resideo VR8205 User manual

INSTALLATION INSTRUCTIONS
68-0049-03
VR8205; VR4205 Direct Ignition
Dual Automatic Valve
Combination Gas Controls
APPLICATION
The VR8205 and VR4205 Direct Ignition Dual Automatic
Valve Combination Gas Controls are for use with direct
ignition systems in gas-fired appliances. The controls
include a safety shutoff, a manual valve, two automatic
operators and a pressure regulator and conduit cover
(VR4205 only).
FEATURES
• VR8205 used with S89C,E,F and S87 series 5 and later.
• VR4205 used with 120 Vac direct ignition modules.
• VR8205 for use with 24 Vac heating appliances and
VR4205 for use with 120 Vac heating appliances that burn
natural or manufactured gas, or liquefied petroleum (LP)
gas.
• Capacity rated at 150 cfh at 1 in. wc pressure drop
[4.2 m3/h at 0.25 kPa].
• 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.
• Two-position gas control knob has ON and OFF positions.
• All adjustments and wiring connections accessible from
top of the control.
• Compact size.
• Straight-through body pattern; right angle adapters
available for inlet and outlet.
• 1/2 in. inlet and 1 /2 in. outlet; adapters available for 3/8
or 3/4 in.
• Adjustable servo regulator effectively maintains almost
constant gas output pressure under wide fluctuations in
gas supply pressure.
• Inlet and outlet screens included.
• Wiring terminal block color-coded brown to indicate direct
ignition 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
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.
• lnlet and outlet pressure taps included; both taps
accessible from top of control.
• Standard-, slow- and step-opening models available.
SPECIFICATIONS
IMPORTANT:
The specifications given in this publication do not
include normal manufacturing tolerances. There-
fore, this unit may not exactly match the listed spec-
ifications. 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.
MODELS:
VR8205 and VR4205 Dual Automatic Valve Combination
Gas Controls for use in Direct Ignition Systems. See
Table 1 for specifications.
SUPPLY VOLTAGE:
VR4205: 120 Vac, 60 Hz.
VR8205: 24 Vac, 60 Hz. (50/60 Hz models available on
request.)
CURRENT DRAW:
VR4205: 0.1A
VR8205: 0.5A
M38605

VR8205; VR4205 DIRECT IGNITION DUAL AUTOMATIC VALVE COMBINATION GAS CONTROLS
68-0049—03 2
aStep pressure not adjustable.
ELECTRICAL CONNECTIONS: 1/4 in. male quick-connects.
Two convenience terminals on top of control (optional).
Terminal block color-coded brown.
TYPE OF GAS: Separate models for natural (and manufac-
tured) or LP gas.
CAPACITY:
At minimum regulation:
Natural gas: 20,000 Btuh [5860W]a.
LP gas: 40,000 Btuh [11,700W].
At 1 in. [0.25 kPa] pressure drop: 150,000 Btuh [44,000W]a.
At maximum regulation: 200,000 Btuh [58,600W]a.
a0.64 sp gr natural gas at 1 in. [0.25 kPa] pressure drop; use
conversion factors in Table 2 to convert for other gases.
BODY PATTERN: Straight-through with 1/2 in. inlet and
1/2 in. outlet. Flanges available for 3/8, 1/2 and 3/4 in.
straight and 90° angle connection. See Table 3.
NOTE: Flange Kits include one flange with attached O-ring
and four mounting screws.
PRESSURE TAPPING: Inlet and outlet taps standard. Taps
accessible from top of control. Tap is 1/8 in. NPT with
plug containing recess for 3/16 in. Allen wrench.
PRESSURE RATING: AGA rating 1 /2 psi [3.5 kPa] inlet pres-
sure.
PRESSURE REGULATION: See Table 1. Regulator adjustment
accessible from top of control.
MOUNTING: Can be mounted 0 to 90 degrees in any direction
from the upright position of the gas control knob, includ-
ing vertically.
TEMPERATURE RATING:
VR8205A,C,H; VR4205H: 0° F to 175° F [-18° C to +79° C].
VR8205M,P,K; VR4205M,P: -40° F to +175° F [-40° C to
+79° C].
DIMENSIONS: See Fig. 1.
APPROVALS:
American Gas Association design certificate: L2025006.
Canadian Gas Association design certificate: L2025006.
