resideo VR4205 User manual

INSTALLATION INSTRUCTIONS
69-0694-02
VR4205 Direct Ignition Combination
Gas Controls
APPLICATION
These direct ignition gas controls are used in gas-fired
appliances with up to 200 cfh capacity on natural gas.
They include safety shutoff, a manual valve, two
automatic operators, pressure regulator, pilot
adjustment and a conduit cover. See Table 1 for
temperature ranges and regulator types.
BODY PATTERN: Straight through with 1/2 in. inlet and
1/2 in. outlet.
PIPE ADAPTERS: Angle and straight adapters available
for 3/8, 1/2 and 3/4 in. pipe. See Table 2. Flange kits
include one flange with attached O-ring, four mount-
ing screws, a 9/64 in. hex wrench and Instructions.
ELECTRICAL RATINGS:
Voltage and Frequency: 120 Vac, 60 Hz.
Thermostat Heat Anticipator Setting: 0.1A
Current Draw: 0.1A
These gas controls are factory-set for natural (and
manufactured) gas or LP gas. Do not attempt to use a
control set for natural (manufactured) gas on LP gas, or
a control set for LP on natural (manufactured) 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 (manufactured) to LP
gas; order part no. 394588 to convert from LP gas to
natural (manufactured) gas. Controls with step opening
regulators cannot be converted.
NOTE: Flange Kits include one flange with attached O-
ring and four mounting screws.
APPROVALS:
American Gas Association design certificate:
UP-70-57A.
Canadian Gas Association design certificate:
1029-CC-8375.
Australian Gas Association certificate: 4214.
Approved for Delta C applications.
INSTALLATION
When Installing This Product...
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a haz-
ardous 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
technician.
4. After installation is complete, check out product
operation as provided in these instructions.
Table 1. Model Number Suffix Letter Designation
Model No.
Suffix
Letter
Ambient
Temperature Range Regulator Type
H0° F to 175° F
[-18°C to 79°C]
Slow-opening
M-40° F to 175° F
[-40° C to 79° C]
Standard
P Step-opening
Table 2. Adapter (Flange) Part Numbers
Inlet/Outlet
Pipe Size
Flange
Type
Part No.
Without 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

VR4205 DIRECT IGNITION COMBINATION GAS CONTROLS
69-0694—02 2
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 knob will not operate by
hand, replace the control using a qualified
service technician. Force or attempted repair
may result in fire or explosion.
CAUTION
1. 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.
2. When a gas control is installed external to the
appliance, a conduit cover must be installed.
IMPORTANT:
1. These gas controls are shipped with protective
seals over inlet and outlet tappings. Do not
remove seals until ready to connect piping.
2. When a gas control is installed external to the
appliance, a conduit cover MUST be installed.
Make sure that conduit cover is placed over the
flange before rotating the conduit cover into
position.
Follow the appliance manufacturer’s instructions if
available; otherwise, use the instructions below as a
guide.
CONVERTING CONTROL FROM NATURAL
GAS TO LP GAS APPLICATION (OR LP GAS
TO NATURAL GAS APPLICATION)
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY OR DEATH
Always change the main burner orifices when
converting from natural to LP gas or from LP to
natural gas. Follow appliance manufacturer’s
specifications and instructions. Controls are
factory-set for natural (and manufactured) or LP
gas. Do not attempt to use a control set for
natural (manufactured) gas on LP gas, or a
control set for LP on natural (manufactured) 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 (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:
Flanges
1. Choose the appropriate flange for your application.
2. Remove seal over control inlet or outlet.
3. Check to ensure that 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. 1. 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 con-
trol 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.
Fig. 1. Firmly fasten flange to valve, but do not
overtighten screws.
LOCATION
The combination gas control is mounted in the appliance
vestible on the gas manifold. If this is a replacement
application, mount the gas control in the same location
as the old control.
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 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 to avoid dust and grease
accumulation.
• Avoid locating gas control where exposure to
corrosive chemical fumes or dripping water are likely.
M3100A
VALVE OUTLET
FLANGE
9/64 INCH HEX SCREWS (4)
6/32 INCH ROUND
SCREWS (1)
CONDUIT
COVER

