Honeywell VR8200A User manual

G.S. • Rev. 1-94 • ©Honeywell Inc. 1994 • Form Number 68-0046—4
CONTENTS
Specifications ................................................2
Ordering Information.................................... 2
Installation .................................................... 4
Startup and Checkout ....................................9
Maintenance ................................................ 12
Operation .................................................... 12
Service ......................................................... 15
VR8200; VR4200
Combination Gas Controls
VR4200
VR8200
(TRADELINE)
The VR8200 Continuous Pilot Dual Automatic
Valve Combination Gas Controls are used in gas-
fired, standing pilot appliances. They include safety
shutoff, a manual valve, two automatic operators, a
pressure regulator, a pilot adjustment, and a conduit
cover (VR4200 only).
■VR8200foruse with24Vac heatingappliancesand
VR4200 for use with 120 Vac heating appliances
that burn natural or liquefied petroleum (LP) gas.
■Capacity rated at 130 feet3/hour at 1 inch wc pres-
sure drop [3.7 m3/hr at 0.25 kPa]. Maximum regu-
lated capacity is 200 feet3/hour [5.7 meter3/hour].
Minimum regulated capacity is 20 feet3/hour
[0.6 meter3/hour].
■Solenoid-operated first automatic valve opens on
thermostat call for heat and closes when call for
heat ends.
■Diaphragm-operated second automatic valve opens
under control of the regulator and closes if gas or
power supply is interrupted.
■Three-position manual gas control knob has ON,
OFF, and PILOT positions.
■Separate reset button must be held down to permit
gas flow while lighting pilot; can be pushed down
only in PILOT position.
■All adjustments, wiring connections and pilot out-
let are accessible from the top of the gas control.
■Compact size.
■Straight-through body pattern; right angle adapters
available for inlet and outlet
■1/2 in. inlet and 1/2 inch outlet; adapters available
for 3/8 or 3/4 inch.
■Adjustable servo regulator effectively maintains
almost constant gas output pressure under wide
fluctuation in gas supply pressure.
■Inlet and outlet screens included.
■Pilot filter included.
■Wiring terminal block color-coded beige to identify
standing pilot models.
■Maybeinstalledatany anglebetween0and90 degrees
from the upright position, including vertically.
■1/4-inch male quick-connect terminals for electri-
cal connections. Combination screw and quick-
connect terminals on TRADELINE®models.
■0°F to +175°F [-18°C to +79°C] temperature
range standard; -40°F to +175°F [-40°C to 79°C]
available.
■ECO connector included with some models: also
available as accessory.
■Inlet and outlet pressure taps included; both taps
accessible from top of gas control.
■Standard-, slow- and step-opening models available.
■Natural to LP gas conversion kit included with
TRADELINE standard and slow-opening models.
Natural to LP gas conversion kit available for non-
TRADELINE standard and slow-opening models.
■LP to natural gas conversion kit available for stan-
dard and slow-opening models.
This is a legacy product document supported by
Resideo. This product is no longer manufactured.

68-0046—4 2
VR8200, VR4200
SPECIFICATIONS • ORDERING INFORMATION
Specifications
IMPORTANT: The specifications given in this publica-
tion do not include normal manufacturing toler-
ances. Therefore, this unit may not exactly match the
listed specifications. Also, this product is tested and
calibrated under closely controlled conditions, and
some minor differences in performance can be ex-
pected if those conditions are changed.
SUPER TRADELINE MODELS
SUPER TRADELINE®controls offer features not avail-
able on TRADELINE or standard models, and are designed
to replace a wide range of Honeywell and competitive
controls.
SUPER TRADELINE model specifications are the
same as those of standard models except as noted below.
SUPER TRADELINE MODEL AVAILABLE: VR8200A
Continuous Pilot Dual Automatic Combination Gas
Control. Models for natural or LP gas.
ADDITIONAL FEATURES:
• Combination 1/4 inch quick-connect and screw ter-
minals (includes convenience terminals).
• One 3/8 inch bushing.
• One 3/4 inch straight flange assembly (with O-ring
and screws).
• One tool for flange hex screws.
• One pilot compression fitting.
• OneQ340A36-inchthermocouplewithadaptersand
clip.
TRADELINE MODELS
TRADELINE models are selected and packaged to
provide ease of stocking, ease of handling and maximum
replacement value. TRADELINE model specifications
are the same as those of standard models except as noted
below.
TRADELINE MODEL AVAILABLE: VR8200A Con-
tinuous Pilot Dual Automatic Combination Gas Con-
trol. Models for natural or LP gas.
