for factory-set nominal outlet pressure and
(pressure gauge). Also move the gas control adjustment range.
knob to the OFF position when removing the a. Remove the pressure regulator adjustment cap
gauge and replacing the plug. Before removing screw.
inlet pressure tap plug, shut off gas supply at Using a screwdriver, turn the inner adjustment screw
the manual valve in the gas piping to the (Fig. 6) clockwise to increase or
appliance or, for LP, at the tank. Also shut off counterclockwise to decrease the gas pressure
gas supply before disconnecting manometer to the burner.
and replacing plug. Repeat Gas Leak Test at b. Always replace the cap screw and tighten
plug with main burner operating. firmly to prevent gas leakage.
5. If the desired outlet pressure or flow rate cannot be
NOTE: Check the inlet pressure before adjusting the achieved by adjusting the gas control, check the
pressure regulator. gas control inlet pressure using a manometer at
the inlet pressure tap of the control. If the inlet
Standard and Slow-Opening pressure is in the nominal range (see Tables 8A
(H, K and M) Models and 8B), replace the control. Otherwise, take the
necessary steps to provide proper gas pressure to
1. Carefully check the main burner lightoff. Make sure the control.
that the main burner lights smoothly and that all 6. Carefully check the burner lightoff at step pressure.
ports remain lit. Make sure the burner lights smoothly and without
2. Check the full rate manifold pressure listed on the flashback to the orifice. Make sure all ports remain
appliance nameplate. Gas control full rate outlet lit. Cycle the burner several times, allowing at least
pressure should match this rating. 60 seconds between cycles for the regulator to
3. With main burner operating, check the control flow resume the step function. Repeat after allowing the
rate using the meter clocking method or check burner to cool. Readjust the full rate outlet
pressure using a manometer connected to the pressure, if necessary, to improve lightoff
outlet pressure tap on the control. See Fig. 6. characteristics.
4. If necessary, adjust the pressure regulator to
match the appliance rating. See Tables 8A and 8B
for factory-set nominal outlet pressure and Two-Stage (Q) Models
adjustment range. Two-stage models require that you check and adjust both
a. Remove the pressure regulator adjustment cap high and low pressure regulator settings. Two-stage
screw. appliance operating sequences vary. Consult the
b. Using a screwdriver, turn the inner adjustment appliance manufacturer instructions for the specific
screw (Fig. 6) clockwise to increase or operating sequence and regulator adjustment procedure
counterclockwise to decrease the gas for the appliance in which the control is installed.
pressure to the burner.
c. Always replace the cap screw and tighten 1. Set appliance to operate on high.
firmly to prevent gas leakage. 2. Carefully check the main burner lightoff. Make sure
5. If the desired outlet pressure or flow rate cannot that the main burner lights smoothly and that all
be achieved by adjusting the gas control, check the ports remain lit.
gas control inlet pressure using a manometer at 3. Check the full rate (high) manifold pressure listed
the inlet pressure tap of the gas control. If the inlet on the appliance nameplate for high pressure. The
pressure is in the nominal range (see Tables 8A gas control full rate outlet pressure should match
and 8B), replace the gas control. Otherwise, take this rating.
the necessary steps to provide proper gas
pressure to the control.

