Honeywell V8200 User manual

PRODUCT DATA
68- 0045- 3
® U.S. Registered Trademark
Copyright © 2001 Honeywell • All Rights Reserved
V8200
Combination Gas Controls
APPLICATION
The V8200 Continuous Pilot Combination Gas Controls are
used in gas-fired, standing pilot appliances. The include a
manual gas valve, safety shutoff, single automatic operator
and a pressure regulator.
FEATURES
• Add ECO switch where codes call for dual safety
shutoff.
• For use with 24 Vac heating appliances that burn
natural or liquefied petroleum (LP) gas.
• Capacity rated at 130 feet3/hour at 1 inch wc pressure
drop (3.7m3/hr at 0.25 kPa). Maximum regulated
capacity is 200 feet3/hour (5.7 meter3/hour). Minimum
regulated capacity is 20 feet3/hour (.6 meter3/hour).
• Diaphragm-operated 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 positions. All
adjustments, wiring connections and pilot outlet 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 inch inlet and 1/2 inch outlet; adapters available
for 3/8 or 3/4 inch inlet or outlet.
• Adjustable servo regulator effectively maintains
almost constant gas output pressure under wide
fluctuations in gas supply pressure. Factory setting
does not need readjustment for specific rating of
furnace.
• Inlet and outlet screens included.
• Pilot filter included.
• Wiring terminal block color-coded beige to identify
standing pilot models.
• May be installed at any angle between 0 and 90 degrees
from the upright position, including vertically.
• 1/4 inch quick-connect terminals for electrical
connections.
• 0°F to 175°F (-18°C to +79°C) temperature range
standard; -40°F to +175°F (-40°C to +79°C) available.
• Inlet and outlet pressure taps included; both taps
accessible from top of gas control.
• Standard, slow, and step-opening models available.
• ECO connector included with some models: also
available as accessory.
• Natural to LP gas conversion kit included with
standard and slow-opening models.
• LP to natural gas conversion kit available for standard
and slow-opening models.
Contents
Application ....................................................................... 1
Features ........................................................................... 1
Specifications ................................................................... 2
Ordering Information ........................................................ 2
Installation ........................................................................ 4
Startup and Checkout ...................................................... 9
Maintenance .................................................................... 11
Operation ......................................................................... 12
Service ............................................................................. 15
Instructions to the Homeowner ........................................ 15

V8200 COMBINATION GAS CONTROLS
68-0045—3 2
ORDERING INFORMATION
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the
TRADELINE® Catalog or price sheets for complete ordering number.
If you have additional questions, need further information, or would like to comment on our products or services, please write or
phone:
1. Your local Home and Building Control Sales Office (check white pages of your phone directory).
2. Home and Building Control Customer Relations
Honeywell, 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9.
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.
SPECIFICATIONS
IMPORTANT:
The specifications given in this publication do not
include normal manufacturing tolerances. Therefore,
this unit may not match the listed specifications
exactly. Also, this product is tested and calibrated
under closely controlled conditions, and some minor
differences in performance can be expected if those
conditions are changed.
Standard Models
Models:
V8200 Continuous Pilot Combination Gas Controls. For
use in standing pilot appliances. See Table 1 for model
specifications. Models with a 7 following the suffix letter,
i.e., V8200A7001, include an ECO connector (Part
No. 394332) that has two 1/4 inch quick-connect terminals.
Electrical Ratings:
Supply Voltage: 24 Vac, 60 Hz.
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:
1/4 inch male quick-connects.
Two convenience terminals on top of control (optional).
Terminal block color-coded beige.
Thermostat Heat Anticipator Setting: 0.30A.
Type of Gas:
V8200 set up for natural gas includes a 393691 LP
Conversion Kit.
Kit for conversion from LP to natural gas is available for
standard and slow opening models. See Accessories.
Table 1. Model Specifications.
Model No.
Suffix
Letter
Opening
Characteristic
Type
of Gas
Standard Factory
Regulator Settings
Ranges of Optional Factory
Regulator Settings
Range of Field
Adjustment
In. wc Kpa in. wc kPa in. wc kPa
A,M Standard
Opening Natural 3.5 0.9 3 to 5 0.7 to 1.2 3 to 5 0.7 to 1.2.
LP 10.0 2.5 8 to 12 2 to 3 8 to 12 2 to 3.
C Step-opening Natural 0.9 step
(50% of full
rate); 3.5 full
rate.
0.2 step
(50% of full
rate); 0.9 full
rate.
Step: 0.7, 0.9, 1.2
or 1.7, as
ordered.
Full Rate: 3 to 5
Step: 0.17, 0.22,
0.30 or 0.48, as
ordered.
Full Rate: 0.7 to 1.2
Step:
none.
Full Rate:
3 to 5.
Step:
none.
Full Rate:
0.7 to 1.2.
LP 2.2 step
(45% of full
rate); 10 full
rate.
0.5 step
(45% of full
rate); 2.5 full
rate.
Step: 1.4, 2.5, 4.0
or 5.5, as
ordered.
Full Rate: 8 to 12.
Step: 0.35, 0.62,
0.99 or 1.37, as
ordered.
Full Rate: 2 to 3.
Step:
none.
Full Rate:
8 to 12.
Step:
none.
Full Rate:
2 to 3.
H Slow-opening Natural 3.5 0.9 3 to 5 0.7 to 1.2 3 to 5 0.7 to 1.2
LP 10.0 2.5 8 to 12. 2 to 3 8 to 12 2 to 3