Australian Gas Association design certificate: 4214.
Approved for Delta C applications.
ACCESSORIES:
• Flanges; see Table 3.
• 394349 9/64 in. hex tool for flange assembly screws.
• 393691 Natural to LP Conversion Kit.
• 394588 LP to Natural Conversion Kit.
Table 1. Model Specifications.
Model No.
Suffix Letter
Opening
Characteristic
Type
of Gas
Standard Factory
Regulator Settings
Optional Factory
Regulator Settings
Range of
Field Adjustment
in. wc kPa in. wc kPa in. wc kPa
VR8205A,M
VR4205M
Standard 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
VR8205C,P
VR4205P
Step-opening Natural Step—0.7,
0.9,1.2 or 1.7,
as ordereda
Full Rate—
3.5
Step—0.17,
0.22, 0.30
or 0.48,
as ordereda
Full Rate— 0.9
Step—0.7,
0.9,1.2 or 1.7,
as ordereda
Full Rate— 3
to 5
Step—0.17,
0.22, 0.30
or 0.48,
as ordereda
Full Rate—
0.7 to 1.2
Step—none;
Full Rate—
3-5
Step—none;
Full Rate—
0.7 to 1.2
LP Step—1.4,
2.5, 4.0 or 5.5,
as ordereda
Full Rate—10
Step—0.35,
0.62, 0.99
or 1.37,
as ordereda
Full Rate— 2.5
Step—1.4,
2.5, 4.0 or 5.5,
as ordereda
Full Rate—
8 to 12
Step—0.35,
0.62, 0.99
or 1.37,
as ordereda
Full Rate— 2-3
Step—none;
Full Rate—
8-12
Step—none;
Full Rate—
2 to 3
VR8205H,K
VR4205H
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
Table 2. Gas Capacity Conversion Factors.
sp gr Multiply Listed Capacity By
0.60 0.516
0.70 0.765
1.53 1.62
Table 3. Flange Part Numbers.
Inlet/Outlet
Pipe Size
Flange
Type
Part No.
Less Hex
Wrench
With Hex
Wrench
3/8 in. NPT Straight 393690-1 393690-11
Elbow 393690-2 393690-12
1/2 in. NPT Straight 393690-6 393690-16
Elbow 393690-3 393690-13
3/4 in. NPT Straight 393690-4 393690-14
Elbow 393690-5 393690-15

VR8205; VR4205 DIRECT IGNITION DUAL AUTOMATIC VALVE COMBINATION GAS CONTROLS
368-0049—03
Fig. 1. Dimensions in in. [mm] of VR4205/VR8205 Combination Gas Control.
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 make sure the product is suitable for your
application.
3. Installer must be a trained, experienced service techni-
cian.
4. After installation is complete, check out product opera-
tion as provided in these instructions.
WARNING
Fire or explosion hazard. Can cause property damage,
severe injury, or death.
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. Always install sediment trap in gas supply line to
prevent contamination of gas control.
4. 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
Never apply a jumper across or short the valve coil
terminals. This may burn out the heat anticipator in
the thermostat or damage the electronic direct
ignition (DI) module.
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 instructions if available;
otherwise, use the instructions provided on the following
pages.
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.
Refer to appliance manufacturer instructions for orifice
specifications and changeover procedure. Gas controls are
factory-set for natural (and manufactured) or LP gas. Do not
attempt to use a control set for natural (and manufactured)
gas on LP gas, or a control set for LP on natural (and
manufactured) gas.
Gas controls with standard or slow-opening regulators can
be converted from one gas to the other with a conversion kit
(ordered separately). Order part no. 393691 to convert from
natural (and manufactured) to LP gas; order part no. 394588
to convert from LP to natural (manufactured) gas. Controls
with step-opening regulators cannot be converted.
Install Adapters to Control
If adapters are to be installed on the gas control, mount them
as follows:
M9062A
3-1/2
(89)
2-11/16 (69)
1 (25)
1/2
(13)
3-5/8 (91)
SWING
RADIUS
CONDUIT COVER (VR4205 ONLY)
1 (25)
1/2
(13)
(FOR FLANGE
MOUNTING)
8-32
TAPPED [4]
4-1/8 (104)
1-1/8
(28)

VR8205; VR4205 DIRECT IGNITION DUAL AUTOMATIC VALVE COMBINATION GAS CONTROLS
68-0049—03 4
FLANGES:
1. Choose the appropriate flange for your application.
2. Remove seal over control inlet or outlet.
3. Assure the O-ring is fitted in the groove of flange. If the
O-ring is not attached or is missing, do not use flange.