9 69-1225—4
VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

4.With main burner operating, check the gas control flow rate cannot be achieved by adjusting the gas
flow rate using the meter clocking method or check control, check the control inlet pressure using a
pressure using a manometer connected to the manometer at the inlet pressure tap of the control.
outlet pressure tap on the gas control. See Fig. 6. If the inlet pressure is in the nominal range
5. If necessary, adjust the high pressure regulator to (see Tables 8A and 8B), replace the gas control.
match the appliance rating. See Tables 8A and 8B Otherwise, take the necessary steps to provide
for factory-set nominal outlet pressure and proper gas pressure to the control.
adjustment range.
a. Remove the pressure regulator adjustment cap
(Fig. 6). Check Safety Shutdown Performance
b. Using a screwdriver, turn the inner adjustment
screw for HI pressure clockwise to
increase or counterclockwise to
decrease the gas pressure to the burner.
WARNING
6. After high pressure has been checked, check low Fire or Explosion Hazard.
pressure regulation. Two-stage appliance Can cause property damage, severe injury
operating sequences vary. Consult the appliance or death.
manufacturers instructions for the specific Perform the safety shutdown test any time work
operating sequence and regulator adjustment is done on a gas system.
procedure for the appliance in which the control is
installed and for instructions on how to prevent the NOTE: Read steps 1 through 7 before starting, and
control from moving to high stage while checking compare to the safety shutdown or safety
the low pressure regulator setting. lockout tests recommended for the intermittent
7. Check the low rate manifold pressure listed on the pilot (IP) ignition module. Where different, use
appliance nameplate. Gas control low rate outlet the procedure recommended for the module.
pressure should match this rating.
8. With main burner operating, check the gas control 1. Turn off gas supply.
flow rate as before (using the meter clocking 2. Set thermostat or controller above room
method or check pressure using a manometer temperature to call for heat.
connected to the outlet pressure tap on the 3. Watch for ignition spark or for glow at hot surface
control). igniter either immediately or following prepurge.
9. If necessary, adjust the low pressure regulator to See IP module specifications.
match the appliance rating. See Tables 8A and 8B 4. Time the length of the spark operation. See the IP
for factory-set nominal outlet pressure and module specifications.
adjustment range. 5. After the module locks out, open the manual gas
a. Remove the pressure regulator adjustment cap cock and make sure no gas is flowing to the pilot or
(Fig. 6). main burner. With modules that continue to spark
Using a screwdriver, turn the inner adjustment screw for until the pilot lights or the system shuts down
LO pressure clockwise to increase or manually, the pilot should light when the manual
counterclockwise to decrease the gas pressure to gas control knob is opened.
the burner. 6. Set the thermostat below room temperature and
10. Once high and low pressure have been checked wait one minute.
and adjusted, replace pressure regulator 7. Operate system through one complete cycle to
adjustment cap. If the desired outlet pressure or make sure all controls operate properly.

Table 8A. Pressure Regulator Specification Pressures (in. wc).

Factory Set Nominal Outlet
Type of Nominal Inlet Pressure Setting Range
Model Type Gas Pressure Range Step Full Rate Step Full Rate
Standard, NAT 5.0 to 7.0 — 3.5 — 3.0 to 5.0
Slow
LP 12.0 to 14.0 — 10.0 — 8.0 to 12.0
Step NAT 5.0 to 7.0 0.9 3.5 None 0.7 to 1.7
LP 12.0 to 14.0 2.2 10.0 None 1.4 to 5.5
Two-Stage NAT 5.0 to 7.0 — 1.7 Low — 0.9 to 3.0 Lowa
3.5 High 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.

69-1225—4 10
 VR8104, VR8204 AND VR8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

Table 8B. Pressure Regulator Specification Pressures (kPa).

Factory Set Nominal Outlet
Type of Nominal Inlet Pressure Setting Range
Model Type Gas Pressure Range Step Full Rate Step Full Rate
Standard, NAT 1.2 to 1.7 — 0.9 — 0.7 to 1.2
Slow
LP 2.9 to 3.9 — 2.5 — 2.0 to 3.0
Step NAT 1.2 to 1.7 0.2 0.9 None 0.17 to 0.48
LP 2.9 to 3.9 0.5 2.5 None 1.4 to 1.37
Two-stage NAT 1.2 to 1.7 — 0.48 Low — 0.22 to 0.75 Lowa
0.9 High 0.75 to 1.2 High
LP 2.9 to 3.9 — 1.2 Low — 0.9 to 1.4 Low
2.5 High 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.

Non-Regulating On-Off (U) Models • Dusty, wet, or corrosive environments. Since these
environments can cause the gas control to deteriorate
Non-regulating VR8204U Valves are designed for more rapidly, the system should be checked more
application in various parts of Europe where a separate, often.
distinct, pressure regulator is required. The VR8204U is
similar to the VR8204A in all other aspects and should be The system should be replaced if:
installed accordingly. • It does not perform properly on checkout or
troubleshooting.
• The gas control is likely to have operated for more
MAINTENANCE than 200,000 cycles.
• The control is wet or looks as if it has been wet.