V8200 COMBINATION GAS CONTROLS
3 68-0045—3
Capacity:
130 feet3/hour (4.2 meter3/hour). Capacity is based on
1000 Btu/feet3, 0.64 specific gravity natural gas at 1 inch
water column pressure drop (37.3 MJ/meter3, 0.64 specific
gravity natural gas as 0.25 kPa pressure drop).
Maximum regulated capacity is 200 feet3/hour
(5.7 meter3/hour).
Minimum regulated capacity is 20 feet3/hour
(0.6 meter3/hour).
Use conversion factors in Table 2 to convert to capacities for
other gases.
Table 2. Gas Capacity Conversion Factors.
Body Pattern:
Straight-through with 1/2 inch inlet and outlet.
Adapters available for 3/8, 1/2 and 3/4 inch straight and angle
connection. See Table 3.
NOTE: Adapters may be field installed or factory installed.
Reference individual OS number specifications for
availability of factory installed. Reference individual
OS number specifications for availability of factory
installed adapters.
Pilot Gas Outlet: Compression fitting for 1/4 inch OD tubing.
Pressure Tapping: Inlet and outlet pressure taps included.
Taps accessible from top of gas control. Taps are 1/8 inch
NPT with plug containing recess for 3/16 inch Allen wrench.
Table 3. Adapter (Flange) Part Numbers.
aA right-angle flange cannot be used on the inlet end of the
ECO Adapter is used.
NOTE: Flange Kits include one flange with attached O-ring,
four mounting screws, 9/64 inch hex wrench and
instruction sheet.
Pressure Rating: AGA rating 1/2 psi (3.5 kPa) inlet
pressure.
Pressure Regulation: See Table 1. Regulator adjustment
accessible from top of gas control.
Mounting: Can be mounted 0 to 90 degrees in any direction
from the upright position of the manual gas control knob,
including vertically.
Temperature Rating:
V8200A,C,H: 0°F to 175°F (-18°C to +79°C).
V8200M: -40°F to +175°F (-40°C to +79°C).
Dimensions: See Fig. 1.
Approvals:
American Gas Association: Design Certificate P-70-42A.
Canadian Gas Association: Design Certificate 1029-CC-6395
Series.
Australian Gas Association: 4214.
Underwriters Laboratories Incorporated Component
Recognized: File Number MH5323.
Optional Specifications: Convenience terminals.
Accessories:
Adapters, see Table 3.
393200-1 ECO Connector.
393691 Natural to LP Conversion Kit.
394588 LP to Natural Conversion Kit.
394349 9/64 inch hex tool for flange assembly screws.
Fig. 1. V8200 dimensions in in. (mm).
Gas
Specific
Gravity
Multiply Listed
Capacity By
Manufactured 0.60 0.516
Mixed 0.70 0.765
Propane 1.53 1.62
3/8 in. 1/2 in. 3/4 in.
Straight 390427B
Bushing (1)
390427C
Bushings (2)
393690-6
Flange Kit 393690-4 Flange Kit
Anglea393690-2
Flange Kit
393690-3
Flange Kit
393690-5
Flange Kit
M16284 1
(25)
(13)
3-5/8 (91)
SWING
RADIUS
1/4 in. QUICK-
CONNECT
TERMINALS
1 (25)
(13)
MV
MV
4-1/8 (104)
1/2
3-1/
2
(99
)
1-11/1
6
(43)
1/2
2-11/16 (69)
OPTIONAL
CONVENIENCE
TERMINAL

