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Intermittent Pilot Dual Automatic
Valve Combination Gas Controls
The VR8204 AND VR4204 Intermittent Pilot
Dual Automatic Valve Combination Gas Controls
are used in gas-fired, intermittent pilot appli-
ances. The controls include a safety shutoff, a
manual valve, two automatic operators, a pres-
sure regulator, a pilot adjustment screw and a
conduit cover (VR4204 only).
VR8204 used with S8600, S8610 and S8620 Control
Modules.
VR4204 used with 120 Vac intermittent ignition mod-
ules.
VR8204 for use with 24 Vac heating appliances and
VR4204 for use with 120 Vac heating appliances that
burn natural or manufactured gas, or liquified petroleum
(LP) gas.
Capacity rated at 150 cfh at 1 in. wc pressure drop
3
[4.2 m
/hr at 0.25 kPa].
Solenoid-operated first automatic valve opens on ther-
mostat call for heat and closes when call for heat ends.
Diaphragm-operated second automatic valve opens un-
der control of the regulator and closes if gas or power
supply is interrupted.
Two-position gas control knob has ON and OFF posi-
tions.
All adjustments and wiring connections are accessible
from top of the control.
Compact size.
Straight-through body pattern; right angle adapters avail-
able for inlet and outlet.
1/2 in. inlet and 1/2 in. outlet; adapters available for 3/8
or 3/4 in.
VR8204; VR4204
Adjustable servo regulator effectively maintains almost
constant gas output pressure under wide fluctuations in
gas supply pressure.
Inlet and outlet screens included.
Pilot filter included.
Wiring terminal block color-coded orange to indicate
intermittent pilot control.
May be installed at any angle between 0 and 90 degrees
from the upright position, including vertically.
1/4 in. male quick-connect terminals for electrical con-
nections.
0° F to 175 F° [-18° C to +79° C] temperature range
standard; -40° F to 175° F [-40° C to +79° C] available.
lnlet and outlet pressure taps provided; both taps acces-
sible from top of control.
Standard-, slow- and step-opening models available.
CONTENTS
Specifications ............................................... 2
Ordering Information .................................. 2
Installation ................................................... 4
Startup and Checkout .................................. 8
Maintenance .............................................. 10
Operation ................................................... 10
Service ........................................................ 13
G. S. • Rev. 1-94 • ©Honeywell Inc. 1994 • Form Number 68-0047-2
1
68-0047-2
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Summarization of Contents
Specifications
TRADELINE® Models
Details on TRADELINE controls for ease of stocking and handling.
Standard Models
Information on standard VR8204 and VR4204 dual automatic valve combination gas controls.
Installation
Converting Between Natural and LP Gas
Procedure and warnings for converting gas controls between natural and LP gas systems.
Install Adapters to Control
Instructions for installing flanges and bushings onto the gas control for connection.
Using Adapters to Solve Swing Radius Problems
Method to use adapters when space limits threading the control directly onto the supply pipe.
Location
Guidelines for positioning the gas control within the appliance for optimal operation and safety.
Install Piping To Gas Control
Steps for connecting gas piping to the control, including using traps and proper pipe preparation.
Install Control
Details on mounting the gas control, ensuring correct flow direction and pipe insertion depth.
Connect Pilot Gas Tubing
Procedure for connecting pilot tubing to the gas control, emphasizing proper fitting and bending techniques.
Wiring Connections
Instructions and diagrams for wiring the gas control to the ignition system and other components.
Startup and Checkout
Gas Control Knob Settings
Explanation of the ON and OFF positions for the gas control knob and its function.
Perform Gas Leak Test
Critical safety procedure to check for gas leaks after installation or maintenance.
Adjust Pilot Flame
Steps to adjust the pilot flame to the correct size for reliable ignition and sensing.
Check Safety Shutdown Performance
Procedure to verify the safety shutdown mechanism functions correctly during operation.
Check and Adjust Gas Input and Burner Ignition
Procedures for verifying and adjusting gas input and burner ignition parameters.
Standard Pressure Regulator
How to check and adjust the pressure regulator for standard models to match appliance specifications.
Slow-opening and Step-opening Pressure Regulators
Instructions for checking and adjusting pressure regulators for slow-opening and step-opening models.
Operation
System Operation With Module
Description of how the gas control operates in conjunction with an intermittent pilot module and thermostat.
Valve Position During Thermostat Off Cycle
Explains the internal valve positions when the thermostat is not calling for heat.
When Thermostat Calls for Heat
Details the sequence of events when the thermostat calls for heat, including pilot ignition.
Standard Regulation
How the servo pressure regulator maintains constant outlet pressure during the ON cycle.
Slow-Opening Regulation
Describes the gradual opening of the second automatic valve in slow-opening models.
Step-Opening Regulation
Explains how step-opening gas controls combine regulators for staged pressure delivery.
When the Call for Heat Ends
Describes how the gas control shuts off gas flow when the thermostat call for heat concludes.
Service
If Main Burner Will Not Come On With Call for Heat
Troubleshooting steps for when the main burner fails to operate despite a call for heat.
Instructions to the Homeowner
Safety and operating instructions for the end-user regarding the gas control.
To Turn On Furnace
Step-by-step procedure for safely turning on the furnace unit.
To Turn Off Appliance
Instructions for safely shutting down the appliance, including vacation shutdown.
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