4. With O-ring facing control, align the screw holes on the
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 control inlet or outlet.
2. Apply moderate amount of good quality pipe com-
pound to bushing, leaving two end threads bare. On LP
installation, use compound resistant to LP gas. Do not
use Teflon tape.
3. Insert bushing in control and thread pipe carefully into
bushing until tight.
Complete instructions below for piping, installing control, and
wiring. Make certain the leak test you perform on the control
after completing the installation includes leak testing the
adapters and screws. If you use a wrench on the valve after
flanges are installed, use the wrench only on the flange, not
on the control. See Fig. 6.
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. Usually this problem can 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 the use
of an adapter increases the overall length of the gas control.
Fig. 2. Fasten flange to control with 25 inchpounds torque.
Fig. 3. Sediment trap installation.
Location
The combination gas control is mounted in the appliance
vestibule on the gas manifold. If this is a replacement
application, mount the gas control in the same location as
the old control.
Locate the combination gas control where it cannot be
affected by steam cleaning, high humidity, or dripping water,
corrosive chemicals, dust or grease accumulation or
excessive heat. To assure proper operation, follow these
guidelines:
• Locate gas control in a well-ventilated area.
• Mount gas control high enough above the cabinet bottom
to avoid exposure to flooding or splashing water.
• Assure the ambient temperature does not exceed the
ambient temperature ratings for each component.
• Cover gas control if appliance is cleaned with water,
steam, or chemicals or to avoid dust and grease
accumulation.
• Avoid locating gas control where exposure to corrosive
chemical fumes or dripping water are likely.
M9055A
VALVE OUTLET
FLANGE
9/64 INCH HEX SCREWS (4)
6/32 INCH ROUND
SCREWS (1)
CONDUIT
COVER,
VR4205
ONLY
DO NOT OVERTIGHTEN SCREWS. TIGHTEN TO 25 INCH-POUNDS.
1
1
GAS
CONTROL
GAS
CONTROL
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
M3077D
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.

VR8205; VR4205 DIRECT IGNITION DUAL AUTOMATIC VALVE COMBINATION GAS CONTROLS
568-0049—03
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 tub-
ing is used, make sure the ends are square, deburred
and clean. All tubing bends must be smooth and with-
out deformation.
2. Run pipe or tubing to the control. If tubing is used,
obtain a tube-to-pipe coupling to connect the tubing to
the control.
3. Install sediment trap in the supply line to the gas con-
trol. See Fig. 3.
Install Control
1. This control can be mounted 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 control.
3. Thread pipe into control. Do not thread pipe too far.
Valve distortion or malfunction may result if the pipe is
inserted too deeply. Refer to Table 4.
4. Apply a moderate amount of good quality pipe com-
pound (do not use Teflon tape) to pipe only, leaving two
end threads bare. On LP installations, use compound
resistant to LP gas. See Fig. 4.
Fig. 4. Use moderate amount of pipe compound.
5. Remove seals over control inlet and outlet if necessary.
6. Connect pipe to control inlet and outlet. Use wrench on
the square ends of the control. If an adapter is used,
place wrench on adapter rather than on control. Refer
to Fig. 5 and 6.
Fig. 5. Top view of gas control.
Table 4. NPT Pipe Thread Length in in.
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).
M3075E
PIPE
OUTLET
PRESSURE
TAP
INLET OUTLET
INLET
PRESSURE TAP
PRESSURE REGULATOR
ADJUSTMENT (UNDER
CAP SCREW)
GAS CONTROL KNOB M9061B
GAS CONTROL KNOB
VR4205
CONDUIT
COVER
OUTLET
PRESSURE
TAP
INLET OUTLET
WIRING
TERMINALS (2)
INLET
PRESSURE TAP
PRESSURE REGULATOR
ADJUSTMENT (UNDER
CAP SCREW)
VR8205
VR4205

VR8205; VR4205 DIRECT IGNITION DUAL AUTOMATIC VALVE COMBINATION GAS CONTROLS
68-0049—03 6
Fig. 6. Proper use of wrench on gas control with and without flanges.
