BlueRhino 200209-450000 Parts list manual

Replacing Control Valve
®
Series:
200209 – 450000
LP Gas

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 1
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 2
®
For assistance call 1.800.762.1142.
Tools required:
• # 2 Phillips screw driver
• 8mm open end wrench
• 9mm open end wrench
• 10mm open end wrench
• 12mm open end wrench
• 5/8” open end wrench
• 3/4” open end wrench
• 7/16” nut driver or wrench (series 235000-450000)
• Locking pliers
• Leak test solution
• Ratchet
• 9/16” socket
• Extension 7.5” in length
• Penetrating oil
• Leak test solution 1 part liquid soap and 3 parts water.
1. Installation and repair should be done by a qualified service person.
2. Use only Blue Rhino Global Sourcing, LLC. factory authorized parts. The use of any part
that is not factory authorized can be dangerous. This will also void your warranty.
Contact 1.800.762.1142.
DANGERS and Cautions

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 1
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 2
®
For assistance call 1.800.762.1142.
Steps 1-5
1. Turn your LP gas tank off, unscrew regulator and remove LP gas tank.
2. Remove the dome.
3. Remove the access panel and the igniter wire, set aside
4. Disconnect the gas line.
5. Remove the 4 screws that hold the engine to the post and remove the engine.

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 3
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 4
®
For assistance call 1.800.762.1142.
Step 6
Remove emitter screen:
A. 200209, 200308, 200605 – remove the 4 screws using a Phillips screw driver that attach the emitter to the emitter bottom, with the
screws removed, remove the emitter.
B. 230000-235000, 450000 – you will need to use the ratchet with an extension along with the 9/16” socket and remove the nut and
washer in the bottom of the emitter. There are 3 bolts that attach the emitter to the emitter bottom Using the #8mm open end
wrench remove these bolts. Remove the emitter screen being careful not to loosen the spacer ring from the burner stud. You will
need this later. (On the 235000-45000 you may want to remove the medium and small domes but it is not necessary).
C. 233000-235020 – there are 3 bolts that hold the emitter to the emitter bottom. Using an #8mm
open end wrench remove these 3 bolts and remove the emitter.

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 3
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 4
®
For assistance call 1.800.762.1142.
Step 7
1. Disconnect the burner supply tube from the control valve, using a 5/8” open end wrench.
Note: There is a brass nut on the top of the control valve. You must remove the brass nut.
2. Remove the 2 screws on either side of the emitter bottom.
Note: 230000 and 235000 do not have these screws.
3. Remove the burner by pulling it up. Be careful not to damage the wires on the pilot assembly.

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 5
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 6
®
For assistance call 1.800.762.1142.
Step 8
1. Disconnect the pilot supply tube using the #10mm open end wrench.
Note: You may need to use the #12mm open end wrench to hold the pilot orice.
2. Remove the 2 screws that hold the pilot assembly to pilot bracket.
3. Remove the pilot assembly.

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 5
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 6
®
For assistance call 1.800.762.1142.
Step 9
Disconnect the thermal-couple
1. Remove the screw from the access panel on the rear of the valve housing.
2. Remove the access panel.
3. Using the #8 mm open end wrench remove the nut with wires coming out of it.
Note: When reinstalling the nut to the back of the control valve nger tighten plus a  turn. Do not overtighten.
4. Remove the tip switch bracket on the front of the valve housing by removing the
Phillips screw. Be careful not to damage the wires.

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 7
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 8
®
For assistance call 1.800.762.1142.
Step 10
Disconnect the control valve
1. Remove the brass nut that holds the control valve in the valve housing using the 3/4” open end wrench
2. Remove the control valve from the valve housing
3. Remove the pilot supply tube using a #12 mm open end wrench.

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 7
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 8
®
For assistance call 1.800.762.1142.
Step 11
Re-install pilot supply tube and the control valve:
1. Connect the pilot supply tube to the control valve
2. Place the control valve into the valve housing. Secure the valve with the brass nut and tighten.

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 9
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 10
®
For assistance call 1.800.762.1142.
Step 12
Reinstall the thermal-couple:
1. Attach the thermal-couple to the back of the control valve in the valve housing. Finger tighten plus a 1/4 turn with
the #8mm open end wrench.
2. Reinstall the small access panel on the back of the valve housing

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 9
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 10
®
For assistance call 1.800.762.1142.
Step 13
1. Slide the burner assembly into the valve housing.
2. Attach the burner supply tube to the top of the control valve. Do not over tighten.
3. Tighten the two screws that hold the burner in place.