ADDITIONAL FEATURES:
• Combination 1/4 inch quick-connect and screw ter-
minals (includes convenience terminals)
• One 3/8 inch bushing
• One 3/4 inch straight flange assembly (with O-ring
and screws)
• One tool for flange hex screws
• One pilot compression fitting
STANDARD MODELS
MODEL: VR8200 and VR4200 Continuous Pilot Dual
Automatic Valve Combination Gas Controls. For use
in standing pilot appliances. See Table 1 for model
specifications.
SUPPLY VOLTAGE:
VR4200: 120 Vac, 60 Hz.
VR8200: 24 Vac, 60 Hz.
(50/60 Hz models available on request.)
POWER UNIT:
Hold-in current: 300 mA maximum.
Drop-out current: 250 to 90 mA.
THERMOCOUPLE:
Nominal output: 30 mV (0.018 ohms).
Open Circuit Turndown Voltage: 2 mV.
ELECTRICAL CONNECTIONS (2): 1/4 inch male quick-
connects. Two convenience terminals on top of control
(optional). Terminal block color-coded beige.
THERMOSTAT HEAT ANTICIPATOR SETTING:
VR4200: 0.1A
VR8200: 0.5A
TYPE OF GAS: VR8200 and VR4200 set up for natural
gas includes a 393691 LP Conversion Kit. Kit for
conversion from LP to natural gas is available for stan-
dard and slow opening models. See Accessories.
CAPACITY:130feet3/hour[4.2meters3/hour].Capacityis
basedon1000Btu/feet3,0.64specificgravitynaturalgas
at 1 inch water column pressure drop [37.3 MJ/meters3,
0.64 specific gravity natural gas at 0.25 kPa pressure
drop].
Maximum regulated capacity is 200 feet3/hour
[5.7 meters3/hour]. Minimum regulated capacity is
20 feet3/hour[0.6 meters3/hour].Use conversionfactors
in Table 2 to convert to capacities for other gases.
Minimum regulated capacity is 40 feet3/hour for
propane.
Ordering Information
When purchasing replacement and modernization products from your TRADELINE®wholesaler or your distributor, refer to the
price sheets for complete ordering number, or specify—
1. Order number, SUPER TRADELINE or 4. Convenience terminals, if desired.
TRADELINE if desired. 5. Accessories, if desired.
2. Natural or LP gas. 6. Order separately: pilot burner, thermocouple, transformer,
3. Step pressure on step-opening control. limit controller, and thermostat or controller as required.
Ifyouhaveadditionalquestions,needfurtherinformation,orwouldliketocommentonourproductsorservices,pleasewriteorphone:
1. Your local Honeywell Residential and Building Controls Sales Office (check white pages of your phone directory).
2. Residential and Building Controls Division Customer Satisfaction
Honeywell Inc., 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386 [phone]
InCanada—HoneywellLimited/HoneywellLimitée,740EllesmereRoad,Scarborough,Ontario M1P 2V9. International Sales
and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan,
Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.

VR8200, VR4200
SPECIFICATIONS
3 68-0046—4
TABLE 2—GAS CAPACITY
CONVERSION FACTORS.
Specific Multiply Listed
Gas Gravity Capacity by
Manufactured 0.60 0.516
Mixed 0.70 0.765
Propane 1.53 1.62
BODYPATTERN:Straight-through with1/2 inch inletand
1/2inch outlet.Flangesavailable for3/8,1/2 and3/4inch
straight and 90°angle connection. See Table 3.
TABLE 1—MODEL SPECIFICATIONS.
