Honeywell VR8300 Continuous Pilot Dual Automatic Valve Combination Gas Controls

Product Overview

The VR8300 series controls are used in gas-fired, standing pilot appliances. They are designed for use with 24 Vac heating appliances that burn natural or liquefied petroleum (LP) gas.

Key Features:

• Safety shutoff, manual valve, two automatic operators, and a pressure regulator.
• Capacity rated up to 200 ft³/hour at 1 inch wc pressure drop (5.7 m³/hour at 0.25 kPa), with a maximum capacity of 300 ft³/hour (8.5 m³/hour) and a minimum of 30 ft³/hour (0.8 m³/hour).
• Solenoid-operated first automatic valve opens on thermostat call for heat and closes when the call ends.
• Diaphragm-operated second automatic valve opens under regulator control and closes if gas or power supply is interrupted.
• Three-position manual gas control knob: ON, OFF, and PILOT.
• Separate reset button, must be held down to permit pilot gas flow while lighting; can only be pushed in PILOT position.
• All adjustments, wiring connections, and pilot outlet are accessible from the top.
• Compact size.
• Straight-through body pattern; right-angle adapters available for inlet and outlet.
• Available in 1/2 and 3/4 inch inlet and outlet sizes; straight and angle flanges are also available.
• Adjustable servo regulator maintains constant gas output pressure under fluctuating supply pressure.
• Inlet screen and pilot filter included.
• Wiring terminal block color-coded beige for standing pilot models.
• May be installed at any angle between 0 and 90 degrees from the upright position, including vertically.
• 1/4 inch male quick-connect terminals for electrical connections.
• Standard temperature range: 0°F to +175°F (-18°C to +79°C); available range: -40°F to +175°F (-40°C to +79°C).
• Inlet and outlet pressure taps accessible from the top.
• Standard-, slow-, and step-opening models available.
• Natural/LP gas conversion kits available for standard and slow-opening models.

Specifications

Important: Specifications do not include normal manufacturing tolerances. Performance may vary slightly from listed specifications due to controlled testing conditions.

Model Series and Features

SUPER TRADELINE MODELS

Offer features not available on TRADELINE or standard models, designed to replace a wide range of Honeywell and competitive controls.

• Available Models: VR8300A Combination Gas Control (3/4 inch inlet x 3/4 inch outlet).
• Additional Features: 393691 Natural to LP gas conversion kit, two 1/2 x 3/4 inch reducer bushings, One Q340 Thermocouple (36 inch lead length), SUPER TRADELINE packaging with cross-reference label and special instruction sheet.

TRADELINE MODELS

Offer features not available on standard models, designed to replace a wide range of Honeywell and competitive controls.

• Available Models: VR8300A Combination Gas Control, VR8300C Combination Gas Control.
• Additional Features: 393691 Natural to LP gas conversion kit (not for VR8300C), 1/2 x 3/4 inch reducer bushings (for 1/2 x 3/4 inch models), two 1/2 x 3/4 inch reducer bushings (for 3/4 x 3/4 inch models), TRADELINE packaging with cross-reference label and special instruction sheet.

STANDARD MODELS

• Models: VR8300 Continuous Pilot Dual Automatic Valve Combination Gas Controls.
• Supply Voltage: 24 Vac, 50/60 Hz.
• Power Unit: Reset current: 300 mA maximum. Drop-out current: 70mA minimum.
• Thermocouple: Nominal output: 30 mV (0.018 ohms). Open Circuit Turndown Voltage: 2mV.
• Electrical Connections: 1/4 inch male quick-connects; two convenience terminals on top (optional). Terminal block color-coded beige.
• Thermostat Heat Anticipator Setting: 0.7 A.

Capacity Specifications

Capacity based on 1000 btu/ft³, 0.64 specific gravity natural gas at 1 inch wc pressure drop.

Model Specifications and Pressure Settings

Separate models are available for natural or LP gas. Natural/LP gas conversion kits are available for standard- and slow-opening models.

Table 1: Model Specifications

Note: Step pressure not adjustable.

Table 7: Pressure Regulator Specification Pressures (inches WC)

Table 8: Pressure Regulator Specification Pressures (kPa)

Gas Capacity Conversion Factors

Flange Part Numbers

Body Pattern: Straight-through.

Inlet x Outlet Sizes Available: 1/2 x 1/2 inch, 1/2 x 3/4 inch, and 3/4 x 3/4 inch with inlet flange.

Adapters: Available for 1/2 and 3/4 inch straight and angle connections. Refer to Table 3.

Note: Flange Kits include one flange with attached O-ring and four mounting screws.