V8200 COMBINATION GAS CONTROLS
68-0045—3 4
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 ensure the product is suitable for your
application.
3. Ensure installer is a trained, experienced service
technician.
4. After installation is complete, use these instructions to
check out product operation.
WARNING
Fire or Explosion Hazard.
Can cause serious injury, death or property
damage.
Follow these warnings exactly.
1. Disconnect power supply before wiring to prevent
electrical shock or equipment damage.
2. To avoid dangerous accumulation of fuel gas, turn
off gas supply at the appliance service valve 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 tightened.
Gas leakage at the connection may result.
4. Always install sediment trap in gas supply line to
prevent contamination of 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.
CAUTION
Equipment Damage Hazard.
Improper wiring can damage equipment.
Never apply a jumper across or short the valve coil
terminals. This may burn out the heat anticipator in the
thermostat.
IMPORTANT:
These gas controls are shipped with protective seals
over inlet and outlet tappings. Do not remove seals
until ready to connect piping.
Follow the appliance manufacturer’s instructions if available;
otherwise, use the instructions provided below.
Convert Between Natural and LP Gas
WARNING
Fire or Explosion Hazard.
Can cause serious injury, death or property
damage.
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
natural gas system.
2. When making conversion, main pilot burner orifices
MUST be changed to meet appliance
manufacture’s specifications.
Standard- or slow-opening gas controls are converted from
one gas to another with a conversion kit. To convert from
natural gas to LP, use the 393691 LP Conversion Kit that is
included with the V8200 gas control. To convert from LP to
natural gas, use the 394588 Natural Gas Conversion Kit
(order separately). Step-opening gas controls can not be
converted.
To convert control from one gas to another:
1. Turn off main gas supply to the appliance.
2. Remove the regulator cap screw and pressure regulator
adjusting screw. See Fig. 2.
3. Remove the existing spring.
4. Insert the replacement spring with tapered end down.
See Fig. 3.
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 eleven complete
turns. This provides a preliminary pressure setting
of about 10.0 in. wc (2.5 kPa) for LP regulator and
3.5 in. wc (0.9 kPa) for natural gas regulator.
6. Check the regulator setting either with a manometer or
by clocking the gas meter. Refer to Startup and
Checkout.
7. Install the new cap screw.
8. Mount conversion label on control.
9. Install control and appliance according to appliance
manufacturer’s instructions.
Fig. 2. Top view of gas control.
OUTLET
PRESSURE
TAP
INLET OUTLET
WIRING
TERMINALS
INLET
PRESSURE TAP
P
RESSURE REGULATOR
A
DJUSTMENT
(
UNDER CAP SCREW)
PILOT OUTLET
PILOT ADJUSTMENT
(UNDER CAP SCREW
)
GAS
CONTROL
KNOB M3093C
RED
RESET
BUTTON
T
HERMOCOUPLE
C
ONNECTION

V8200 COMBINATION GAS CONTROLS
5 68-0045—3
Fig. 3. Installation of conversion
kit in regulated gas control.
Install Adapters To Gas Control
Install adapters to gas control as follows:
Flanges
1. Choose the appropriate flange for your application.
NOTE: A right angle inlet flange cannot be used on the inlet
end with ECO connected.
2. Remove seal over gas control inlet or outlet.
3. Ensure the O-ring is fitted in the groove of flange. If the
O-ring is not attached or is missing, do not use the
flange.
4. With O-ring facing the gas 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.
Bushings
1. Remove seal over gas control inlet or outlet.
2. Apply moderate amount of good quality pipe compound
to bushing, leaving two end threads bare. On LP gas
installation, use compound resistant to LP gas. Do NOT
use Teflon tape.
3. Insert bushing in gas control and thread pipe carefully
into bushing until tight.
Using Adapters to Solve Swing Radius
Problems
In some field service applications, it is difficult or impossible to
thread the control onto the gas supply pipe because of space
limitations. This problem can be resolved in many instances
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.
Fig. 4. Install flange to 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, dust or grease accumulation, or excessive heat.
To ensure proper operation, follow these guidelines.
1. Locate gas control in a well ventilated area.
2. Mount gas control high enough above the cabinet
bottom to avoid exposure to flooding or splashing water.
3. Ensure the ambient temperature does not exceed the
ambient temperature ratings for each component.
4. Cover gas control if appliance is cleaned with water,
steam, or chemicals or to avoid dust and grease
accumulation.
5. Avoid locating gas control where exposure to corrosive
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 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.
1. Use new, properly reamed pipe free from chips. If tubing
is used, ensure the ends are square, deburred and
clean. 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-tube coupling to connect the tubing to
the gas control.
3. Install sediment trap in the supply line to the gas control.
See Fig 5.
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 M3081A
VALVE OUTLET
FLANGE
9/64 INCH HEX SCREWS (4)
CONDU
IT
COVER
6/32 INCH ROUND
SCREWS (1)

V8200 COMBINATION GAS CONTROLS
68-0045—3 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 control so gas flow is in the direction of the
arrow on the bottom of the gas control.
3. Thread pipe the amount shown in Table 4 for insertion
into the gas control. Do not thread pipe too far. Valve
distortion or malfunction may result if the pipe is
inserted too deeply into the gas control.
4. Apply a moderate amount of good quality pipe
compound (DO NOT use Teflon tape) to pipe only,
leaving two end threads bare. On LP installations, use
compound resistant to LP gas.
5. Remove seals over gas control inlet and outlet if
necessary.
6. Connect pipe to gas control inlet and outlet. Use wrench
on the square ends of the gas control. If an adapter is
used, place wrench on adapter rather than gas control.
Refer to Figs. 2 and 7.
Fig. 5. Install sediment trap.
Fig. 6. Use moderate amounts of pipe compound.
Table 4. NPT Pipe Thread Length in inches.
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: When replacing a gas control, cut off old
compression 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
end of the control until it bottoms. While holding
tubing all the way in, slide compression fitting into
place and engage threads—turn until finger tight. Then
tighten one more turn with wrench. Do not overtighten.
Refer to Fig. 8.
5. Connect other end of tubing to pilot burner according to
pilot burner manufacturer’s instructions.
GAS
CONTROL
GAS
CONTRO
L
HORIZONTAL
DROP
PIPED
GAS
SUPPLY
PIPED
GAS
SUPPLY
3 IN.
(76 MM)
MINIMUM
3 IN.
(76 MM)
MINIMUM
RISER
GAS
CONTROL
TUBING
GAS
SUPPLY
HORIZONTAL
DROP
3 IN.
(76 MM)
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.
Pipe Size
Thread Pipe
This Amount
Maximum Depth Pipe Can Be
Inserted 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
).
M3075
B
PIPE