Model No. Opening Type Standard Factory Optional Factory Range of Field
Suffix Charac- of Settings Regulator Settings Adjustment
Letter teristic Gas in. wc kPa in. wc kPa in. wc kPa
VR8200A, M Standard- Natural 3.5 0.9 3 to 5 0.7 to 1.2 3 to 5 0.7 to 1.2
VR4200A, M opening LP 10.0 2.5 8 to 12 2 to 3 8 to 12 2 to 3
VR8200C, P Step- Natural Step—0.7, Step—0.17, Step—0.7, Step—0.17, Step—none; Step—none;
VR4200C, P opening 0.9, 1.2 or 0.22, 0.30 or 0.9, 1.2 or 0.22, 0.30 or Full Rate— Full Rate—
1.7, as 0.48 as 1.7, as 0.48 as 3-5 0.7 to 1.2
ordered
a
ordered
a
ordered
a
ordered
a
Full Rate— Full Rate— Full Rate— Full Rate—
3.5 0.9 3 to 5 0.7 to 1.2
LP Step—1.4, Step—0.35, Step—1.4, Step—0.35, Step—none; Step—none;
2.5, 4.0 or 0.62, 0.99 or 2.5, 4.0 or 0.62, 0.99 or Full Rate— Full Rate—
5.5, as 1.37, as 5.5, as 1.37, as 8-12 2 to 3
ordered
a
ordered
a
ordered
a
ordered
a
Full Rate— Full Rate— Full Rate— Full Rate—
10 2.5 8 to 12 2 to 3
VR8200H Slow- Natural 3.5 0.9 3 to 5 0.7 to 1.2 3 to 5 0.7 to 1.2
VR4200H opening LP 10.0 2.5 8 to 12 2 to 3 8 to 12 2 to 3
VR8200J Delayed and Natural 3.5 0.9 3 to 5 0.7 to 1.2 3 to 5 0.7 to 1.2
Slow-opening LP 10.0 2.5 8 to 12 2 to 3 8 to 12 2 to 3
aStep pressure not adjustable.
Fig. 1—VR8200, VR4200 dimensions in in. [mm].
NOTE: Flange Kits include one flange with attached O-ring
and four mounting screws. TRADELINE kits include
9/64 in. hex wrench, as noted.
PILOT GAS OUTLET: Compression fitting for 1/4 in. OD
tubing.
TABLE 3—FLANGE PART NUMBERS.
Part Number
Inlet/Outlet Flange Less Hex With Hex
Pipe Size Type Wrench Wrench
3/8 in. NPT Straight 393690-1 393690-11
Elbowa393690-2 393690-12
1/2 in. NPT Straight 393690-6 393690-16
Elbowa393690-3 393690-13
3/4 in. NPT Straight 393690-4 393690-14
Elbowa393690-5 393690-15
aElbow (angle) flanges cannot provide right hand inlet
when the ECO connector is used.
M9059
3 
[89]
1
2
1 
[43]
11
16
11
16
2 [69]
1 [25]
1
2[13]
1
8
4 [104]
3-5/8 [91]
SWING
RADIUS
CONVENIENCE TERMINALS CONDUIT 
COVER
VR4200
3 
[89]
1
2
1 
[43]
11
16
11
16
2 [69] 1
4
3 [83]
1 [25]
1
2[13]
1
8
4 [104]
3-5/8 [91]
SWING
RADIUS
1/4 INCH QUICK-CONNECT 
TERMINALS
CONVENIENCE TERMINALS
VR8200
1 SCREW TERMINALS ON 
TRADELINE MODELS ONLY.
1

VR8200, VR4200
SPECIFICATIONS • INSTALLATION
68-0046—4 4
PRESSURETAPPING:Inletandoutletpressuretapsacces-
sible from top of gas control. Taps are 1/8 inch NPT with
plug containing recess for 3/16 inch Allen wrench.
PRESSURE RATING: A.G.A. rating 1/2 psi [3.5 kPa] inlet
pressure.
PRESSURE REGULATION: See Table 1. Regulator ad-
justment accessible from top of gas control.
MOUNTING: Can be mounted 0 to 90 degrees in any
direction from the upright position of the gas control
knob, including vertically.
TEMPERATURE RATING:
VR8200A,C,H,J; VR4200A,C,H: 0°F to +175°F [-18°C
to +79°C].
VR8200M,P; VR4200M,P: -40°F to +175°F [-40°C to
+79°C].
DIMENSIONS: See Fig. 1.
APPROVALS:
AmericanGas Associationdesign certificate:L2025006.
Canadian Gas Association design certificate: L2025006.
Australian Gas Association design certificate: 4214.
Approved for Delta C applications.
OPTIONAL SPECIFICATIONS:
• Convenience terminals.
ACCESSORIES:
• Flanges, see Table 3.
• 393200-1 ECO Connector.
• 393691 Natural to LP Conversion Kit.
• 394588 LP to Natural Conversion Kit.
• 3943499/64inchhextoolforflangeassemblyscrews.
IMPORTANT: These gas controls are shipped with pro-
tective seals over inlet and outlet tappings. Do not
remove seals until ready to connect piping.
Follow the appliance manufacturer instructions if avail-
able; otherwise, use the instructions provided below.
WHEN INSTALLING THIS PRODUCT…
1. Read these instructions carefully. Failure to fol-
low them could damage the product or cause a hazardous
condition.
2. Check the ratings given in the instructions and on the
producttoensuretheproductissuitableforyourapplication.
