resideo VR8204A User manual

INSTALLATION INSTRUCTIONS
69-0423-04
VR8204A,M Intermittent Pilot
Combination Gas Control
APPLICATION
These intermittent pilot 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, a pressure regulator and a pilot
filter.
Ambient Temperature Range:
VR8204A: 0° F to 175° F [-18° C to 79° C].
VR8204M: -40° F to 175° F [-40° C to 79° C].
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 1. Flange kits include one
flange with attached O-ring, four mounting screws, a
9/64 in. hex wrench and instruction sheet.
Electrical Ratings:
Voltage and frequency: 24 Vac, 60 Hz.
Current draw: 0.5 A with both operators energized.
These gas 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 regulators can be converted from
one gas to the other with a conversion kit (order
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.
Approvals
American Gas Association Design Certificate: P-70-42A.
Canadian Gas Association Design Certificate:
1029-CC-6395 series.
Australian Gas Association Certificate: 4214.
NOTE: Elbow (angle) flanges cannot be used to pro-
vide a right hand inlet when the ECO connector
is used.
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. The installer must be a trained, experienced ser-
vice technician.
4. After installation is complete, use these instruc-
tions to check out product operation.
Table 1. Adapter (Flange) Part Numbers.
Inlet/Outlet Pipe
Size Flange Type Part Number
3/8 inch NPT Straight 393690-11
Elbowa393690-12
1/2 inch NPT Straight 393690-16
Elbowa393690-13
3/4 inch NPT Straight 393690-14
Elbowa393690-15

VR8204A,M INTERMITTENT PILOT COMBINATION GAS CONTROL
69-0423—04 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. Do not bend pilot tubing at control or pilot after
compression nut has been tightened, or 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, call a qualified service
technician to replace the gas control. Force or
attempted repair can 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 intermittent pilot (IP) 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’s instructions if
available; otherwise, use the instructions provided on
page 2 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 and pilot 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 regulators can be converted from
one gas to the other with a conversion kit (order
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.
Install Adapters to Gas 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 the flange. If the O-ring is not attached or
missing, do not use flange.
4. With O-ring facing control, line up 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 gas control inlet or outlet.
2. Apply moderate amount of good quality pipe com-
pound to bushing, leaving two end threads bare. On
LP installations, use compound resistant to LP
gas. Do NOT use Teflon tape.
3. Insert bushings in control and thread pipe carefully
into bushing until tight.
Fig. 1. Fasten flange to valve firmly, but do not
overtighten screws.
Complete installation below for piping, installing control,
connecting pilot tubing 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 the
control.
Location
Do not locate the combination gas control where adverse
environments such as steam cleaning, high humidity or
dripping water, corrosive chemicals, dust or grease
accumulation, or excessive heat are prevalent.
To ensure proper operation, follow these guidelines:
• Locate in a well ventilated area.
• Mount high enough above the cabinet bottom to avoid
exposure to flooding or splashing water.
• Ensure that the ambient temperature does not exceed
the ambient temperature ratings for each component.
• Cover if appliance is cleaned with water, steam, or
chemicals or to avoid dust and grease accumulation.
• Avoid locating where exposure to corrosive chemical
fumes or dripping water is likely.
Mount the combination gas control in the appliance
vestibule on the gas manifold. If this is a replacement
application, mount the control in same location as old
control.
M4602
VALVE OUTLET
FLANGE
9/64 INCH HEX SCREWS (4)

VR8204A,M INTERMITTENT PILOT COMBINATION GAS CONTROL
369-0423—04
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, 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 Gas Control
1. This control can be mounted 0-90 degrees, in any
direction, from the upright position of the gas con-
trol 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 the amount shown in Table 2 for inser-
tion into control of adapter. DO NOT THREAD PIPE
TOO FAR. Valve distortion or malfunction may
result if the pipe is inserted too deeply.
Fig. 2. Install sediment trap.
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. Refer to Fig. 3.
Fig. 3. Use moderate amount of pipe compound.
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 a
flange is used, place wrench on flange rather than
on gas control. Refer to Fig. 4 and 5.
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
M3077C
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 2. 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).
M3075D
PIPE