V8200 COMBINATION GAS CONTROLS
7 68-0045—3
Fig. 7. Proper use of wrench on gas control.
Fig. 8. Always use new compression fitting.
Connect Thermocouple
If a supplementary limit or energy cutoff (ECO) are used,
insert the ECO connector (order Part No. 393200Ñ1) as
shown in Fig. 9, then connect thermocouple lead. If not,
insert thermocouple lead directly. This is an electrical
connection and must be clean and dry. Never use pipe
compound. Tighten only 1/4 turn beyond finger tight to
give good electrical continuity. Do not overtighten.
Fig. 9. Installing thermocouple and optional
ECO connector to the power unit.
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
M3079
GAS CONTROL
TIGHTEN NUT ONE TURN
BEYOND FINGER TIGHT.
FITTING BREAKS OFF AND CLINCHES
TUBING AS NUT IS TIGHTENED.
TO PILO
T
BURNER
M3076A
THERMOCOUPLE
LEAD
ECO
CONNECTOR
1THIS IS AN ELECTRICAL CONECTION AND MUST B
E
CLEAN AND DRY. DO NOT USE PIPE COMPOUND.M3095
1

V8200 COMBINATION GAS CONTROLS
68-0045—3 8
WIRING
WARNING
Electrical Shock Hazard.
Can cause serious injury, death or equipment
damage.
Disconnect power supply before making wiring
connections to prevent electrical shock or equipment
damage.
Follow the wiring instructions furnished by the appliance
manufacturer, if available, or use the general instructions
provided below.
All wiring must comply with applicable electrical codes and
ordinances.
1. Check the power supply rating on the gas control and
if it matches the available supply. Install transformer,
thermostat and other controls as required.
2. Connect control circuit to gas control terminals.
See Figs. 3 and 10.
3. Adjust thermostat heat anticipator to 0.30 rating
stamped on valve operator.
Fig. 10. Gas control wiring connections.
Connect Supplementary Limit or ECO
(if used)
The leadwires from the high limit or ECO must be equipped
with insulated 1/4 inch 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.
Table 5. Maximum Length of Supplementary Limit Leadwires when using Q340A Thermocouple.
Table 6. Maximum Length of Supplementary Limit Leadwires when using Q309A Thermocouple.
L1
(HOT
)
L2 1
24V
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 CAN BURN OUT ANTICIPATOR IN THERMOSTAT.
CONVENIENCE TERMINALS SERVE ONLY AS A TIE POINT.
THEY ARE NOT INTERNALLY WIRED TO THE CONTROL CIRCUIT
OR TO GROUND.
OPTIONAL HIGH LIMIT.
1
2
3
4
2
3
4
M2915
Thermocouple Length
Maximum Leadwire Length x 2 (wires)
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 Do Not Use.
Thermocouple Length
Maximum Leadwire Length x 2 (wires)
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.

V8200 COMBINATION GAS CONTROLS
9 68-0045—3
STARTUP AND CHECKOUT
WARNING
Fire or Explosion Hazard.
Can cause serious injury, death or property
damage.
1. Do not force the gas control knob. Use only your
hand to push down the reset button or turn 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.
• ON—permits main burner and pilot gas flow. Gas control
and thermostat 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 serious injury, death or property
damage.
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.
2. If a gas leak is detected, tighten the pipe connection.
3. Stand clear while lighting main burner to prevent injury
caused from hidden gas leaks which could cause
flashback in the appliance vestibule. Light the main
burner.
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. If a gas leak is detected, tighten adapter screws, joints,
and pipe connections.
6. Replace the part if gas leak can not 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. Turn the gas control knob counterclockwise to
PILOT. Push down and hold the gas control knob while
lighting the pilot flame.
3. Hold the gas control knob down about one minute, then
release.
a. If the pilot flame goes out, turn the gas control knob
clockwise to OFF and repeat steps one
through three.
b. If pilot flame remains lit, turn the gas control knob
counterclockwise to ON.
Adjust the Pilot Burner Flame
The pilot flame should envelop 3/8 to 1/2 inch
(10 to 13 millimeters) of the thermocouple tip. Refer to Fig. 11.
To adjust 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 ensure proper operation.
Fig. 11. Proper flame adjustment.
Light Main Burner
Follow the appliance manufacturer’s instructions or set the
thermostat setting above room temperature to call for heat.
M3086B
PROPER FLAME
ADJUSTMENT 3/8 TO 1/2 IN.
(10 TO 13 MM)
THERMOCOUPL
E