3. Ensure installer is a trained, experienced service
technician.
4. Afterinstallation iscomplete,use theseinstructionsto
check out product operation.
WARNING
FIRE OR EXPLOSION HAZARD,
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY, OR DEATH.
Follow these warnings exactly:
1. Disconnect power supply before wiring to pre-
vent electrical shock or equipment damage.
2. To avoid dangerous accumulation of fuel gas,
turnoffgassupplyattheapplianceservicevalve
before starting installation, and perform Gas
Leak Test after completion of installation.
3. Do not bend pilot tubing at gas control or pilot
burner after compression fitting has been tight-
ened, or gas leakage at the connection may result.
4. Always install sediment trap in gas supply line
to prevent contamination of gas control.
5. Donotforcethegascontrolknob.Useonlyyour
hand to push down the reset button or turn the
gascontrol knob.Neveruseanytools. Ifthe gas
control knob or reset button will not operate by
hand, the gas control should be replaced by a
qualifiedservice technician.Forceor attempted
repair may result in fire or explosion.
CAUTION
Never apply a jumper across or short the valve coil
terminals.Thismayburnouttheheatanticipatorin
the thermostat.
!
CONVERTING BETWEEN NATURAL AND LP GAS
WARNING
FIRE OR EXPLOSION HAZARD,
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY, OR DEATH.
1. Do not use a gas control set for natural gas on
an LP gas system or a gas control set for LP
gas on a natural gas system.
2. When making conversion, main pilot burner
orifices must be changed to meet appliance
manufacturer specifications.
VR8200 and VR4200 gas controls can be converted
fromonegastoanother.ToconvertfromnaturalgastoLP,
usethe393691LPConversionKitthatisincludedwiththe
gas control. To convert from LP to natural gas, use the
394588NaturalGas ConversionKit(ordered separately).
VR8200C,P and VR4200C,P gas controls cannot be con-
verted.
To convert control from one gas to another:
1. Turn off main gas supply to the appliance.
2. Removetheregulatorcapscrewandpressureregulator
adjusting screw. See Fig. 2 or 3.
3. Remove the existing spring.
4. Insert the replacement spring with the tapered end
down. See Fig. 4.
5. Install the new plastic pressure regulator adjustment
screw so that the top of the screw is flush (level) with the top
of the regulator. Turn the pressure regulator adjustment
screw clockwise six complete turns. This provides a
preliminary pressure setting of about 10.0 in. wc [2.5 kPa]
!
!
Installation

Fig. 2—Top view of standard VR8200, VR4200
gas control.
5 68-0046—4
VR8200, VR4200
INSTALLATION
4. With O-ring facing the gas control, align the screw
holesonthegascontrolwiththeholesintheflange.Insert
and tighten the screws provided with the flange. See Fig.
5. Tighten the screws to 25 inch pounds of torque to
provide a gas-tight seal.
Bushings
1. Remove seal over gas control inlet or outlet.
2. Apply moderate amount of good quality pipe com-
poundtobushing,leavingtwoendthreadsbare.OnLPgas
installation, use compound resistant to LP gas. Do NOT
use Teflon tape.
OUTLET
PRESSURE 
TAP
INLET OUTLET
INLET
PRESSURE TAP
PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)
PILOT OUTLET
PILOT ADJUSTMENT
(UNDER CAP SCREW)
GAS
CONTROL
KNOB
M9060
RED
RESET
BUTTON
THERMOCOUPLE
CONNECTION
VR4200 
CONDUIT COVER
OUTLET
PRESSURE 
TAP
INLET OUTLET
WIRING
TERMINALS (2)
INLET
PRESSURE TAP
PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)
PILOT OUTLET
PILOT ADJUSTMENT
(UNDER CAP SCREW)
GAS
CONTROL
KNOB
RED
RESET
BUTTON
THERMOCOUPLE
CONNECTION
VR4200
VR8200
Fig. 3—Top view of TRADELINE VR8200.
OUTLET
PRESSURE 
TAP
INLET OUTLET
WIRING
TERMINALS (2)
INLET
PRESSURE TAP
PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)
PILOT OUTLET
PILOT ADJUSTMENT
(UNDER CAP SCREW)
GAS
CONTROL
KNOB
M2916
RED
RESET
BUTTON
THERMOCOUPLE
CONNECTION
SCREW
TERMINALS (2)
for LP regulator and 3.5 in. wc [0.9 kPa] for natural gas
regulator.
6. Checktheregulator settingeitherwitha manometer
or by clocking the gas meter. Refer to Startup and Check-
out section.