VR8204A,M INTERMITTENT PILOT COMBINATION GAS CONTROL
69-0423—04 4
Fig. 5. Proper use of wrench on gas control with and without adapters.
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
control after compression nut 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 brass compression fitting from the pilot
outlet (Fig. 4). Slip the fitting over the tubing and
slide out of the way.
NOTE: When replacing a control, cut off old compres-
sion fitting and replace with the compression
fitting provided on the combination gas control.
Never use the old compression fitting as it may
not provide a gas-tight seal. Refer to Fig. 6.
Fig. 6. Always use new compression fittings.
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 fitting into place and
engage threads—turn until finger tight. Then
tighten one more turn with wrench. Do not over-
tighten.
5. Connect other end of tubing to pilot burner accord-
ing to pilot burner manufacturer’s instructions.
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 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 gas control
and make sure it matches the available supply.
Install thermostat and other controls as required.
2. Connect control circuit to gas control terminals.
See Fig. 5 and 7.
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
M2914A
GAS CONTROL
TIGHTEN NUT ONE TURN
BEYOND FINGER-TIGHT. TO PILOT
BURNER
FITTING BREAKS OFF AND CLINCHES
TUBING AS NUT IS TIGHTENED. M3076B

VR8204A,M INTERMITTENT PILOT COMBINATION GAS CONTROL
569-0423—04
Fig. 7. Wiring connections for 24 volt control in intermittent ignition system with S86.
STARTUP AND CHECKOUT
WARNING
Fire or Explosion Hazard
Can cause property damage, severe injury, or
death.
1. Do not force the gas control knob. Use only
your hand to turn the gas control knob. Never
use any tools.
2. If the gas control knob will not operate by hand,
call a qualified service technician to replace
the gas control.
Gas Control Knob Settings
The gas control knob settings are as follows:
OFF prevents pilot and main gas flow through the control.
ON permits gas to flow into the control body. Under
control of the thermostat and intermittent pilot module,
gas can flow to the pilot and main burners.
NOTE: Controls are shipped with the gas control knob
in the ON position.
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.
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 module.
Gas Leak Test
1. Paint pipe connections upstream of gas control
with rich If a gas leak is detected, tighten the pipe
connection.
2. If leak is detected, tighten pipe connections.
3. Stand clear of main burner while lighting to prevent
injury caused from hidden leaks which could cause
flashback in the appliance vestibule. Light main
burner.
4. With main burner in operation, pain 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 can’t be stopped.
2
S86 MODULE
24V
(1) (GND)
MV
GND
(BURNER)
PILOT GAS
SUPPLY
PILOT BURNER
GROUND
Q345, Q346, Q348,
Q362, Q381
PILOT BURNER/
IGNITER-SENSOR
THERMOSTAT
OR CONTROLLER
PV/MV
PV
MV
PV/MV
PV
L1
(HOT)
(HOT)
L2
1
4
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
MAXIMUM CABLE LENGTH 3 FT (0.9M).
CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER.
2
3
4
1
LIMIT
CONTROLLER
AIR PROVING
SWITCH
COMBUSTION
AIR BLOWER
MOTOR
L2
L1
3
M18851
24V (2)
GAS CONTROL
TERMINALS
COMBUSTION
AIR BLOWER
RELAY