Pilot Gas Outlet: Compression fitting for 1/4 inch OD tubing.

Pressure Tapping: Inlet and outlet pressure taps accessible from the top. Taps are 1/8 inch NPT with plug for 3/16 inch Allen wrench.

Pressure Rating: A.G.A. rating 1/2 psi [3.5 kPa] inlet pressure.

Pressure Regulation: See Table 1. Regulator adjustment accessible from the top.

Mounting: Can be mounted 0-90 degrees from upright position, including vertically.

Temperature Rating: VR8300A,C,H: 0°F to +175°F [-18°C to +79°C]. VR8300M,P: -40°F to +175°F [-40°C to +79°C].

Installation

WARNING: FIRE OR EXPLOSION HAZARD

Follow these warnings exactly:

• Disconnect power supply before wiring to prevent electrical shock or equipment damage.
• Turn off gas supply at the appliance service valve before starting installation and perform a Gas Leak Test afterward to avoid dangerous fuel gas accumulation.
• Do not bend pilot tubing at the gas control or pilot burner after the compression fitting is tightened, as this may cause gas leakage.
• Always install a sediment trap in the gas supply line to prevent contamination of the gas control.
• Do not force the gas control knob. Use only your hand for the reset button or knob. If they do not operate by hand, the control should be replaced by a qualified service technician.

CAUTION: Never apply a jumper across or short the valve coil terminals, as this may burn out the thermostat's heat anticipator.

IMPORTANT: Gas controls are shipped with protective seals over inlet and outlet tappings. Remove these seals only when ready to connect piping.

Follow appliance manufacturer's instructions or the instructions provided below.

Converting Between Natural and LP Gas

WARNING: FIRE OR EXPLOSION HAZARD

Do not use a gas control set for natural gas on LP gas, or vice versa. To convert a gas control, contact your Honeywell representative. Standard- or slow-opening controls can be converted using a kit (Part Number 393691 for Natural to LP; Part Number 394588 for LP to Natural). Step-opening controls cannot be converted.

Installing Adapters to Control

If adapters are to be installed, mount them as follows:

Figure 2 illustrates the process of installing a flange to the gas control. It shows the flange with an O-ring, the gas control inlet/outlet, and the mounting screws, emphasizing the correct alignment and tightening of screws to ensure a gas-tight seal.

Bushings:

• Remove seal over gas control inlet or outlet.
• Apply a moderate amount of good quality pipe compound (resistant to LP gas for LP installations; do NOT use Teflon tape) to the bushing, leaving two end threads bare.
• Insert bushing into gas control and thread pipe carefully into the bushing until tight.

Using Adapters to Solve Swing Radius Problems: Adapters can resolve issues where threading the gas control directly onto the supply pipe is difficult due to space limitations. Using an adapter increases the overall length of the gas control.

Choosing Gas Control Location

Locate the gas control in a well-ventilated area, away from steam cleaning, high humidity, dripping water, corrosive chemicals, dust, grease accumulation, or excessive heat. Mount the control high enough above the cabinet bottom to avoid flooding or splashing water. Ensure ambient temperature does not exceed ratings. Cover the control if cleaning with water, steam, or chemicals, or to avoid dust/grease. Avoid locations with corrosive fumes or dripping water.

Installing Piping to Gas Control

All piping must comply with local codes, ordinances, or the National Fuel Gas Code (ANSI Z223.1 NFPA No. 54). Tubing installation must comply with approved standards.

• Use new, properly reamed pipe free from chips. Ensure tubing ends are square, deburred, and clean. Tubing bends must be smooth and without deformation.
• Run pipe or tubing to the gas control. Use a tube-to-pipe coupling if using tubing.
• Install a sediment trap in the supply line to the gas control. Figure 3 depicts the correct installation of a sediment trap, showing different piping configurations and emphasizing a minimum 3-inch vertical drop before the gas control.

Installing Gas Control

Figure 1 shows the physical dimensions of the VR8300 gas control. It illustrates the overall size, mounting hole locations, and the positions of electrical terminals (1/4 inch quick-connects) and pressure taps.

• Mount the gas control 0-90 degrees from the upright position, including vertically.
• Mount the gas control so gas flow is in the direction of the arrow on the bottom.
• Thread pipe the amount shown in Table 4 for insertion into the gas control. Do not thread pipe too far, as this may distort or malfunction the valve.

Table 4: NPT Pipe Thread Length

Figure 4 illustrates the proper application of pipe compound to pipe threads. It shows applying compound to the pipe threads, leaving the first two threads bare, and warns against using Teflon tape.