7. Install the new cap screw.
8. Mount conversion label on control.
9. Installcontrol andapplianceaccordingtoappliance
manufacturer instructions.
INSTALL ADAPTERS TO GAS CONTROL
Ifadapters aretobe installedonthegascontrol, mount
them as follows:
Flanges
1. Choose the appropriate flange for your application.
2. Remove seal over gas control inlet or outlet.
3. Ensure the O-ring is fitted into the groove of the
flange. If the O-ring is not attached or is missing, do not
use the flange.
Fig. 5—Install flange to gas control.
Fig. 4—Installation of conversion kit in
regulated gas control.
M9051
VALVE OUTLET
FLANGE
9/64 INCH HEX SCREWS (4) 

6/32 INCH ROUND
SCREWS (1) 
CONDUIT
COVER,
VR4204
ONLY
DO NOT OVERTIGHTEN SCREWS. TIGHTEN TO 
25 INCH-POUNDS.
1
1
COLOR CODE FOR
LP
GAS NATRUAL
GAS
CAP SCREW BLACK SILVER
PRESSURE
REGULATOR
ADJUSTING
SCREW WHITE WHITE
SPRING RED STAINLESS
STEEL
PRESSURE
REGULATOR
HOUSING
M8083

68-0046—4 6
VR8200, VR4200
INSTALLATION
3. Insert bushing in gas control and thread pipe carefully
into bushing until tight.
Complete the instuctions below for piping, installing
control, connecting pilot trubing, thermocouple and wiring.
Make certain the leak test you perform on the control after
completingtheinstallationincludesleaktestingtheadapters
andscrews.Ifyouuseawrenchonthe valveafterflangesare
installed, use the wrench only on the flange, not on the
control.
USING ADAPTERS TO SOLVE SWING RADIUS
PROBLEMS
In some field service applications, it is difficult or
impossible to thread the gas control onto the gas supply
pipebecauseofspacelimitations.Usuallythisproblemcan
be resolved by using an adapter. The adapter is installed on
the end of the supply pipe in place of the gas control,
following the same precautions and instructions that are
used for installing the gas control. After the adapter is
installed, the gas control is attached to the adapter as
outlined above. Note that using an adapter increases the
overall length of the gas control.
CHOOSE GAS CONTROL LOCATION
Do not locate the gas control where it may be affected by
steam cleaning, high humidity, dripping water, corrosive
chemicals,dustorgreaseaccumulation,orexcessiveheat.To
ensure 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.
• Ensure the ambient temperature does not exceed the
ambient temperature ratings for each component.
• Cover gas control if the appliance is cleaned with
water, steam, or chemicals to avoid dust and grease
accumulation.
• Avoid locating gas control where exposure to corro-
sive chemical fumes or dripping water are likely.
Locate the gas control in the appliance vestibule on the
gas manifold. In replacement applications, locate the gas
control in the same location as the old gas control.
Install Piping to Gas Control
All piping must comply with local codes and ordi-
nances or with the National Fuel Gas Code (ANSI Z223.1
NFPA No. 54), whichever applies. Tubing installation must
comply with approved standards and practices.
1. Use new, properly reamed pipe free from chips. If
tubingisused,ensuretheendsaresquare,deburredandclean.
All tubing bends must be smooth and without deformation.
2. Run pipe or tubing to the gas control. If tubing is
used, obtain a tube-to-pipe coupling to connect the tubing
to the gas control.
3. Install sediment trap in the supply line to the gas
control. See Fig. 6.
Install Gas Control
1. Mount the gas control 0-90 degrees, in any direction,
from the upright position of the gas control knob, including
vertically.
2. Mount the gas control so gas flow is in the direction
of the arrow on the bottom of the gas control.
3. Threadpipeintogascontrol.Donotthreadpipetoofar.
Valvedistortionormalfunctioncanresultifthepipeisinserted
too deeply into the gas control. Refer to Table 4.
4. Apply a moderate amount of good quality pipe com-
pound(Donot useTeflontape)topipeonly,leavingtwo end
threads bare. On LP installations, use compound resistant to
LP gas. (See Fig. 7.)
Fig.7—Usemoderateamountofpipecompound.
Fig. 6—Install sediment trap.
GAS
CONTROL
GAS
CONTROL
HORIZONTAL
DROP
PIPED
GAS
SUPPLY
PIPED
GAS
SUPPLY
3 INCHES
[76]
MINIMUM
3 INCHES
[76]
MINIMUM
RISER
GAS
CONTROL
TUBING
GAS
SUPPLY
HORIZONTAL
DROP
3 INCHES
[76]
MINIMUM
RISER
M3077
2
1
2
2
1
2
ALL BENDS IN METALLIC TUBING SHOULD BE SMOOTH.
