Installation Guide for Honeywell models including: CS8510, VS8520 Milivolt Gas Valce
Read these instructions carefully. Failure to follow them could damage the product or cause a hazard- ous condition. 2. Check the ratings given in the ...
69-1172 - VS8510, VS8520 Millivolt Gas Valve
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This is a legacy product document supported by Resideo. It is no longer manufactured VS8510, VS8520 Millivolt Gas Valve INSTALLATION INSTRUCTIONS APPLICATION INSTALLATION E The VS8510, VS8520 Millivolt Gas Valves are compact and have a 60,000 Btuh capacity (1 in. pressure drop for straight-through configuration). The design makes it ideal for fireplace and space heating applications. T The TRADELINE® models VS8510, VS8520 Millivolt Gas Valves have added piping versatility. The installer can carry a single valve model. This one model allows piping the inlet, outlet, and pilot through the bottom or side. Plugs E are provided to plug the unused tappings. 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 technician. 4. After installation is complete, check out product operation as provided in these instructions. SPECIFICATIONS WARNING Main Gas Connection: L Valve: 3/8 in. NPT thread. Pilot Gas Connection and Flow: Connection Size: 7/16-24 UNS. Flow: 1700 Btuh at 4.0 in. wc pressure drop. Thermocouple and Pilot Threads: OWARNING Metric and UNS. Ambient Temperature Range: 0°F to 175°F (-18°C to 79°C). Option for 225°F (107°C). Pressure Regulation: S Servo regulator with adjustable outlet pressure. Natural Gas: 3.5 in. wc. LP Gas: 11 in. wc. Regulator Adjustments: Natural Gas: 3 in. to 5 in. field adjustable. B LP Gas: 8 in. to 12 in. field adjustable. Voltage: VS8510: 750 mV operator. VS8520: 750 mV operator, 30 mV thermocouple. OApprovals: Oxygen Depletion Hazard. Improper ventilation can cause injury or death due to asphyxiation. Use only vented gas valve models on vented appliances. Use only unvented gas valve models on unvented appliances. Fire or Explosion Hazard. Can cause property damage, severe injury or death. Follow these warnings exactly: 1. To avoid dangerous accumulation of fuel gas, turn off gas supply at the appliance service valve before starting installation, and perform a Gas Leak Test after the installation is complete. 2. Always install the sediment trap in the gas supply line to prevent contamination of the gas control. 3. 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 does not operate by hand, the gas control should be replaced by a qualified service technician. Force or attempted repair can result in fire or explosion. International Approval Services (IAS) Certificate: C2030022. European Community (CE) Certificate: Applied for. ®U.S. Registered Trademark Copyright © 1999 Honeywell Inc. · All Rights Reserved X-XX UL 69-1172-3 VS8510, VS8520 MILLIVOLT GAS VALVE CAUTION · Ensure the ambient temperature does not exceed the ambient temperature ratings for each component. Equipment Damage or Electrical Shock Hazard. Can short equipment circuitry or shock individuals. Disconnect power supply before installation. · Cover gas control when cleaning appliance with water, steam, or chemicals to avoid dust and grease accumulation. · Avoid placing gas control in a location with possible exposure to corrosive chemical fumes or dripping CAUTION Equipment Damage. Can burn out heat anticipator in thermostat. Never apply a jumper across or short the valve coil terminals. IMPORTANT These gas controls are shipped with protective seals over all inlet and outlet tappings. Do not remove the seals until ready to connect the piping. Follow the appliance manufacturer instructions, if available; otherwise, use these instructions. 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 water. Install Piping to Gas Control All piping must comply with local codes and ordinances and with the National Fuel Gas code (ANSI Z223.1 NFPA No. 54). Tubing installation must comply with approved standards and practices. E 1. Use new, properly reamed pipe free from chips. When using tubing, ensure that the ends are square, deburred and clean. All tubing bends must be smooth and without deformation. 