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 11
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 12
®
For assistance call 1.800.762.1142.
Step 14
1. Attach the pilot to the pilot bracket.
2. Connect the pilot supply tube to the pilot.

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 11
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 12
®
For assistance call 1.800.762.1142.
Step 15
200209, 200308, 200605
1. Attach the emitter to the valve housing, using 3 screws.
2. Secure.
230000 - 450000
1. Place the spacer ring on the burner stud.
2. Insert the burner stud through the bottom of the emitter. Secure with washer and nut. Do not fully tighten.
3. Align the holes of the emitter with the valve housing, and secure with screws.
4. Tighten nut inside emitter.

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 13
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 14
®
For assistance call 1.800.762.1142.
Steps 16-19
16. Attach the engine to the post
17. Burner Connections
1. Make sure the regulator valve and hose connections are securely fastened to the
burner and the tank.
2. If your unit was assembled for you, visually check the connection between the burner
pipe and orice. Make sure the burner pipe ts over the orice.
WARNING: Failure to inspect this connection or follow these instructions could
cause a re or an explosion which can cause death, serious bodily injury, or
damage to property.
3. Please refer to diagram for proper installation.
4. If the burner pipe does not rest ush to the orice, please contact 1.800.762.1142 for
assistance.
18. Attach the dome
19. Attach the LP gas tank

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 13
®
For assistance call 1.800.762.1142.
Replacing Control Valves Series 200209 – 450000 LP Gas 404121 14
®
For assistance call 1.800.762.1142.
Step 20 - IMPORTANT
Perform leak check.
WARNING
FOR YOUR SAFETY
If you smell gas -
1. Shut off gas to appliance.
2. Extinguish any open flame.
3. If odor continues, immediately call your gas supplier or your fire department.
1. Do not operate if gas leak is present. Gas leaks may cause a fire or explosion.
2. You must follow all leak-checking procedures before operating. To prevent fire or explosion hazard when testing for
a leak:
a. Always perform leak test before lighting the heater and each time the tank is connected for use.
b. No smoking. Do not use or permit sources of ignition in the area while conducting a leak test.
c. Conduct the leak test outdoors in a well-ventilated area.
d. Do not use matches, lighters, or a flame to check for leaks.
e. Do not use heater until any and all leaks are corrected.
If you are unable to stop a leak, disconnect the LP gas supply. Call a gas appliance serviceman or your local LP gas
supplier.

Replacing Control Valves Series 200209 – 450000 LP Gas 404121 15
®
For assistance call 1.800.762.1142.
Tank/Gas Line Connection
1. Make 2-3 oz. of leak solution by mixing one part liquid dishwashing soap with three
parts water.
2. Make sure control knobs are off.
3. Turn LP gas tank ON at valve.
4. Spoon leak check solution at all “x” locations
5. If any bubbles appear turn LP gas tank OFF, reconnect and re-test. If you continue to see
bubbles after several attempts, disconnect LP gas source and contact 1.800.762.1142 for
assistance.
6. If no bubbles appear after one minute turn tank OFF, wipe away solution and proceed.
Pilot, Pilot Supply Tube and Burner Supply Tube
1. Make 2-3 oz. of leak solution by mixing one part liquid dishwashing soap with three parts
water.
2. Turn LP gas tank ON at valve.
3. Turn control knob on to LOW
4. Remove access panel
5. Place leak solution on pilot supply tube at the pilot and at the control valve.
6. Place leak solution on the burner supply tube.
7. If any bubbles appear turn control valve OFF, check all connection to make sure they are
tight, and retest. If you continue to see bubbles after several attempts, turn control valve off
and disconnect LP gas source and contact 1.800.762.1142 for assistance.
8. If no bubbles appear after one minute turn tank OFF, wipe away solution and proceed.
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Blue Rhino Global Sourcing, LLC
104 Cambridge Plaza Drive, Winston-Salem, NC 27104 USA
1.800.762.1142, www.bluerhino.com
© 2004 Blue Rhino Global Sourcing, LLC All Rights Reserved.
Endless Summer® is a registered trademark of Blue Rhino Global Sourcing, LLC All Rights Reserved.
Blue Rhino® is a registered trademark of Ferrellgas, L.P. All Rights Reserved.
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