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.
TABLE 4—NPT PIPE THREAD LENGTH IN INCHES.
Maximum Depth
Pipe Thread Pipe Pipe can be Inserted
Size This Amount into Control
3/8 9/16 3/8
1/2 3/4 1/2
3/4 13/16 3/4
TWO IMPERFECT 
THREADS GAS 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).
M3075A
PIPE

Fig. 8—Proper use of wrench on gas control.
VR8200, VR4200
INSTALLATION
APPLY WRENCH 
FROM TOP OR 
BOTTOM OF GAS 
CONTROL TO 
EITHER SHADED AREA
WHEN FLANGE IS NOT USED
APPLY WRENCH
TO FLANGE ONLY
WHEN FLANGE IS USED
M2914
Connect Pilot Gas Tubing
1. Cut tubing to desired length and bend as necessary
for routing to pilot burner. Do not make sharp bends or
deform the tubing. Do not bend tubing at gas control or
pilot burner after compression fitting has been tightened,
as this may result in gas leakage at the connection.
2. Square off and remove burrs from end of tubing.
3. Unscrew compression fitting from the pilot outlet
(Fig. 2). Slip the compression fitting over the tubing and
slide out of the way.
NOTE:Whenreplacingagascontrol,cutoffoldcompres-
sion fitting and replace with the new compression
fitting provided on the gas control. Never use the old
compression fitting as it may not provide a gas-tight
seal.
4. Push tubing into the pilot gas tapping on the outlet
endofthecontroluntilitbottoms.Whileholdingtubingall
thewayin,slidecompressionfittingintoplaceandengage
threads—turn until finger tight. Then tighten one more
turn with wrench. Do not overtighten. Refer to Fig. 9.
5. Connect the other end of tubing to pilot burner
according to pilot burner manufacturer instructions.
7 68-0046—4
5. Remove seals over gas control inlet and outlet if
necessary.
6. Connect pipe to gas control inlet and outlet. Use
wrenchonthesquareendsofthe gascontrol. Ifan adapter
isused,placewrenchonadapterratherthanongascontrol.
Refer to Figs. 2, 3 and 8.
Install Thermocouple
The Q340A Thermocouple (with adapters) is pro-
vided with SUPER TRADELINE models of the
VR8200A. Install the Q340A as follows:
1. Determine if the pilot burner requires a thermo-
couplewithapush-incliporattachmentnut,andattachthe
correct adapter to the Q340.
2. a. For push-in clip type pilot burners: From beneath,
insertthetipoftheQ340intotheholeorbarrelofthe
pilot burner. Push in firmly to lock in place.
b. For attachment nut type pilot burners: From be-
neath, insert the tip of the Q340 into the hole or
barrel in the pilot burner. Engage the threads of the
attachment nut and tighten securely.

68-0046—4 8
Fig. 10—Installing thermocouple to the power
unit.
VR8200, VR4200
INSTALLATION
THERMOCOUPLE 
LEAD
ECO
CONNECTOR
1THIS IS AN ELECTRICAL CONECTION AND MUST BE
CLEAN AND DRY. DO NOT USE PIPE COMPOUND.
M3095
1
Fig. 11—Wiring connections for 24 volt control.
L1 
HOT
L2 1
24 V
THERMOSTAT
OPTIONAL
CONVENIENCE
TERMINALS TH/TR
TH
TR GAS CONTROL
TERMINALS
HIGH LIMIT
CONTROLLER
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
DO NOT JUMPER THESE TERMINALS. THIS SHORTS VALVE COIL
AND MAY BURN OUT ANTICIPATOR IN THERMOSTAT.
CONVENIENCE TERMINALS SERVE AS A TIE POINT ONLY. THEY
ARE NOT INTERNALLY WIRED TO THE CONTROL CIRCUIT 
OR TO GROUND.
OPTIONAL HIGH LIMIT.
1
2
3
4
2
3
4
M2915
Fig. 12—Wiring connections for 120 volt
control.
120V
THERMOSTAT
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
DO NOT JUMPER THESE TERMINALS. THIS
SHORTS VALVE COIL AND MAY BURN OUT
ANTICIPATOR IN THERMOSTAT.
OPTIONAL HIGH LIMIT.