WIRING
Follow the wiring instructions furnished by the appliance
manufacturer, if available, or use the general instructions
provided below. Where these instructions differ from the
appliance manufacturer, follow the appliance manufacturer
instructions.
All wiring, including insulated quick connect terminals, must
comply with applicable electrical codes and ordinances.
Disconnect power supply before making wiring connections
to prevent electrical shock or equipment damage.
1. Check the power supply rating on the valve and make
sure it matches the available supply. Install trans-
former, thermostat, and other controls as required.
2. For VR4205, when the gas control is installed external
to the appliance, install the conduit cover on the con-
duit fitting. Do not secure conduit cover at this time.
3. Connect control circuit to gas control terminals. See
Fig. 5 and 7-9.
NOTE: Use leadwires with insulated terminals.
4. For VR4205, make sure conduit cover is in position and
secured to the gas valve with the screw provided. See
Fig. 2.
5. Adjust thermostat heat anticipator as instructed in
appliance manual (i.e., usually 0.1A for VR4205 and
0.5A for VR8205).
Fig. 7. Wiring connections for 120 volt control in direct
ignition system.
APPLY WRENCH
TO FLANGE ONLY
WHEN FLANGE IS USED
APPLY WRENCH
FROM TOP OR
BOTTOM OF GAS
CONTROL TO
EITHER SHADED AREA
WHEN FLANGE IS NOT USED
M3079C
IGNITION MODULE
L1
(HOT)
L2
LIMIT CONTROLLER
Q347 IGNITER-SENSOR
120V (GND)
VALVE
VALVE
GND
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION. M3090B
BURNER
120V
VR4205
DUAL VALVE
COMBINATION
GAS CONTROL
L2
L1
1
2
1
2

VR8205; VR4205 DIRECT IGNITION DUAL AUTOMATIC VALVE COMBINATION GAS CONTROLS
768-0049—03
Fig. 8. Wiring connections for 24 volt control in S87 Direct
Ignition System.
Fig. 9. Wiring connections for 24 volt control in S89C Direct
Ignition System.
STARTUP AND CHECKOUT
WARNING
Fire or explosion hazard. Can cause property damage,
severe injury, or death.
1. Do not force the gas control knob on the appliance.
Use only your hand to turn the gas control knob.
Never use any tools.
2. If the knob will not operate by hand, the control
should be replaced by a qualified service
technician.
Gas Control Knob Settings
Gas control knob settings are as follows:
OFF: Prevents main gas flow through the control.
ON: Permits gas to flow into the control body. Under control
of the thermostat and direct ignition module, gas can flow to
the main burner.
NOTE: 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 soap and water solution any
time work is done on a gas system.
Gas Leak Test
1. Paint pipe connections upstream of gas control with
rich soap and water solution. Bubbles indicate gas
leak.
2. If leak is detected, tighten pipe connections.
3. Stand clear of main burner while lighting to prevent
injury caused from hidden leaks that could cause
flashback in the appliance vestibule. Light main burner.
4. With main burner in operation, paint pipe joints (includ-
ing adapters) and control inlet and outlet with rich soap
and water solution.
5. If another leak is detected, tighten adapter screws,
joints, and pipe connections.
6. Replace part if leak cannot be stopped.
Turn On System
Rotate the gas control knob counterclockwise to ON.
Turn On Main Burner
Follow instructions provided by appliance manufacturer or
turn up thermostat to call for heat.
MV
MV
24V
24V (GND)
S87B CONTROL MODULE
ALARM
VALVE
VALVE
GND
TEMPERATURE
CONTROLLER
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
MAXIMUM IGNITER-SENSOR CABLE LENGTH: 3 ft. (0.9 m) OR LESS.
3A REPLACEABLE FUSE.
ALARM TERMINAL PROVIDED ON SOME MODELS.