• Remove seals over gas control inlet and outlet if necessary.
• Connect pipe to gas control inlet and outlet. Use a wrench on the square ends of the gas control. If an adapter is used, place the wrench on the adapter, not the control. Refer to Figures 5 and 6.

Connecting Pilot Gas Tubing

Figure 5 provides a top view of the standard gas control, labeling key components like the pressure regulator adjustment screw, pilot outlet, thermocouple connection, reset button, pilot adjustment screw, and optional convenience terminals.

Figure 6 demonstrates the correct method for applying a wrench when connecting piping. It shows applying the wrench to the hexagonal flats of the control or flange, avoiding force on the control body.

• Cut tubing to desired length and bend as necessary for routing to the pilot burner. Avoid sharp bends or deformation. Do not bend tubing after the compression fitting is tightened.
• Square off and remove burrs from the tubing end.
• Unscrew the compression fitting from the pilot outlet, slip it over the tubing, and slide it out of the way.
• Push the tubing into the pilot gas tapping until it bottoms. While holding the tubing, slide the compression fitting into place, engage threads, and turn finger tight. Then, tighten one more turn with a wrench. Do not overtighten. Refer to Figure 7.
• Figure 7 illustrates the proper tightening of a new compression fitting, showing tightening one turn beyond finger tight.
• Connect the other end of the tubing to the pilot burner according to the manufacturer's instructions.

Connecting Thermocouple

Figure 8 shows the connection of the thermocouple lead to the power unit. It highlights that this is an electrical connection requiring cleanliness and dryness, and specifies tightening the connection only 1/4 turn beyond finger tight for good electrical continuity. Do not overtighten.

Wiring

Follow appliance manufacturer's wiring instructions or the general instructions provided. All wiring must comply with applicable electrical codes and ordinances.

• Disconnect power supply before making wiring connections to prevent shock or damage.
• Check the power supply rating on the gas control to ensure it matches the available supply. Install transformer, thermostat, and other controls as required.
• Connect the control circuit to the gas control terminals. Refer to Figures 5 and 9.
• Figure 9 presents a wiring diagram for a 24-volt control system, showing connections between the gas control terminals, thermostat, high limit controller, and power supply.
• Adjust the thermostat heat anticipator to the 0.70 rating stamped on the valve operator.

Maximum Leadwire Lengths for Thermocouples

Table 5: Maximum Length of Supplementary Limit Leadwires (Using Q340A Thermocouple)

Table 6: Maximum Length of Supplementary Limit Leadwires (Using Q309A Thermocouple)

Start-Up and Checkout

WARNING: FIRE OR EXPLOSION HAZARD

• Do not force the gas control knob. Use only your hand to push the reset button or turn the knob. Never use tools.
• If the knob or reset button does not operate by hand, or if the reset button stays depressed, the control should be replaced by a qualified service technician.

Gas Control Knob Settings:

• OFF: Prevents pilot and main burner gas flow.
• PILOT: Permits pilot gas flow only. Knob must be held depressed or thermocouple heated sufficiently to hold the safety control valve open.
• ON: Permits main burner and pilot gas flow. Thermostat controls main burner gas flow.

Note: Gas controls are shipped with the knob in the ON position.

Perform Gas Leak Test

WARNING: FIRE OR EXPLOSION HAZARD

Check for gas leaks with a rich soap and water solution any time work is done on a gas control.

1. Paint all pipe connections upstream of the gas control with a rich soap and water solution. Bubbles indicate a gas leak.
2. If a leak is detected, tighten the pipe connection.
3. Stand clear while lighting the main burner to prevent injury from hidden gas leaks that could cause flashback. Light the main burner.
4. With the main burner operating, paint all pipe joints (including adapters) and gas control inlet/outlet with rich soap and water solution.
5. If another leak is detected, tighten adapter screws, joints, and pipe connections.
6. Replace the part if a gas leak cannot be stopped.

Light the Pilot Burner Flame

1. Turn the gas control knob clockwise to OFF. Wait five minutes to dissipate unburned gas. Sniff around the appliance. Do not relight if gas is smelled.
2. Turn the gas control knob counterclockwise to PILOT. Push down and hold the knob while lighting the pilot flame.
3. Hold the knob down for about one minute, then release.
4. If the pilot flame goes out, turn the knob clockwise to OFF and repeat steps one through three.
5. If the pilot flame remains lit, turn the knob counterclockwise to ON.

Adjust the Pilot Burner Flame

The pilot flame should envelop 3/8 to 1/2 inch [10 to 13 millimeters] of the thermocouple tip. Figure 10 illustrates the correct pilot flame adjustment.