L1
(HOT)
L2
1
HIGH LIMIT
CONTROLLER
M3092A
GAS CONTROL TERMINALS
L2
L1
2
3
1
2
3
Fig. 9—Always use new compression fitting.
Connect Thermocouple
Connect thermocouple lead as shown in Fig. 10. This
is an electrical connection and must be clean and dry.
Neverusepipe compound.Tighten only 1/4turn beyond
finger tight to give good electrical continuity. Do not
overtighten.
WIRING
Follow the wiring instructions furnished by the appli-
ancemanufacturer,ifavailable,orusethegeneral instruc-
tions provided below. Where these instructions differ
from the appliance manufacturer, follow the appliance
manufacturer instructions.
All wiring including 1/4 in. quick-connect terminals,
must comply with applicable electrical codes and ordi-
nances.
Disconnect power supply before making wiring con-
nectionstopreventelectricalshockorequipmentdamage.
1. Check the power supply rating on the valve and
make sure it matches the available supply. Install thermo-
stat, and other controls as required.
2. For the VR4200, when the gas control is installed
external to the appliance, install the conduit cover on the
conduit fitting. Do not secure conduit cover at this time.
3. Connectcontrolcircuittogascontrolterminals.See
Figs. 2, 3 and 11, 12.
NOTE: Use leadwires with insulated terminals.
4. FortheVR4200, makesuretheconduit coverisin
position and secured to the gas valve with the screw
provided. See Fig. 5.
5. Adjustthermostatheatanticipatorasinstructedin
the appliance manual (i.e., usually 0.1A for VR4200
and 0.5A for VR8200).
Connect Supplementry Limit or ECO (If Used)
The leadwires from the high limit or ECO must be
equipped with insulated 1/4 in. female quick-connect
terminals. Leadwire lengths must not exceed the lengths
shown in Tables 5 and 6. Connect the high-limit or ECO
leadwires to the two terminals on the ECO connector.
GAS CONTROL BODY
TIGHTEN NUT ONE TURN
BEYOND FINGER TIGHT
FITTING BREAKS OFF AND CLINCHES 
TUBING AS NUT IS TIGHTENED
TO 
BURNER
M3076A

TABLE 6—MAXIMUM LENGTH OF SUPPLEMENTARY LIMIT LEADWIRES
WHEN USING Q309A THERMOCOUPLE.
Thermocouple Maximum Leadwire Length x 2 (wires)
Length Awg No. 14 Awg No. 16 Awg No. 18
inches meters inches meters inches meters inches meters
12 0.3 47 1.2 30 0.8 18 0.5
18 0.5 41 1.0 26 0.7 16 0.4
24 0.6 35 0.9 22 0.6 14 0.4
30 0.8 29 0.8 18 0.5 11 0.3
36 0.9 23 0.6 15 0.4 9 0.2
40 1.0 19 0.5 12 0.3 7 0.2
48 1.2 11 0.3 7 0.2
60 1.5 DO NOT USE.
TABLE 5—MAXIMUM LENGTH OF SUPPLEMENTARY LIMIT LEADWIRES
WHEN USING Q340A THERMOCOUPLE.
Thermocouple Maximum Leadwire Length x 2 (wires)
Length Awg No. 14 Awg No. 16 Awg No. 18
inches meters inches meters inches meters inches meters
18 0.5 35 0.9 22 0.6 13 0.3
24 0.6 29 0.7 18 0.5 11 0.3
30 0.8 23 0.6 15 0.4 9 0.2
36 0.9 17 0.4 11 0.3 6 0.2
48 1.2
60 1.5 DO NOT USE.
9 68-0046—4
VR8200, VR4200
INSTALLATION • STARTUP AND CHECKOUT
WARNING
FIRE OR EXPLOSION HAZARD,
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY, OR DEATH.
1. Do not force the gas control knob. Use only
yourhandtopushdowntheresetbuttonorturn
the gas control knob. Never use any tools.
2. If the gas control knob or reset button will not
operate by hand, or if the reset button stays
depressed after it is released, the gas control
should be replaced by a qualified service
technician.
GAS CONTROL KNOB SETTINGS
The gas control knob has three settings:
OFF: Prevents pilot and main burner gas flow.
PILOT: Permits pilot gas flow only. Gas control knob
must be held depressed or thermocouple must be
heated sufficiently to hold the safety control valve
open.
!
Startup and Checkout
ON: Permits main burner and pilot gas flow. Thermostat
and gas control control main burner gas flow.
NOTE: Gas controls are shipped with the gas control knob
in the ON position.