M9043B
L1
(HOT)
L2
1
2
1
2
3
DUAL VALVE
COMBINATION
GAS CONTROL
Q347 IGNITER-SENSOR
BURNER
4
4
5
IGNITER-SENSOR AND
BURNER GROUND
3
5
ALARM, IF USED
WHITE
BLUE
BLACK
BLUE
HOT
SURFACE
IGNITER-
SENSOR
VALVE
VALVE (GND)
24V
TH-W
24V (GND)
GND (BURNER)
S89C,G,J/S890C,G,J
HOT SURFACE
IGNITION CONTROL
L2
HSI
L1
HSI
LIMIT
CONTROLLER
BURNER
GROUND
THERMOSTAT
OR CONTROLLER
DUAL VALVE
COMBINATION
GAS CONTROL
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED. MAKE SURE L1 AND L2 ARE NOT
REVERSED; THIS WOULD PREVENT FLAME DETECTION.
ALTERNATE LIMIT CONTROLLER LOCATION.
SEN TERMINAL AND Q354 FLAME SENSOR ON D MODELS ONLY.
M9047A
MV
MV
L1
(HOT)
L2
VENT
DAMPER PLUG
1
2
1
2
3
3
SEN
Q354 FLAME
SENSOR

VR8205; VR4205 DIRECT IGNITION DUAL AUTOMATIC VALVE COMBINATION GAS CONTROLS
68-0049—03 8
Check and Adjust Gas Input and Burner Ignition
CAUTION
1. Do not exceed input rating stamped on appliance
nameplate, or manufacturer recommended burner
orifice pressure for size orifice(s) used. Make
certain primary air supply to main burner is
properly adjusted for complete combustion. Follow
appliance manufacturer instructions.
2. IF CHECKING GAS INPUT BY CLOCKING GAS
METER. Make certain there is no gas flow through
the meter other than to the appliance being
checked. Other appliances must remain off with
their pilots extinguished (or their consumption
must be deducted from the meter reading). Convert
flow rate to Btuh as described in form 70-2602,
Gas Controls Handbook, and compare to Btuh input
rating on appliance nameplate.
3. IF CHECKING GAS INPUT WITH MANOMETER: Be
sure gas control is in OFF position before removing
outlet pressure tap plug to connect manometer
(pressure gauge). Also turn gas control knob back
to OFF when removing gauge and replacing plug.
Before removing inlet pressure tap plug, shut off
gas supply at the manual valve in the gas piping to
the appliance or, for LP, at the tank. Also shut off
gas supply before disconnecting manometer and
replacing plug. Repeat Gas Leak Test at plug with
main burner operating.
STANDARD PRESSURE REGULATOR
1. Check the manifold pressure listed on the appliance
nameplate. Gas control outlet pressure should match
the nameplate.
2. With main burner operating, check gas control flow rate
using the meter clocking method or check pressure by
using a manometer connected to the outlet pressure
tap on the gas control. See Fig. 5.
3. If necessary, adjust pressure regulator to match appli-
ance rating. See Table 5 or 6 for factory set nominal
outlet pressure and adjustment setting range.
a. Remove pressure regulator adjustment cap screw.
b. Using screwdriver, turn inner adjustment screw
clockwise to increase or counterclockwise to
decrease gas pressure to burner.
c. Always replace cap screw and tighten firmly to pre-
vent gas leakage.
4. If desired outlet pressure or flow rate cannot be
achieved by adjusting the gas control, check gas con-
trol inlet pressure using a manometer at the gas control
inlet pressure tap. If inlet pressure is in the nominal
range (see Table 5 or 6), replace gas control. Otherwise,
take the necessary steps to provide proper gas pres-
sure on the control.
SLOW-OPENING AND STEP-OPENING PRESSURE
REGULATORS
1. Check the full rate manifold pressure listed on the
appliance nameplate. Gas control full rate outlet pres-
sure should match this rating.
2. With main burner operating, check gas control flow rate
using the meter clocking method or pressure using a
manometer connected to the outlet pressure tap on the
gas control. See Fig. 5.
3. If necessary, adjust pressure regulator to match appli-
ance rating. See Table 5 or 6 for factory set nominal
outlet pressure and adjustment setting range.
a. Remove pressure regulator adjustment screw.
b. Using screwdriver, turn inner adjustment screw
clockwise to increase or counterclockwise to
decrease gas pressure to burner.
c. Always replace cap screw and tighten firmly to pre-
vent gas leakage.
4. If desired outlet pressure or flow rate cannot be
achieved by adjusting the gas control, check gas con-
trol inlet pressure using a manometer at the gas control
inlet pressure tap. If inlet pressure is in the nominal
range (see Table 5 or 6), replace gas control. Otherwise,
take the necessary steps to provide proper gas pres-
sure to the control.