V8200 COMBINATION GAS CONTROLS
68-0045—3 10
Check and Adjust Gas Input to Main Burner
CAUTION
Equipment Damage Hazard.
Can cause equipment damage or incomplete
combustion.
1. Do not exceed the input rating stamped on the
appliance nameplate, or manufacturer’s
recommended burner orifice pressure for the size
orifice(s) used. Ensure the main burner primary air
supply is properly adjusted for complete combustion
(refer to the appliance manufacturer’s instructions).
2. If Checking Gas Input by Clocking the Gas Meter:
• E n s u r e t h a t t h e o n l y g a s f l o w t h r o u g h t h e m e t e r i s
that of the appliance being tested.
• Ensurethatotherappliancesareturned offand
that their pilot burners are extinguished (or
deduct their gas consumptions from the
meter reading).
• Convert the flow rate to Btuh as described in the
Gas Controls Handbook (form number
70-2602) and compare to the Btuh input rating on
the appliance nameplate.
3. If Checking Gas Input with a Manometer (Pressure
Gauge):
• Ensure 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 replacing 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 and before
disconnecting the manometer and replacing the
outlet pressure tap plug.
• Perform the Gas Leak Test at the inlet pressure 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 Fig. 2.
3. If necessary, adjust the pressure regulator to match the
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
counterclockwise to decrease the main
burner gas pressure.
c. Always replace the cap screw and tighten firmly to
ensure proper operation.
4. If the desired outlet gas pressure or gas flow rate
cannot be achieved by adjusting the gas control, check
the gas control inlet pressure using a manometer at the
inlet pressure tap. If the inlet pressure is in the normal
range (refer to Table 7 or 8), replace the gas control.
Otherwise, take the necessary steps to provide proper
gas pressure to the gas control.
Step-Opening Pressure Regulator
1. The gas control outlet pressure should match the
manifold pressure listed on the appliance nameplate.
2. With 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 Fig. 2.
3. If necessary, adjust the pressure regulator to match the
appliance rating. Refer to Table 7 or 8 for factory set
nominal outlet pressures and adjustment ranges.
a. Remove the pressure regulator adjustment cap
screw.
b. Using a screwdriver, turn the inner adjustment
screw clockwise to increase or
counterclockwise to decrease the main burner
gas pressure.
c. Always replace the cap screw and tighten firmly to
ensure proper operation.
4. If desired outlet pressure or flow rate cannot be
achieved by adjusting the gas control, check the inlet
pressure using a manometer at inlet pressure tap or
upstream of the gas control. If the inlet pressure is in the
normal range (refer to Table 7 or 8), replace the existing
gas control. Otherwise, take the necessary steps to
provide proper gas pressure to the gas control.
5. Carefully check main burner lightoff at the step
pressure. Ensure the main burner lights smoothly and
without flashback to the orifice and that all ports remain
lit. Cycle the main burner several times, allowing at least
30 seconds between cycles for the regulator to resume
the step function. Repeat after allowing main burner to
cool. Readjust the full rate outlet pressure if necessary
to improve lightoff characteristics.

V8200 COMBINATION GAS CONTROLS
11 68-0045—3
Table 7. Pressure Regulator Specification Pressures in Inches wc.
Table 8. Pressure Regulator Specification Pressures in kPa.
Check Safety Shutdown performance
WARNING
Fire or Explosion Hazard.
Can cause serious injury, death or equipment
damage.
Perform the safety shutdown test any time work is
done on a gas system.
1. Place gas control knob in PILOT position. Main
burner should go off and pilot should remain lit.
2. Extinguish pilot flame. Pilot gas flow should stop
within 2-1/2 minutes. Safety shutoff of pilot gas
proves complete shutdown since safety shutoff
valve prevents main burner and pilot gas flow.
3. Relight pilot burner and operate system through
one complete cycle to ensure all controls operate
properly.
MAINTENANCE
WARNING
Fire or Explosion Hazard.
Can cause serious injury, death or property
damage.
Improper cleaning or reassembly may cause gas
leakage. When cleaning, ensure that control is
reassembled properly and perform gas leak test.
Regular preventive maintenance is important in applications
that place a heavy load on system controls, such as in the
commercial cooking and agricultural and industrial industries
because:
• In many such applications, particularly commercial
cooking, the equipment operates 100,000-200,000 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.
The maintenance program should include regular checkout
of the gas control as outlined under Startup and Checkout,
and the control system as described in the appliance
manufacturer’s literature.
Maintenance frequency must be determined individually for
each application. Some considerations are:
• Cycling frequency. Appliances that may cycle 100,000
times annually should be checked monthly.
• Intermittent use. Appliances that are used seasonally
should be checked before shutdown and again before the
next use.
• Consequence of unexpected shutdown. Where the cost of
an unexpected shutdown would be high, the system should
be checked more often.
• Dusty, wet, or corrosive environment. Since these
environments can cause the gas control to deteriorate
more rapidly, the system should be checked more often.
The gas control should be replaced if:
• It does not perform properly on checkout or
troubleshooting.
• The gas control knob is hard to turn or push down, or it fails
to pop back up when released.
• The gas control is likely to have operated for more than
200,000 cycles.
Model Type of Gas
Nominal Inlet
Pressure Range
Outlet Pressure
Nominal Factory Setting Setting Range
Step Full Rate Step Full Rate
Standard, Slow-
Opening
Natural 5.0 to 7.0 — 3.5 — 0.7 to 1.2
LP 12.0 to 14.0 — 10.0 — 8.0 to 12.0
Step-Opening Natural 5.0 to 7.0 0.9 3.5 — 3.0 to 5.0
LP 12.0 to 14.0 2.2 10.0 — 8.0 to 12.0
Model Type of Gas
Nominal Inlet
Pressure
Range
Outlet Pressure
Nominal Factory Setting Setting Range
Step Full Rate Step Full Rate
Standard, Slow-
Opening Natural 1.2 to 1.7 — 0.9 — 0.7 to 1.2
LP 2.9 to 3.9 — 2.7 — 2.0 to 3.0
Step-Opening Natural 1.2 to 1.7 0.2 0.9 — 0.7 to 1.2
LP 2.9 to 3.9 0.9 2.7 — 2.0 to 3.0