1. Remove the pilot adjustment cover screw (refer to Figure 5).
2. Turn the inner adjustment screw clockwise to decrease or counterclockwise to increase the pilot flame.
3. Always replace the cover screw after adjustment and tighten firmly.

Light Main Burner

Follow the appliance manufacturer's instructions or set the thermostat above room temperature to call for heat.

Check and Adjust Gas Input to Main Burner

CAUTION:

• Do not exceed the input rating stamped on the appliance nameplate or manufacturer-recommended burner orifice pressure. Ensure main burner primary air supply is properly adjusted for complete combustion.
• Checking Gas Input by Clocking the Gas Meter: Ensure only the appliance being tested is using gas. Turn off other appliances and their pilot burners (or deduct their gas consumption). Convert flow rate to Btuh as described in the Gas Controls Handbook (form number 70-2602) and compare to the appliance nameplate input rating.
• Checking Gas Input with a Manometer: Ensure the gas control knob is in the PILOT position before removing the outlet pressure tap plug to connect the manometer. Turn the knob back to PILOT when removing the manometer and replacing the plug. Shut off gas supply at the appliance service valve (or gas tank for LP) before removing the plug or disconnecting the manometer. Perform Gas Leak Test at the inlet pressure tap plug.

Pressure Regulator Adjustment

Standard-Opening and Slow-Opening Pressure Regulator:

1. The gas control outlet pressure should match the manifold pressure listed on the appliance nameplate.
2. With the main burner operating, check gas control flow rate using the meter clocking method or check gas pressure using a manometer connected to the outlet pressure tap (refer to Figure 5).
3. If necessary, adjust the pressure regulator to match the appliance rating using Tables 7 or 8 for ranges.
4. Remove the pressure regulator adjustment cap and screw.
5. Using a screwdriver, turn the inner adjustment screw clockwise to increase or counterclockwise to decrease gas pressure.
6. Always replace the cap screw and tighten firmly.
7. If desired pressure or flow rate cannot be achieved, check the gas control inlet pressure using a manometer. If inlet pressure is within normal range (Tables 7 or 8), replace the gas control. Otherwise, address the inlet pressure issue.

Step-Opening Pressure Regulator:

1. The gas control outlet pressure should match the manifold pressure listed on the appliance nameplate.
2. With the main burner operating, check gas control flow rate using the meter clocking method or check gas pressure using a manometer connected to the outlet pressure tap (refer to Figure 5).
3. If necessary, adjust the pressure regulator to match the appliance rating using Tables 7 or 8 for ranges.
4. Remove the pressure regulator adjustment cap screw.
5. Using a screwdriver, turn the inner adjustment screw clockwise to increase or counterclockwise to decrease gas pressure.
6. Always replace the cap screw and tighten firmly.
7. If desired pressure or flow rate cannot be achieved, check the gas control inlet pressure using a manometer. If inlet pressure is within normal range (Tables 7 or 8), replace the gas control. Otherwise, address the inlet pressure issue.
8. Carefully check main burner lightoff at the step pressure. Ensure smooth lighting without flashback and that all ports remain lit. Cycle the main burner several times with 30-second intervals between cycles for the regulator to resume step function. Readjust full rate outlet pressure if necessary.

Check Safety Shutdown Performance

WARNING: FIRE OR EXPLOSION HAZARD

Perform the safety shutdown test any time work is done on a gas system.

1. Place gas control knob in PILOT position. Main burner should go off, and pilot should remain lit.
2. Extinguish pilot flame. Pilot gas flow should stop within 2-1/2 minutes. This proves complete shutdown.
3. Relight pilot burner and operate the system through one complete cycle to ensure all controls operate properly.

Ordering Information

When purchasing replacement or modernization products, refer to wholesaler or distributor price sheets for complete ordering numbers, or specify:

1. Order number.
2. Natural or LP gas.
3. Step pressure on VR8300C, P.
4. Convenience terminals, if desired.
5. Accessories, if desired.
6. Order separately: pilot burner, thermocouple, transformer, limit controller, and thermostat or controller as required.

Contact Information

For additional questions, further information, or comments on products or services, please write or phone:

1. Your local Honeywell Residential and Building Controls Division Sales Office (check white pages of your phone directory).
2. Residential and Building Controls Division Customer Satisfaction, Honeywell Inc., 1885 Douglas Drive North, Golden Valley, Minnesota 55422-4386 (612) 542-7500.
3. In Canada: Honeywell Limited/Honeywell Limitée, 740 Ellesmere Road, Scarborough, Ontario M1P 2V9.
4. International sales and service offices are located in principal cities worldwide.