2. Run pipe or tubing to the control. Tubing requires a tube-to-pipe coupling to connect the tubing to the T control. 3. Install sediment trap in the supply line to the gas control. See Fig. 1. Select Desired Pipe Connections E The TRADELINE VS8510 and VS8520 Valves include two tapped control inlets, two tapped control outlets, and two tapped pilot locations (see Fig. 2). This provides the option of piping the valve inlet, outlet, and pilot through the bottom or side. Plugs are provided to plug the unused Ltappings. Before piping the valve, determine the necessary gas on a natural gas system. 2. When making a conversion, be sure the main pilot burner orifices are changed to meet the WARNING appliance manufacturer specifications. Refer to the appliance manufacturer instructions for orifice specifications and changeover procedure. Gas controls O are factory-set for natural (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. VS8510A and VS8520A gas controls with a standard S regulator can be converted from one gas to the other with a conversion kit (ordered separately). Order part no. 395991 to convert from natural (manufactured) to LP gas. Order part no. 395992 to convert from LP to natural B (manufactured) gas. piping configuration. Fire or Explosion Hazard. Can cause property damage, severe injury or death. 1-inlet, 1-outlet and 1-pilot port must be plugged with the plugs provided. Plug Unused Pipe Connections 1. Apply a moderate amount of good quality pipe compound (do not use Teflon tape) to plugs, leaving two end threads bare (see Fig. 3). On LP Gas installations, use compound resistant to LP gas. 2. Remove seals from unused inlet, outlet, and pilot, if necessary. 3. Connect plugs to unused inlet and outlet using an Allen wrench. OVS8510E and VS8520E gas controls with a Convertible High/Low regulator can be converted from one gas to the other with a conversion kit (ordered separately). Order part no. 396087-1 to convert from LP to natural (manufactured) gas. Order part no. 396087-2 to convert from natural (manufactured) to LP gas. High/Low regulator models VS8510D and VS8520D NOTE: Torque the inlet and outlet plugs to 150 lb-in. 4. Connect plug to unused pilot using a wrench. NOTE: Torque the pilot plug to 30 lb-in. or 1/4 turn past finger-tight. cannot be converted. Location Locate the combination gas control where it cannot 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: · Locate gas control in a well-ventilated area. · Mount gas control high enough to avoid exposure to flooding or splashing water. Install Control 1. Mount control 0 to 90 degrees relative to the upright position of the gas control knob. 2. Mount the control so gas flow is in the direction of the arrow on the side of the control. 3. Thread pipe 9/16 in. into the control. 4. Apply a moderate amount of good quality pipe compound (do not use Teflon tape) to pipe only, leaving two end threads bare (see Fig. 3). On LP gas installations, use compound resistant to LP gas. 69-1172--3 2 VS8510, VS8520 MILLIVOLT GAS VALVE 5. Remove seals from control inlet and outlet, if necessary. SIDE INLET 6. Connect pipe to control inlet and outlet. Use a wrench on either side of the pipe outlet (see Fig. 4). BOTTOM INLET 1 PILOT PILOT DROP 1 HORIZONTAL PIPED GAS GAS CONTROL SUPPLY 3 INCHES (76 MM) MINIMUM GAS CONTROL DROP HORIZONTAL 1 TUBING GAS SUPPLY RISER 3 INCHES (76 MM) MINIMUM GAS CONTROL RISER PIPED GAS SUPPLY 3 INCHES (76 MM) MINIMUM CAUTION GAS LEAKAGE HAZARD E SIDE OUTLET BOTTOM OUTLET 1 T 1 ALL UNUSED CONNECTIONS MUST BE PLUGGED. Fig. 2. Piping and plugging TRADELINE VS8510 and VS8520. M12769A E TWO IMPERFECT THREADS GAS CONTROL LPIPE 1 FAILURE TO FOLLOW PRECAUTIONS CAN RESULT IN A GAS-FILLED WORK AREA. SHUT OFF THE MAIN GAS SUPPLY BEFORE REMOVING END CAP. TEST FOR GAS LEAKAGE WHEN INSTALLATION IS COMPLETE. ALL BENDS IN METALLIC TUBING SHOULD BE SMOOTH. Fig. 1. Sediment trap installation. M4603A THREAD PIPE ACCORDING TO INSTALLATION PROCEDURE FOR INSERTION INTO GAS CONTROL. APPLY A MODERATE AMOUNT OF PIPE COMPOUND TO PIPE ONLY (LEAVE TWO END THREADS BARE). M6913 Fig. 3. Use moderate amount of pipe compound. SO APPLY WRENCH BFROM BOTTOM OF GAS CONTROL TO O SHADED AREA M6916 Fig. 4. Proper use of wrench on gas control. 