WARNING SERVICE
Fire or Explosion Hazard.
Can cause property damage, severe injury,
or death.
Do not disassemble the gas control; it contains
no replaceable components. Attempted
WARNING
Fire or Explosion Hazard.
disassembly, repair, or cleaning can damage the Can cause property damage, severe injury
control, resulting in gas leakage. or death.
Do not disassemble the control; it contains no
Regular preventive maintenance is important for replaceable components. Attempted
applications in the commercial cooking and agricultural disassembly, repair, or cleaning can damage
and industrial industries that place a heavy load on the gas control, resulting in gas leakage.
system controls because:

• In many such applications, particularly commercial

cooking, the equipment operates 100,000 to 200,000 CAUTION
cycles per year. Such heavy cycling can wear out the Equipment Damage.
gas control in one to two years. Can burn out valve coil terminals.
• Exposure to water, dirt, chemicals and heat can Never apply a jumper across (or short) the valve
damage the gas control and shut down the control coil terminals, even temporarily.
system.
The maintenance program should include regular After servicing, verify proper system operation.
checkout of the control as outlined in the Startup and
Checkout section, and the control system as described in
the appliance manufacturer literature. If Main Burner Does Not Come
Maintenance frequency must be determined individually
On With Call For Heat
for each application. Some considerations are: 1. Confirm the gas control knob is in the ON position.
• Cycling frequency. Appliances that may cycle 20,000 2. Adjust thermostat several degrees above room
times annually should be checked monthly. temperature.
• Intermittent use. Appliances that are used seasonally 3. Using ac voltmeter, check for 24V at gas control:
should be checked before shutdown and again before • If pilot lights, measure across MV/PV and MV.
the next use. • If pilot does not light, measure across MV/PV
• Consequence of unexpected shutdown. Where the and PV before safety lockout occurs.
cost of an unexpected shutdown would be high, the 4. If voltage is incorrect or not present, check control
system should be checked more often. circuit for proper operation.
5. If 24V is present, replace gas control.

11 69-1225—4
VR8104, VR8204 AND VR 8304 INTERMITTENT PILOT COMBINATION GAS CONTROLS

INSTRUCTIONS TO THE STOP: Read the Warnings Above Before

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:
WARNING 1. Set the thermostat to its lowest setting to reset the
Fire or Explosion Hazard. safety control.
Can cause property damage, severe injury, 2. Disconnect all electric power to the appliance.
or death. 3. Remove the burner access panel if provided on
Follow these warnings exactly: your appliance.
1. Pilot flame is lit automatically. Do not light the 4. Turn the gas control knob clockwise to the
pilot flame manually. OFF position.
2. Before lighting the pilot burner flame, smell 5. Wait five minutes to clear out any unburned gas.
around the appliance for gas. Be sure to smell Then if you smell gas, STOP! Follow Step 2 in the
next to the floor because LP gas is heavier Warning above. If you do not smell gas, continue
than air. If you smell gas: with the next step.
• Turn off the gas supply at the appliance 6. Turn the gas control knob counterclockwise
service valve. On LP gas systems, turn off to the ON position.
the gas supply at the gas tank. 7. Replace the burner access panel.
• Do not light any appliances in the house. 8. Reconnect all electric power to the appliance.
• Do not touch electrical switches or use the 9. Set the thermostat to the desired setting.
phone. 10. If the appliance does not turn on, turn the gas
• Leave the building and use a neighbor’s control knob to the OFF position and contact a
phone to call your gas supplier. qualified service technician for assistance.
• If you cannot reach your gas supplier, call
the fire department.
3. Replace the gas control in the event of any Turning Off the Appliance
physical damage, tampering, bent terminals,
missing or broken parts, stripped threads, or Vacation Shutdown
evidence of exposure to heat.
Set the thermostat to the desired room temperature while
IMPORTANT you are away.
Follow the operating instructions provided by
the heating appliance manufacturer. The Complete Shutdown
information below describes a typical control Turn off power to the appliance. Turn off the gas supply
application, but the specific controls used and to the appliance. Turn the gas control knob to OFF. The
the procedures outlined in your appliance appliance will completely shut off. Follow the procedure
manufacturer instructions can differ, requiring in the Instructions to the Homeowner section above to
special instructions. resume normal operation.

Home and Building Control Home and Building Control

Honeywell Inc. Honeywell Limited-Honeywell Limitée
1985 Douglas Drive North 35 Dynamic Drive
Golden Valley, Minnesota 55422 Scarborough, Ontario
M1V 4Z9
Printed in U.S.A. on recycled
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