5. STEP-OPENING PRESSURE REGULATORS ONLY. Care-
fully check burner lightoff at step pressure. Make sure
burner lights smoothly and without flashback to orifice.
Make sure all ports remain lit. Cycle burner several
times, allowing at least 30 seconds between cycles for
regulator to resume step function. Repeat after allow-
ing burner to cool. Readjust full rate outlet pressure, if
necessary, to improve lightoff characteristics.
Table 5. Pressure Regulator Specification Pressures (in. wc).
Model
Type
Type
of Gas
Nominal Inlet
Pressure Range
Factory Set Nominal Outlet Pressure Setting Range
Step Full Rate Step Full Rate
Standard,
slow-opening
Natural 5.0 - 7.0 — 3.5 — 3.0 - 5.0
LP 12.0 - 14.0 — 10.0 — 8.0 - 12.0
Step-opening Natural 5.0 - 7.0 0.9 3.5 — 3.0 - 5.0
LP 12.0 - 14.0 2.2 10.0 — 8.0 -12.0
Table 6. Pressure Regulator Specification Pressures (kPa).).
Model
Type
Type
of Gas
Nominal Inlet
Pressure Range
Factory Set Nominal Outlet Pressure Setting Range
Step Full Rate Step Full Rate
Standard,
slow-opening
Natural 1.2 - 1.7 — 0.9 — 0.7 - 1.2
LP 2.9 - 3.9 — 2.5 — 2.0 - 3.0
Step-opening Natural 1.2 - 1.7 0.9 0.9 None 0.7 - 1.2
LP 2.9 - 3.9 2.2 2.5 None 2.0 - 3.0

VR8205; VR4205 DIRECT IGNITION DUAL AUTOMATIC VALVE COMBINATION GAS CONTROLS
968-0049—03
Check Safety Lockout (Slow-opening
Controls Only)
1. With the system power off and the thermostat set to
call for heat, manually shut off the gas supply.
2. Energize ignitor control and start timing safety lockout
time. When spark ignition terminates, stop timing.
When using the VR8205H or VR4205H step-opening
control, the specified ignitor control safety lockout time
must exceed 8.5 seconds for system to function prop-
erly.
3. After spark cutoff, manually reopen gas control knob.
No gas should flow to the main burner.
4. Reset system by adjusting thermostat below room
temperature, waiting 30 seconds, and moving thermo-
stat setting up to call for heat. Normal ignition should
occur.
Check Safety Shutdown Performance
WARNING
Fire or explosion hazard. Can cause property damage,
severe injury, or death.
Perform the safely shutdown test any time work is
done on a gas system.
NOTE: Read steps 1-7 below before starting and compare
to the safety shutdown or safety lockout tests rec-
ommended for the direct ignition (DI) module. Where
they differ, use the procedure recommended for the
module.
1. Turn off gas supply.
2. Set thermostat or controller above room temperature to
call for heat.
3. Watch for ignition spark or for glow at hot surface
igniter either immediately or following prepurge. See DI
module specifications.
4. Time the length of the igniter operation. See DI module
specifications.
5. After the module locks out, open manual gas cock and
make sure no gas is flowing to the burner.
6. Set the thermostat below room temperature and wait
one minute.
7. Operate system through one complete cycle to make
sure all controls operate properly.
MAINTENANCE
Regular preventive maintenance is important in applications
that place a heavy load on systems 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, see Startup and Checkout section, and the
control system as described in the appliance manufacturer
literature.
Maintenance frequency must be determined individually for
each application. Some considerations are:
• Cycling frequency. Appliances that may cycle 20,000
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.
Gas valves exposed to high ammonia conditions; i.e., those
used in greenhouses or animal barns, may fail in one or two
years. Contact your sales representative to request a gas
valve with corrosion resistant construction.
The gas control should be replaced if:
• It does not perform properly on checkout or
troubleshooting.
• The gas control knob is hard to turn.
• The gas controls is likely to have operated for more than
200,000 cycles.
OPERATION
The VR8205;VR4205 gas controls provide ON-OFF manual
control of gas flow. In the OFF position, gas flow to the main
burner is mechanically blocked. In the ON position, gas flows
to the main burner under control of the thermostat, the direct
ignition (DI) module, and the two automatic main valves.