PERFORM GAS LEAK TEST
WARNING
FIRE OR EXPLOSION HAZARD,
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY, OR DEATH.
Check for gas leaks with rich soap and water
solution any time work is done on a gas control.
GAS LEAK TEST
1. Paint all pipe connections upstream of the gas control
with a rich soap and water solution. Bubbles indicate a gas
leak.
!

68-0046—4 10
2. Ifa gasleak isdetected, tightenthe pipeconnection.
3. Stand clear while lighting main burner to prevent
injury caused from hidden gas leaks, which could cause
flashbackintheappliancevestibule.Lightthemainburner.
4. With the main burner in operation, paint all pipe
joints (including adapters) and gas control inlet and
outlet with rich soap and water solution.
5. Ifanothergasleakisdetected,tightenadapterscrews,
joints, and pipe connections.
6. Replace the part if gas leak cannot be stopped.
LIGHT THE PILOT BURNER FLAME
1. Turn the gas control knob clockwise to OFF.
Wait five minutes to dissipate any unburned gas. Sniff
around the appliance near the floor. Do not relight the
pilot flame if you smell gas.
2. Turnthegas controlknobcounterclockwise to
PILOT. Push down and hold the gas control knob while
lighting the pilot flame.
3. Hold down the gas control knob about one minute,
then release.
• If the pilot flame goes out, turn the gas control
knob clockwise to OFF and repeat steps 1
through 3.
• If pilot flame remains lit, turn the gas control
knob counterclockwise to ON.
VR8200, VR4200
STARTUP AND CHECKOUT
ADJUST THE PILOT BURNER FLAME
The pilot flame should envelop 3/8 to 1/2 in. [10 to
13 mm] of the thermocouple tip. Refer to Fig. 13. To ad-
just the pilot flame:
1. Remove the pilot adjustment cover screw. Refer to
Fig. 2.
2. Turn the inner adjustment screw clockwise
to decrease or counterclockwise to increase the pilot
flame.
3. Always replace the cover screw after adjustment and
tighten firmly to assure proper operation.
LIGHT MAIN BURNER
Follow the appliance manufacturer instructions or set the
thermostat setting above room temperature to call for heat.
Fig. 13—Proper flame adjustment.
3/8 TO 1/2 INCH
10 TO 13 mm
PROPER FLAME
ADJUSTMENT
THERMOCOUPLE
M3086
!
CHECK AND ADJUST GAS INPUT TO MAIN
BURNER
CAUTION
1. Do not exceed the input rating stamped on the
appliance nameplate, or manufacturer recom-
mended burner orifice pressure for the size
orifice(s) used. Assure the main burner primary
air supply is properly adjusted for complete
combustion(refertotheappliancemanufacturer
instructions).
2. IFCHECKING GASINPUTBYCLOCKING
THE GAS METER:
• Assure that the only gas flow through the
meter is that of the appliance being tested.
• Assure that other appliances are turned off
and their pilot burners are extinguished (or
deduct their gas consumptions from the
meter reading).
• ConverttheflowratetoBtuhasdescribedin
the Gas Controls Handbook (form 70-2602)
and compare to the Btuh input rating on the
appliance nameplate.
3. IF CHECKING GAS INPUT WITH A MA-
NOMETER (PRESSURE GAUGE):
• Assure the gas control knob is in the PILOT
position before removing the outlet pressure
tap plug to connect the manometer.
• Turn the gas control knob back to PILOT
when removing the manometer and replac-
ing outlet pressure tap plug.
• Shut off the gas supply at the appliance
service valve or, for LP gas, at the gas tank
before removing the outlet pressure tap plug
andbeforedisconnectingthemanometerand
replacing the outlet pressure tap plug.
• Perform the Gas Leak Test at the inlet pres-
sure tap plug.
Standard-Opening and Slow-Opening Pressure
Regulator
1. The gas control outlet pressure should match the
manifold pressure listed on the appliance nameplate.
2. With the main burner operating, check the gas control
flow rate using the meter clocking method or check the gas
pressure using a manometer connected to the gas control
outlet pressure tap. Refer to Figs. 2 and 3.
3. Ifnecessary,adjustthepressureregulatortomatchthe
appliance rating. Refer to Table 7 or 8 for the factory-set
nominal outlet pressures and adjustment ranges.
a. Remove the pressure regulator adjustment cap
and screw.
b. Using a screwdriver, turn the inner adjustment
screw clockwise to increase or counter-
clockwise to decrease the main burner gas
pressure.
c. Always replace the cap screw and tighten firmly
to assure proper operation.