V8200 COMBINATION GAS CONTROLS
68-0045—3 12
OPERATION
The V8200 Gas Control provides 3-position (OFF-PILOT-ON)
manual control of gas flow. The OFF position prevents pilot
and main burners gas flow. The PILOT position allows pilot
burner gas flow only. The ON position allows pilot burner and
main burner gas flow under control of the thermostat and the
automatic valve operation.
When the thermostat calls for heat, the automatic valve
operator allows gas flow as long as the control is powered and
the pilot is burning. The servo pressure regulator monitors
outlet pressure to provide an even main burner gas flow. Loss
of power closes the automatic valve, but leaves the pilot lit,
ready to return to normal service when power is restored. On
loss of pilot flame or flame too small to reliably light main
burner, the safety shutoff valve and the automatic valve close,
shutting off gas flow to both pilot and main valves. Gas control
operation is described in more detail below.
Valve Position During Thermostat OFF Cycle
The valves are positioned as shown in Fig. 12 when the:
• manual gas control knob is in the ON position.
• pilot burner is lit.
• thermostat is not calling for heat.
The power unit holds the safety shutoff valve disc off its seat
and the manual valve is open, so gas can flow into the control.
Pilot gas flows through a port in the bushing around the reset
button shaft to the pilot burner. The valve operator is
deenergized, closing the channel to the pressure regulator,
and opening a channel to the underside of the automatic valve
diaphragm. The combination of gas pressure under the
automatic valve diaphragm, spring pressure, and the lack of
outlet pressure hold the automatic valve firmly closed,
blocking main burner gas flow.
When Thermostat Calls for Heat
The gas control allows pilot and main burner gas flow during
the thermostat ON cycle, as shown in Fig. 13. When the
thermostat calls for heat, the magnetic valve operator is
energized and lifts the automatic operator valve disc off its
seat. This diverts gas flow from the automatic valve
diaphragm and causes a reduction of pressure on the
underside of this diaphragm. The reduced pressure on the
bottom of the automatic valve diaphragm repositions the
automatic valve diaphragm downward away from the valve
seat, allowing main burner gas flow.
Standard-Opening Pressure Regulation (V8200A)
During the ON cycle, the servo pressure regulator provides
close control of outlet pressure, even if inlet pressure and flow
rate vary widely. Any outlet pressure change is immediately
reflected back to the pressure regulator diaphragm, which
repositions to change the flow rate through the regulator valve
and, thus, through the automatic valve.
If outlet pressure begins to rise, the pressure regulator
diaphragm moves slightly higher, allowing less gas flow to the
gas control outlet. This increases gas pressure under the
automatic valve and repositions the valve disc closer to the
seat. Thus, flow of gas through the automatic valve is
reduced, and outlet pressure falls to the desired level.
If outlet pressure begins to fall, the pressure regulator
diaphragm moves slightly lower allowing more gas flow to the
gas control outlet. This decreases gas pressure under the
automatic valve diaphragm and repositions the valve disc
further from the seat. Thus, flow of gas through the automatic
valve is increased, and outlet pressure rises to the desired
level.

V8200 COMBINATION GAS CONTROLS
13 68-0045—3
Fig. 12. Position of Gas Control components during the thermostat OFF cycle. Standard gas control shown.
Step-Opening Pressure Regulation (V8200C)
Step-opening gas controls actually combine two pressure
regulators, one for the low pressure and one for the full-rate
pressure. When the thermostat calls for heat, the automatic
operator valve disc opens. The low pressure regulator
maintains outlet pressure at the preset step rate for several
seconds. Then the regulator valve is forced full open by the
timing diaphragm, which is operated by bleed gas. When the
low pressure regulator is full open, the high pressure regulator
maintains the desired full-rate outlet pressure as described for
the standard regulator.
The step model requires approximately 60 seconds to reset
once the main burner goes off. If it is re-energized within
60 seconds, it may bypass or shorten the length of the low
pressure step. The burner may relight at the full flow rate.
Slow-Opening Pressure Regulation (V8200H)
Slow-opening gas controls function the same as standard
models except that when the thermostat calls for heat,
the automatic valve opens gradually. Opening is slowed
because a gas flow restrictor in the passage from the
automatic operator slows the rate at which gas pressure
is reduced under the automatic valve diaphragm after the
automatic operator opens. Outlet pressure to the main burner
increases gradually from 0 inches wc [0 kPa] to rated output
pressure within 3-6 seconds (for an 80,000 Btuh furnace at
7 inches wc [1.8 kPa] inlet pressure and 3.5 inches wc
[0.9 kPa] outlet pressure).
GAS CONTROL KNOB
G
AS
C
ONTROL
I
NLET
AUTOMATIC
VALVE OPERATOR AUTOMATIC
OPERATOR
SOLENOID
AUTOMATIC
OPERATOR
VALVE DISC
SERVO PRESSURE
REGULATOR
GAS
CONTROL
OUTLET
AUTOMATIC
VALVE DIAPHRAGM
NOTE: AUTOMATIC VALVE OPERATOR AND
SERVO PRESSURE REGULATOR SHOWN OUTSIDE
GAS CONTROL FOR EASE IN TRACING GAS FLOW.
SLOW-OPENING GAS CONTROL HAS A GAS FLOW RESTRICTOR IN THIS PASSAGE.
M16282
1
1
PILOT
GAS
OUTLET
RED RESET
BUTTON
MANUAL VALVE
SAFETY
SHUTOFF
VALVE
POWER UNIT
RESET BUTTON
VALVE DISC