System Operation With Module
When the thermostat calls for heat, the DI module is
energized. The module activates the first and second
automatic valves of the gas control, which allow gas to flow
to the main burner. At the same time, the DI module
generates a spark at the igniter-sensor to light the main
burner.
The second automatic valve diaphragm, controlled by the
servo pressure regulator, opens and adjusts gas flow as long
as the system is powered. The servo pressure regulator
monitors outlet pressure to provide an even flow of gas to the
main burner. Loss of power (thermostat satisfied)
deenergizes the DI module and closes the automatic valves.
The system is ready to return to normal service when power
is restored through the thermostat.
If the igniter-sensor stops detecting a flame at the main
burner, the trial for ignition is restarted. On DI modules with
lockout timers, the automatic valves are de-energized and
ignition stops after the lockout period. On modules without
lockout timers, the trial for ignition continues indefinitely.
If main burner flame is restarted successfully, operation
continues as described above. Gas control operation is
described in more detail below.

VR8205; VR4205 DIRECT IGNITION DUAL AUTOMATIC VALVE COMBINATION GAS CONTROLS
68-0049—03 10
Valve Position During Thermostat Off
Cycle
The valve is positioned as shown in Fig. 10 when the:
• manual gas control knob is in the ON position.
• thermostat is not calling for heat.
The first automatic valve is closed. The second automatic
valve operator is de-energized, closing the channel to the
pressure regulator, and opening a channel to the underside of
the second automatic valve operator valve diaphragm.
The combination of spring pressure under the second
automatic valve diaphragm and lack of outlet pressure holds
the diaphragm firmly closed. Gas flow to the main burner is
blocked by both valves.
When Thermostat Calls For Heat
When the thermostat calls for heat, the DI module generates
a spark at the main burner and the first automatic valve and
second automatic valve operators are energized (Fig. 11).
The first automatic valve opens, and the second automatic
valve operator valve disc is lifted off its seat.
This diverts gas flow from the second 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
diaphragm downward, away from the valve seat, allowing gas
to flow to the main burner.
Standard Regulation
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 diaphragm and repositions the valve disc
closer to the seat. Thus, flow of gas through the second
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
second automatic valve diaphragm and repositions the valve
disc further from the seat. Thus, flow of gas through the
second automatic valve is increased. and outlet pressure
rises to the desired level.
Fig. 10. Position of gas control components during thermostat off cycle.
FIRST
AUTOMATIC
VALVE
SOLENOID
CONTROL
KNOB
GAS
CONTROL
INLET
SECOND AUTOMATIC
VALVE OPERATOR
SECOND
AUTOMATIC
OPERATOR
SOLENOID
SECOND
AUTOMATIC
OPERATOR
VALVE DISC
SERVO PRESSURE
REGULATOR
GAS
CONTROL
OUTLET
SECOND AUTOMATIC
VALVE DIAPHRAGM
FIRST AUTOMATIC VALVE
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. M9114B
1
1

VR8205; VR4205 DIRECT IGNITION DUAL AUTOMATIC VALVE COMBINATION GAS CONTROLS
11 68-0049—03
Slow-Opening Regulation
Slow-opening gas controls function the same as standard
models except that when the thermostat calls for heat, the
second automatic valve opens gradually. Opening is slowed
because a flow restructure in the passage from the second
automatic operator slows the rate at which gas pressure is
reduced under the second automatic valve diaphragm after
the second automatic operator opens. Outlet pressure to the
main burner increases gradually from 0 in. wc [0 kPa] to rated
output pressure within 3-6 seconds (for an 80,000 Btuh
furnace at 7 in. wc [1.8 kPa] inlet pressure and 3.5 in. wc
[0.9 kPa] outlet pressure).
Step-Opening Regulation
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 fully open
by the timing diaphragm, which is operated by bleed gas.
When the low pressure regulator is fully 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 reenergized within 60
seconds, it may bypass or shorten the length of the low
pressure step. The burner may relight at the full flow rate.
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.
Fig. 11. Position of gas control components during burner on cycle.
SERVICE
WARNING
Fire or explosion hazard. Can cause property damage,
severe injury, or death.
Do not disassemble the gas control; it contains no
replaceable components. Attempted disassembly or
repair may damage the control..