VR4205 DIRECT IGNITION COMBINATION GAS CONTROLS
369-0694—02
Install Piping to 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, make sure the ends are square,
deburred and clean. All tubing bends must be
smooth and without deformation.
2. Run pipe or tubing to the control. If tubing is used,
obtain a tube-to-pipe coupling to connect the tub-
ing to the control.
3. Install sediment trap in the supply line to the gas
control. See Fig. 2.
Install Control
1. This control can be mounted 0-90 degrees, in any
direction including vertically, from the upright posi-
tion of the gas control knob.
2. Mount the control so gas flow is in the direction of
the arrow on the bottom of the control.
3. Thread pipe the amount shown in Table 3 for inser-
tion into control. Do not thread pipe too far. Valve
distortion or malfunction may result if the pipe is
inserted too deeply.
Fig. 2. Sediment trap installation.
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. See Fig. 3.
5. Remove seals over control inlet and outlet if neces-
sary.
6. Connect pipe to control inlet and outlet. Use
wrench on the square ends of the control. If a
flange is used, place wrench on the flange rather
than on the control. Refer to Figs. 4 and 5.
Fig. 3. Use moderate amount of pipe compound.
Fig. 4. Top view of gas control.
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
M3077B
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 3. 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).
M3075C
PIPE
OUTLET
PRESSURE
TAP
INLET OUTLET
WIRING
TERMINALS (2)
INLET
PRESSURE TAP
PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)
GAS CONTROL KNOB
M3094A

VR4205 DIRECT IGNITION COMBINATION GAS CONTROLS
69-0694—02 4
Fig. 5. 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’s, follow the appliance
manufacturer’s instructions.
All wiring must comply with applicable electrical codes
and ordinances, including insulated quick connect
terminals.
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
transformer, thermostat, and other controls as
required.
2. 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. Connect control circuit to gas control terminals.
See Figs. 4 and 6.
NOTE: Use leadwires with insulated terminals.
4. Make sure conduit cover is in position and secured
to the gas valve with the screw provided. See Fig. 1.
5. Adjust thermostat heat anticipator as instructed in
appliance manual (i.e., usually 0.1A). Fig. 6. Wiring connections for 120 volt control in direct
ignition system.
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
M3084
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.
M3090A
BURNER
120V
VR4205
DUAL VALVE
COMBINATION
GAS CONTROL
L2
L1
21
1
2

VR4205 DIRECT IGNITION COMBINATION GAS CONTROLS
569-0694—02
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, replace the
control using 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 mod-
ule, 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
(including 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.
CHECK AND ADJUST GAS INPUT AND
BURNER IGNITION
CAUTION
1. Do not exceed input rating stamped on
appliance nameplate, or manufacturer’s
recommended burner orifice pressure for size
orifice(s) used. Make certain primary air supply
to main burner is properly adjusted for
complete combustion. Follow instructions of
appliance manufacturer.
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 PILOT position before
removing outlet pressure tap plug to connect
manometer (pressure gauge). Also turn gas
control knob back to PILOT 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 appli-
ance nameplate. Gas control outlet pressure
should match the nameplate.
2. With main burner operating, check gas control flow
rate by using the meter clocking method or check
pressure by using a manometer connected to the
outlet pressure tap on the gas control. See Fig. 4.
3. If necessary, adjust pressure regulator to match
appliance rating. See Tables 4 and 5 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
prevent gas leakage.
4. If desired outlet pressure or flow rate cannot be
achieved by adjusting the gas control, check gas
control inlet pressure by using a manometer at the
gas control inlet pressure tap. If inlet pressure is in
the normal range (see Tables 4 and 5), replace gas
control. Otherwise, take the necessary steps to
provide proper gas pressure on the control.