V8200 COMBINATION GAS CONTROLS
68-0045—3 14
Fig. 13. Position of Gas Control components during the thermostat ON cycle. Standard gas control shown.
When the Call for Heat Ends
When the call for heat ends, the first automatic valve and
the second automatic valve operator close, bypassing the
regulator(s) and shutting off the main burner and the pilot.
As pressure inside the gas control and underneath the
automatic valve diaphragm equalizes, spring pressure
closes the second automatic valve to provide a second
barrier to gas flow.
Safety Shutoff Operation
In the safety shutoff position, pilot and main burner gas flow is
prevented.
Safety shutoff occurs:
• When the gas control knob is manually turned to OFF.
• When the pilot goes out or becomes too small to sustain
normal ignition.
Gas control knob turned to off
When the gas control knob is turned to OFF, the manual valve
closes, shutting off main burner gas flow. With the loss of
outlet pressure, the automatic valve closes and is held closed
by spring pressure on the diaphragm. As the gas control knob
is turned to OFF, it pulls up and locks the reset button. The
small valve seat attached to the reset button closes and shuts
off gas flow to the pilot.
When the pilot goes out, thermocouple current drops and the
power unit drops out, closing the safety shutoff valve.
When pilot flame goes out
When pilot flame goes out or is too small to reliably light the
main burner, thermocouple output drops below the power unit
hold-in value. The power unit drops out, closing the safety
valve and stopping all gas flow through the control. With the
loss of outlet pressure, the automatic valve closes and is held
closed by spring pressure on the diaphragm.
ECO Operation (if used)
Safety shutoff can be initiated on high limit action by including
an ECO switch in the thermocouple circuit. The ECO switch
senses plenum temperature and breaks the thermocouple
circuit if plenum temperature is too high. When this happens,
the power unit drops out closing the safety valve and stopping
all gas flow through the control. With the loss of outlet
pressure, the automatic valve closes and is held closed by
spring pressure on the diaphragm.
GAS CONTROL KNOB
G
AS
C
ONTROL
I
NLET
AUTOMATIC
VALVE OPERATOR AUTOMATIC
OPERATOR
SOLENOID
AUTOMATIC
OPERATOR
VALVE DISC
SERVO PRESSURE
REGULATOR
GAS
CONTROL
OUTLET
AUTOMATIC
VALVE DIAPHRAGM
NOTE: AUTOMATIC VALVE OPERATOR AND
SERVO PRESSURE REGULATOR SHOWN OUTSIDE
GAS CONTROL FOR EASE IN TRACING GAS FLOW.
SLOW-OPENING GAS CONTROL HAS A GAS FLOW RESTRICTOR IN THIS PASSAGE.
M16283
1
1
PILOT
GAS
OUTLET
RED RESET
BUTTON
MANUAL VALVE
SAFETY
SHUTOFF
VALVE
POWER UNIT
RESET BUTTON
VALVE DISC