CAUTION
Do not apply a jumper across (or short) the valve coil
terminals, even temporarily. Doing so may burn out
the heat anticipator in the thermostat or damage the
DI module.
FIRST
AUTOMATIC
VALVE
SOLENOID
CONTROL
KNOB
GAS
CONTROL
INLET
SECOND AUTOMATIC
VALVE OPERATOR
SECOND
AUTOMATIC
OPERATOR
SOLENOID
SECOND
AUTOMATIC
OPERATOR
VALVE DISC
SERVO PRESSURE
REGULATOR
GAS
CONTROL
OUTLET
SECOND AUTOMATIC
VALVE DIAPHRAGM
FIRST AUTOMATIC VALVE
NOTE: SECOND 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. M9115A
1
1

VR8205; VR4205 DIRECT IGNITION DUAL AUTOMATIC VALVE COMBINATION GAS CONTROLS
© 2021 Resideo Technologies, Inc. All rights reserved.
This product is manufactured by Resideo Technologies, Inc. and its affiliates.
www.resideo.com
Resideo Technologies, Inc.
1985 Douglas Drive North, Golden Valley, MN 55422
1-800-468-1502
68-0049—03 M.S. Rev. 04-21 | Printed in United States
IMPORTANT:
Allow 60 seconds after shutdown before re-energiz-
ing step-opening model to assure lightoff at step
pressure.
If Main Burner Will Not Come On With
Call for Heat
1. Confirm that gas control knob is in the ON position.
2. Adjust thermostat several degrees above room tem-
perature.
3. Using ac voltmeter, measure voltage across MV termi-
nals at gas control.
4. If no voltage is present, check control circuit for proper
operation.
5. If proper control system voltage is present, replace gas
control.
Instructions to the Homeowner
For Your Safety, Read Before Lighting
WARNING
If you do not follow the warnings below and the
lighting instructions exactly, a fire or explosion can
result with property damage, personal injury or loss
of life.
1. Before lighting, smell around the appliance area for
gas. If the appliance uses LP (bottled) gas, be sure
to smell next to the floor because LP gas is heavier
than air. If you smell gas, immediately shut off the
manual valve in the gas piping to the appliance, or
on LP, at the tank. Do not try to light any appliance.
Do not touch any electrical switch or use the
phone. Leave the building and call your gas
supplier. If your gas supplier cannot be reached,
call the fire department.
2. Do not force the gas control knob on the appliance.
Use only your hand to turn the gas control knob.
Never use any tools. If the knob will not operate by
hand, replace the control using a qualified service
technician. Force or attempted repair can result in
fire or explosion.
3. The gas control must be replaced if it has been
flooded with water. Call a qualified service
technician.
4. The gas control is a safety device. It must be
replaced in case of any physical damage such as
bent terminals, missing or broken parts, stripped
threads, or evidence of exposure to heat.
IMPORTANT:
Follow the operating instructions provided by the
manufacturer of your heating appliance. The infor-
mation below will be of assistance in a typical con-
trol application, but the specific controls used and
the procedures outlined by the manufacturer of your
appliance may differ, requiring special instructions.
To Turn On Furnace
STOP: Read the safety information above.
1. The lighting sequence on this appliance is automatic;
do not attempt to manually light the main burner.
2. If the furnace does not come on when the thermostat is
set several degrees above room temperature, set the
thermostat to the bottom of its range to reset safety
control.
3. Remove burner access panel if provided on your appli-
ance.
4. Turn the gas control knob (Fig. 5) clockwise to OFF.
5. Wait five minutes to allow any gas in the combustion
chamber to vent. If you then smell gas in the appliance
area or near the floor in an LP installation, immediately
shut off the manual valve in the gas piping to the appli-
ance, or on LP, at the tank. Do not touch any electrical
switch or use the phone. Leave the building and call
your gas supplier. If your gas supplier cannot be
reached, call the fire department. Failure to do so may
result in fire or explosion.
6. If you don’t smell gas, turn knob on gas control coun-
terclockwise to ON.
7. Replace burner access panel.
8. Reset thermostat to desired temperature.
9. If burner does not come on when room temperature is
below thermostat setting, turn gas control knob to OFF
and contact a qualified service technician for assis-
tance.
To Turn Off Appliance
Turn gas control knob clockwise to OFF.