3 69-1172--3 VS8510, VS8520 MILLIVOLT GAS VALVE Wiring MILLIVOLT Follow the wiring instructions furnished by the appliance THERMOSTAT manufacturer, if available, or use the general instructions provided below. Where these instructions differ from the appliance manufacturer, follow the appliance manufacturer instructions. For typical wiring diagrams, see Fig. 5 and 6. HIGH LIMIT 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. 2. Install the transformer, thermostat, and other controls, as required. This valve can only be used in a self-generating system. 3. Adjust the thermostat heat anticipator to the 0.1A at 750 mV rating stamped on the valve operator. OPERATION The Millivolt Gas Valve System has two configurations. The first configuration includes a gas valve, quick drop-out thermocouple, thermopile, millivolt thermostat and a pilot burner. In this configuration, the thermopile drives the operator and the quick dropout thermocouple operates the power unit. See Fig. 5. The second configuration includes a gas valve, thermopile, millivolt thermostat, and a pilot burner. The thermopile drives the operator and the power CONTROL Q313 THERMOPILE VS8510 HI/LO MILLIVOLT GAS VALVE E HI PILOT LO ON OFF T HI/LO REGULATOR GAS CONTROL KNOB PILOT ADJUSTMENT SCREW M6918 EFig. 6. Millivolt system wiring diagram without quick drop-out thermocouple. LPilot Gas Lighting Procedure unit. See Fig. 6. As an option, a piezo can be mounted on the valve to ignite the pilot burner. The piezo creates a spark when the plunger is depressed. The connecting wires of the piezo include a terminal to connect to the electrode of the pilot burner. The piezo is replaceable. O MILLIVOLT THERMOSTAT TARGET Q313 THERMOPILE QUICK DROP-OUT THERMOCOUPLE S HIGH LIMIT BCONTROL ELECTRODE Lighting Standard Pilot (Without Piezo) 1. Turn the knob counterclockwise to the PILOT position, push the knob down, and hold it in position. The pilot valve opens and allows gas to flow to the pilot burner. 2. Light the pilot burner while holding down the knob until a strong flame is present (approximately 60 seconds). 3. Release the knob. The shaft moves upward and engages the safety valve lever that opens the safety valve. 4. Turn the knob counterclockwise to the ON position. On a call-for-heat, the main valve opens and the main burner ignites. Lighting Pilot with Piezo 1. Turn the knob counterclockwise to PILOT position, push the knob down, and hold in position. LO ON OFF OHI The pilot valve opens and allows gas to flow to the VS8520 HI/LO MILLIVOLT GAS VALVE pilot burner. 2. Push the plunger on the piezo until the pilot burner lights. Hold the knob down until a strong flame is present (approximately 60 seconds). PILOT 3. Release the knob. The shaft will move upward and engage the safety valve lever that opens the safety valve. 4. Turn the knob counterclockwise to the ON position. On a call-for-heat, the main valve opens and the main burner ignites. HI/LO REGULATOR GAS CONTROL KNOB PILOT ADJUSTMENT SCREW M6917A Fig. 5. Millivolt system wiring diagram with quick drop-out thermocouple 69-1172--3 4 VS8510, VS8520 MILLIVOLT GAS VALVE Shutoff Procedure 1. To shut off the system, turn the knob clockwise to the OFF position. This action closes the main gas and safety valves. However, the power unit must drop out before the lighting sequence can begin again. The VS8510 drops out within three minutes. The VS8520 drops out within 30 seconds. 2. To relight the pilot light, follow the steps in the Pilot Gas Lighting Procedure section. HI/LO Regulator As you turn the HI/LO knob (see Fig. 7 for knob location), the gas pressure changes. 1. Turn the knob clockwise toward the HI setting to increase gas pressure. 2. Turn the knob counterclockwise toward the LO setting to decrease gas pressure. Minimum and maximum regulator settings vary for each gas valve. See the gas valve label for actual minimum and maximum ranges. Table 1 lists available regulator ranges for the V8510 and V8520 TRADELINE Gas Valves. WIRING TERMINALS INLET PRESSURE TAP PILOT ADJUSTMENT SCREW Standard Pressure Regulator 1. Check the manifold pressure listed on the appliance nameplate. Gas control outlet pressure should match the nameplate. 