VR4205 DIRECT IGNITION COMBINATION GAS CONTROLS
69-0694—02 6
Slow-opening and Step-opening Pressure
Regulators
1. Check the full rate manifold pressure listed on the
appliance nameplate. Gas control full rate outlet
pressure should match this rating.
2. With main burner operating, check gas control flow
rate by using the meter clocking method or check
pressure by using a manometer connected to the
outlet pressure tap on the gas control. See Fig. 4.
3. If necessary, adjust pressure regulator to match
appliance rating. See Tables 4 and 5 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
prevent gas leakage.
4. If desired outlet pressure or flow rate cannot be
achieved by adjusting the gas control, check gas
control inlet pressure by using a manometer at the
gas control inlet pressure tap. If inlet pressure is in
the normal range (see Tables 4 and 5), replace gas
control. Otherwise, take the necessary steps to
provide proper gas pressure to the control.
5. STEP-OPENING PRESSURE REGULATORS ONLY.
Carefully 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 allowing burner to cool.
Readjust full rate outlet pressure, if necessary, to
improve lightoff characteristics.
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 VR4205H slow-opening
control, the specified igniter control safety lockout
time must exceed 8.5 seconds for system to func-
tion properly.
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 up
thermostat setting 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 safety shutdown test any time work
is done on a gas system.
NOTE: Read steps 1-7 below before starting and com-
pare to the safety shutdown or safety lockout
tests recommended for the direct ignition (DI)
module. When they differ, use the procedure
recommended for the module.
1. Turn off gas supply.
2. Set thermostat or controller above room tempera-
ture 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 length of igniter operation. See DI module
specifications.
5. After the module locks out, open manual gas cock
and make sure no gas is flowing to burner.
6. Set thermostat below room temperature and wait
one minute.
7. Operate system through one complete cycle to
make sure all controls operate properly.
Table 4. Pressure Regulator Specification Pressures in in. wc.
Model Type Type of Gas
Nominal Inlet
Pressure Range
Factory Set Nominal Outlet
Pressure Adjustment Setting Range
Step Full Rate Step Full Rate
Standard, slow Natural 5.0-7.0 -- 3.5 -- 3-5
LP 12.0-14.0 -- 10.0 -- 8-12
Step Natural 5.0-7.0 0.9 3.5 None 3-5
LP 12.0-14.0 2.2 10.0 None 8-12
Table 5. Pressure Regulator Specification Pressures in kPa.
Model Type Type of Gas
Nominal Inlet
Pressure Range
Factory Set Nominal Outlet
Pressure Adjustment Setting Range
Step Full Rate Step Full Rate
Standard, slow Natural 1.2-1.7 -- 0.9 -- 0.7-1.2
LP 2.9-3.9 -- 2.5 -- 2-3
Step Natural 1.2-1.7 0.2 0.9 None 0.7-1.2
LP 2.9-3.9 0.5 2.5 None 2-3

VR4205 DIRECT IGNITION COMBINATION GAS CONTROLS
769-0694—02
SERVICE
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY OR DEATH
Do not take this control apart; it contains no
replaceable components. Attempted disassembly
or repair can 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 module.
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
temperature.
3. Using ac voltmeter, measure voltage across L1 and
L2 terminals 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 OPERATING
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY OR DEATH
Follow these warnings exactly:
1. Main burner is lit automatically. Do not
manually light.
2. Before lighting main burner, 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, replace the gas
control using 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.
IMPORTANT:
Follow the operating instructions provided by
the manufacturer of your heating appliance. The
information below will be of assistance in a typ-
ical control application, but the specific controls
used and the procedures outlined by the manu-
facturer of your appliance may differ, and
require special instructions.
TO TURN ON FURNACE
STOP: READ THE SAFETY WARNING INFORMATION
ABOVE.
1. The lighting sequence on this appliance is auto-
matic; DO NOT ATTEMPT TO MANUALLY LIGHT
THE MAIN BURNER.
2. If the furnace does not come on when the thermo-
stat is set several degrees above room tempera-
ture, set the thermostat to the bottom of its range
to reset safety control.
3. Remove burner access panel if provided on your
appliance.
4. Turn the gas control knob (Fig. 4) clockwise to OFF.
5. Wait five minutes to allow any gas in the combus-
tion chamber to vent. If you then smell gas in the
appliance area or near the floor for an LP installa-
tion, immediately shut off the manual valve in the
gas piping to the appliance 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 do not smell gas, turn knob on gas control
counterclockwise to ON.
7. Replace burner access panel.
8. Reset thermostat to desired temperature.
9. If burner does not come on when room tempera-
ture is below thermostat setting, turn gas control
knob to OFF and contact a qualified service techni-
cian for assistance.
TO TURN OFF APPLIANCE
Turn gas control knob clockwise to OFF.

VR4205 DIRECT IGNITION COMBINATION GAS CONTROLS
© 2020 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
69-0694—02 M.S. Rev. 04-20 | Printed in United States