VR8204A,M INTERMITTENT PILOT COMBINATION GAS CONTROL
69-0423—04 6
Adjust Pilot Flame
The pilot flame should envelop 3/8 to 1/2 in. [10 to
13 mm] of the tip of the igniter-sensor. See Fig. 8.
1. Remove pilot adjustment screw clockwise to
decrease or counterclockwise to increase
pilot flame.
2. Replace cover screw after adjustment to prevent
gas leakage.
Fig. 8. Proper flame adjustment.
Check and Adjust Gas Input to Main Burner
CAUTION
1. Do not exceed the input rating stamped on the
appliance nameplate, or manufacturer
recommended burner orifice pressure for the
size orifice(s) used. Make certain the primary
air supply to the main burner is properly
adjusted for complete combustion (refer to the
appliance manufacturer instructions).
2. IF CHECKING GAS INPUT BY CLOCKING THE
GAS METER:
• Make sure that the only gas flow through the
meter is that of the appliance being checked.
• Other appliances must remain off with their
pilots extinguished (or their consumption
must be deducted from the meter reading).
• Convert the flow rate to Btuh as described in
form 70-2602, Gas Controls Handbook, and
compare to the Btuh input rating on the
appliance nameplate.
3. IF CHECKING GAS INPUT WITH A MANOMETER
(PRESSURE GAUGE):
• Make certain 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 using the meter clocking method or pressure
using a manometer connected to the outlet pres-
sure tap on the gas control. Refer to Fig. 4.
3. If necessary, adjust pressure regulator to match
appliance rating. Refer Table 3 for factory set nom-
inal outlet pressure and adjustment range.
a. Remove the pressure regulator adjustment cap
and screw.
b. Using a screwdriver, turn the inner adjustment
screw clockwise to increase or counter-
clockwise to decrease the main burner
gas pressure.
c. Always replace the cap screw and tighten
firmly to safeguard proper operation.
4. If desired outlet pressure or flow rate cannot be
achieved by adjusting the control, check the con-
trol inlet pressure using a manometer at the inlet
pressure tap. If inlet pressure is in normal range
(refer to Table 3), replace the control. Otherwise,
take the necessary steps to provide proper gas
pressure on the control.
Check Safety Shutdown Performance
WARNING
Fire or Explosion Hazard
Can cause property damage, severe injury, or
death.
Perform the safety shutdown test anytime 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 intermittent pilot
(IP) module. Where they differ, use the proce-
dure recommended for the module.
1. Turn off gas supply.
2. Set the thermostat or controller above room tem-
perature to call for heat.
3. Watch for spark at pilot burner either immediately
or following prepurge. See IP module specifica-
tions.
4. If module has timed ignition, time length of spark
operation. See IP module specifications.
5. After the module locks out, open manual gas con-
trol knob and make sure no gas is flowing to pilot
or main burner.
With modules that continue spark until pilot lights
or system is shut down manually, pilot should light
when manual gas control knob is opened.
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.
PROPER FLAME
ADJUSTMENT
IGNITER-
SENSOR
M3080A
3/8 TO 1/2 INCH
(10 TO 13 mm)

VR8204A,M INTERMITTENT PILOT COMBINATION GAS CONTROL
769-0423—04
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. Attempts 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 electronic module.
If Main Burner Will not Come On with Call
for Heat
1. Confirm that the gas control knob is in the ON posi-
tion.
2. Adjust the thermostat several degrees above room
temperature.
3. Using ac voltmeter, check for 24 V at gas control.
• If pilot lights, measure across MV/PV and MV.
• If pilot does not light, measure across MV/PV
and PV before safety lockout occurs.
4. If voltage is incorrect or not present, check control
circuit for proper operation.
5. If 24 V 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 the warnings below and the lighting
instructions exactly.
1. Before lighting, smell all around the appliance
area for gas. If the appliance uses LP (Bottled
gas, also 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. Don’t 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, the control should be
replaced by a qualified service technician.
Force or attempted repair may 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
manufacturer of you 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, requiring
special instructions.
Table 3. Pressure Regulator Specification Pressures in Inches WC.
Model Type of Gas
Nominal Inlet
Pressure Range
Outlet Pressure
Nominal Factory Outlet Setting Adjustment Setting Range
Step Full Rate Step Full Rate
Standard Natural 5.0 - 7.0 — 3.5 — 3.0 - 5.0
LP 12.0 - 14.0 — 10.0 — 8.0 - 12.0
Table 4. Pressure Regulator Specification Pressures in kPa.
Model Type of Gas
Nominal Inlet
Pressure Range
Outlet Pressure
Nominal Factory Outlet Setting Adjustment Setting Range
Step Full Rate Step Full Rate
Standard Natural 1.2 - 1.7 — 0.9 — 0.7 - 1.2
LP 2.9 - 3.9 — 2.7 — 2.0 - 3.0

VR8204A,M INTERMITTENT PILOT COMBINATION GAS CONTROL
© 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
69-0423—04 M.S. Rev. 06-20 | Printed in United States
TO TURN ON FURNACE
STOP: Read the Warnings Above
1. The lighting sequence on this appliance is auto-
matic; DO NOT ATTEMPT TO MANUALLY LIGHT
THE PILOT.
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 the burner access panel if provided on
your appliance.
4. Turn the gas valve 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 in an LP installa-
tion, immediately shut off the manual valve in the
gas piping to the appliance or, ON LP, AT THE
TANK. Don’t touch any electrical switch or use the
phone. Do not try to light any appliance. 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
counterclockwise to ON.
7. Replace burner access panel.
8. Reset thermostat to desired temperature.
9. If appliance will not operate, turn the gas control
knob to OFF and contact a qualified service tech-
nician for assistance.
Turning Off the Appliance
Turn gas control knob clockwise to OFF.