2. With the main burner operating, check the gas control flow rate. Use either the meter clocking method or a manometer. When using a manometer: attach a plastic tube with a 1/4 in. shell ID to the manometer and connect the manometer to the outlet pressure tap on the gas control (see Fig. 8). 3. If necessary, adjust the pressure regulator to match the appliance rating. See Table 1 for regulator adjustment ranges. a. Remove pressure regulator adjustment cap E screw. b. Using a screwdriver, turn inner adjustment screw clockwise to increase or counter- clockwise to decrease gas pressure to burner. c. Always replace cap screw and tighten firmly to T prevent gas leakage. 4. If desired outlet pressure or flow rate cannot be achieved by adjusting the gas control, check gas control inlet pressure using a manometer at the gas control inlet pressure tap. If inlet pressure is within the range shown in Table 1, replace gas control; Eotherwise, take the necessary steps to provide proper gas pressure on the control. WIRING LTERMINALS INLET PRESSURE TAP LO ON OFF ON OFF HI PILOT PILOT OUTLET O PRESSURE TAP HI/LO REGULATOR GAS CONTROL KNOB M6914 S Fig. 7. Top view of gas control with HI/LO regulator. OUTLET PRESSURE TAP PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW) GAS CONTROL KNOB PILOT ADJUSTMENT SCREW M6915 Fig. 8. Top view of gas control with standard regulator. Table 1. HI/LO and Standard Regulator Specification Pressures in in. wc (kPa). BType of Gas HI/LO Regulator Setting Ranges HI LO Standard Regulator Setting Ranges ONatural LP 3.0 in. to 3.5 in. 9.0 in. to 11.0 in. 1.2 in. to 2.5 in. 3.7 in. to 6.5 in. 3.0 in. minimum to 5.0 in. maximum 8.0 in. minimum to 12.0 in. maximum 5 69-1172--3 VS8510, VS8520 MILLIVOLT GAS VALVE CHECKOUT Check and Adjust Gas Input WARNING Fire or Explosion Hazard. Forcing the gas control knob can cause property damage, severe injury, or death. Use only your hand to turn the gas control knob. Gas Control Knob Settings Gas control knob settings are as follows: OFF: Prevents main gas flow through the control. ON: Permits main burner and pilot gas flow. Gas control and thermostat control main burner gas flow. PILOT: Opens pilot valve and allows gas flow to pilot burner. HI/LO: Manually adjusts outlet pressure. NOTE: Controls are shipped with the gas control knob in the ON position. Perform Gas Leak Test WARNING Fire or Explosion Hazard. Fuel gas accumulation can cause property damage, severe injury, or death. Perform Gas Leak Test every time work is done to the system. and Burner Ignition IMPORTANT 1. Do not exceed the input rating stamped on the appliance nameplate, or manufacturer recommended burner orifice pressure for size orifice(s) used. Be sure primary air supply to the main burner is properly adjusted for complete combustion. Follow the instructions of the appliance manufacturer. 2. IF CHECKING GAS INPUT BY CLOCKING GAS METER: Be sure there is no gas flow through the meter other than to the appliance being checked. E Other appliances must remain off with the pilots extinguished (or the consumption must be deducted from the meter reading). Convert the flow rate to Btuh as described in the Gas Controls Handbook, form 70-2602, and compare to T the Btuh input rating on the appliance nameplate. 3. IF CHECKING GAS INPUT WITH MANOMETER: Both the inlet and outlet pressure taps have a captive screw. To measure the pressure of the tap, loosen, but do not remove the captive screw, attach a plastic tube with a 1/4 in. shell ID and connect the manometer. After checking the Epressure, turn the gas control knob to the OFF position. Before opening the outlet pressure tap, be sure the gas control is in the OFF position. Before opening the inlet pressure tap, shut off the Lgas supply at the manual valve in the gas piping WARNING Fire or Explosion Hazard. Flashbacks caused by hidden gas leaks can cause property damage, severe injury, or death. Stand away from the main burner while lighting. OWARNING Gas Leak Test 1. Paint the pipe connections upstream of the gas control with rich soap and water solution. Bubbles indicate a gas leak. 2. If a leak is detected, tighten the pipe connections. S 3. Light the main burner. 