V8200 COMBINATION GAS CONTROLS
15 68-0045—3
SERVICE
WARNING
Fire or Explosion Hazard.
Can cause serious injury, death or property
damage.
Do not disassemble the gas control; it contains no
replaceable components. Attempted disassembly or
repair may damage the gas control.
CAUTION
Equipment Damage Hazard.
Miswiring equipment will damage the equipment.
Do not apply a jumper across or short the valve coil
terminals. This may burn out the heat anticipator in the
thermostat.
IMPORTANT
Allow 60 seconds after shutdown before
re-energizing step-opening model to ensure lightoff
at step pressure.
If the Pilot Burner Flame Will Not Light
1. Ensure the main gas supply valve is open and the pilot
gas supply line is purged of air.
2. Attempt to light pilot burner flame following procedures
in “Light the Pilot Burner Flame”. If pilot burner flame
still will not light:
a. Check the pilot gas adjustment screw. If closed,
readjust the pilot flame. Refer to “Adjust the Pilot
Burner Flame”.
b. Perform the Gas Leak Test at the compression
fitting. If a gas leak is detected, replace the old
compression fitting or tighten the newly installed
one. Refer to Fig. 8.
c. Ensure that the pilot burner tubing or pilot burner
orifice is not clogged.
If the Pilot Burner Flame Goes Out When the
Gas Control Knob is Released
1. Ensure the gas control knob is held in at least one
minute to allow the thermocouple time to heat.
2. Check the pilot burner flame adjustment. Refer to
“Adjust the Pilot Burner Flame”.
3. Check the wiring between the thermocouple and the
gas control valve operator.
4. Ensure thermocouple connection to the power unit is
tightened 1/4 turn beyond finger tight.
5. If pilot burner flame still goes out, measure the open
and closed thermocouple output voltage. Compare
it to the acceptable range charts in the thermocouple
specifications or in the Gas Controls Handbook.
Replace the thermocouple if voltages are outside the
acceptable range.
6. Check the power unit resistance. If above 11 ohms,
replace the gas control.
If the Main Burner Will Not Come On With a
Call for Heat
1. Ensure the gas control knob is in the ON position.
2. Adjust the thermostat several degrees above room
temperature.
3. Use an ac voltmeter to measure the voltage across
terminals TH and TR. If:
a. No voltage is present, check the control circuit for
proper operation.
b. 24 Vac is present, but first operator did not “click”
open, check for excessive inlet gas pressure. If inlet
gas pressure is correct, replace the gas control.
4. Measure the open and closed thermocouple output
voltages and compare to the acceptable range charts in
the thermocouple specifications or in the Gas Controls
Handbook. Replace the thermocouple if voltages are
outside the acceptable range.
If the Main Burner is Overfiring
Adjust the gas control pressure regulator to the correct
pressure. If the regulator cannot be adjusted and supply
pressure is in the normal range, replace the gas control.
INSTRUCTIONS TO THE HOMEOWNER
WARNING
Fire or Explosion Hazard.
Can cause serious injury, death or property
damage.
Follow these warnings exactly:
1. Pilot burner flame must be lit manually. Follow these
instructions exactly.
2. Before lighting pilot burner flame, smell around the
appliance for gas. Be sure to smell next to floor
because LP gas is heavier than air.
3. IF YOU SMELL GAS:
•Turn off the gas supply at the appliance service
valve. On LP gas systems, turn off 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 neighbor’s phone to
call your gas supplier.
•If you can not reach your gas supplier, call the
fire department.
4. Do not force the gas control knob. Use only your
hand to push down or 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 a fire or explosion.
5. The gas control must be replaced in case of any
physical damage, tampering, bent terminals,
missing or broken parts, stripped threads, or
evidence of exposure to heat.

68-0045—3 G.R. Rev. 3-01 customer.honeywell.com
Home and Building Control Home and Building Control
Honeywell Honeywell Limited-Honeywell Limitée
1985 Douglas Drive North 35 Dynamic Drive
Golden Valley, MN 55422 Scarborough, Ontario
M1V 4Z9
Printed in U.S.A. on recycled
paper containing at least 10%
post-consumer paper fibers.
IMPORTANT:
Follow the operating instructions provided by the
manufacturer of your heating appliance. The
information below will be of assistance in a typical
gas control application, but the specific controls used
and the procedures outlined by the manufacturer or
your appliance may differ, requiring special
instructions.
Lighting the Pilot Burner Flame
STOP: READ THE WARNINGS ABOVE.
The pilot burner flame must be lit manually. If the pilot burner
flame has gone out, follow these instructions exactly.
1. Set the thermostat to its lowest setting.
2. Disconnect all electric power to the appliance.
3. Remove the gas control access panel.
4. Push in the gas control knob slightly and turn
clockwise to OFF.
NOTE: The gas control knob can not be turned from PILOT
to OFF unless it is pushed in slightly. Do not force the
gas control knob.
5. Wait five minutes to clear out any unburned gas. If you
then smell gas, STOP! Follow ÒBÓ in the Warnings
above. If you do not smell gas, continue with the next step.
6. Remove the pilot burner access panel located below
and behind the gas control.
7. Find the pilot burner by following the metal tube from
the gas control. The pilot burner is between the two
burner tubes behind the pilot burner access panel.
8. Turn the gas control knob counterclockwise to
PILOT.
9. Push and hold the gas control knob all the way in.
Immediately light the pilot burner flame with a match
and continue holding the gas control knob in for one
minute after the pilot burner flame is lit.
10. Release the gas control knob and it will pop back up.
The pilot burner flame should remain lit. If pilot burner
flame goes out, repeat steps one through ten.
a. If the gas control knob does not pop up when
released, stop immediately and call your service
technician or gas supplier.
b. If the pilot flame will not stay lit after several tries,
turn the gas control knob to OFF and call your
service technician or gas supplier.
11. Turn the gas control knob counterclockwise to ON.
12. Replace the pilot burner access panel.
13. Replace the gas control access panel.
14. Reconnect all electric power to the appliance.
15. Set the thermostat to the desired setting.
Turning Off the Appliance
Vacation Shutdown
Set the thermostat to the desired room temperature while you
are away.
Complete Shutdown
Push the gas control knob in slightly and turn
clockwise to OFF. Do not force. Appliance will
completely shut off. Follow the Lighting Procedures above to
resume normal operation.