4. With the main burner in operation, paint the pipe joints (including adapters and plugs) and control inlet and outlet with a rich soap and water solution. 5. If another leak is detected, tighten the adapter Bscrews, joints, plugs and pipe connections. to the appliance or, for LP Gas, at the tank. Repeat the Gas Leak Test at the pressure tap with the main burner operating. Check Safety Shutdown Performance Fire or Explosion Hazard. Improper shutdown can cause property damage, severe injury or death. 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. The VS8510 pilot gas flow should stop within three minutes; the VS8520 pilot gas flow stops within thirty seconds. Safety shutoff 6. Replace device if leak cannot be stopped. of pilot gas proves complete shutdown because OTurn on System Rotate the gas control knob counterclockwise Turn on Main Burner to ON. safety shutoff valve prohibits main burner and pilot gas flow. 3. Relight pilot burner and operate the system through one complete cycle to ensure all controls operate properly. Follow the instructions provided by the appliance manufac- turer or turn up the thermostat to call for heat. 69-1172--3 6 VS8510, VS8520 MILLIVOLT GAS VALVE MAINTENANCE If Main Burner does not Come on with Call for Heat WARNING Fire or Explosion Hazard. Improper assembly and cleaning can cause property damage, severe injury or death. Do not attempt to take apart the gas control or clean it. Regular preventive maintenance is important in applications that place a heavy load on system controls such as those used in the commercial cooking and agricultural and industrial industries because: E · In applications such as commercial cooking, the equipment operates 100,000 to 200,000 cycles per year. This 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 WARNING T system. The maintenance program should include regular checkout of the system as outlined in the Checkout section, and checkout of the control system as described in the appliance manufacturer literature. E Maintenance frequency must be determined 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 L 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. Because these environments can cause the gas control to deteriorate O more rapidly, the system should be checked more often. Any control should be replaced if it does not perform properly on checkout or service. In addition, replace any SERVWICAE RNIBNG S module if it is wet or looks like it has ever been wet. 1. Confirm that the gas control knob is in the ON position. 2. Adjust the thermostat several degrees above the room temperature. 3. Use a dc voltmeter to measure the voltage across the TPTH and TP terminals. 4. If no voltage is present, check the control circuit for proper operation. 5. If proper control system voltage is present, replace the gas control. Warning to the Appliance Owner. For Your Safety, Read Before Lighting Appliance. Fire or Explosion Hazard. Can cause property damage, severe injury or death. Exactly follow the warnings and the lighting instructions. 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 Gas, 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 does not operate by hand, have a qualified service technician replace the control. 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. OFire 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 can damage the control resulting in gas leakage. IMPORTANT Follow the operating instructions provided by the manufacturer of your heating appliance. CAUTION Equipment Damage. Can burn out heat anticipator in thermostat. Do not apply a jumper across (or short) the valve coil terminals even temporarily. 7 69-1172--3 VS8510, VS8520 MILLIVOLT GAS VALVE OBSOLETE Home and Building Control Honeywell Inc. Honeywell Plaza P.O. Box 524 Minneapolis, MN 55408-0524 69-1172--3 L.C. Rev. 2-99 Home and Building Control Honeywell Limited-Honeywell Limitée 155 Gordon Baker Road North York, Ontario M2H 3N7 Printed in U.S.A. on recycled paper containing at least 10% post-consu8mer paper fibers. www.honeywell.com