background image

VR

8104

, VR

820

4 AN

D VR

8304

 I

N

T

E

R

M

IT

TEN

T PI

LO

T CO

M

B

IN

A

T

IO

N

 G

A

S CO

N

T

R

O

L

S

69

-122

5—4

6

Fi

g

. 3.

 S

e

d

im

e

n

t t

rap i

n

st

al

la

ti

on.

Ins

tall Con

trol

1.

M

ount

ed 0

 t

o

 90 d

egr

ees i

n

 an

y di

re

c

ti

on,

 in

cl

ud

in

g

 

ver

ti

cal

ly

fr

om

 t

he upr

ight

 p

o

si

ti

o

n

 of

 t

he gas 

cont

ro

l kno

b.

2.

M

ount

 so 

th

e

 ga

fl

o

w

 i

s

 i

n

 t

he di

re

ct

ion of

 t

he 

ar

ro

w

 on t

he bot

to

m

 of

 t

h

e

 con

tr

ol

.

3.

Thr

ea

the pi

pe t

h

e am

ount

 show

in

 T

abl

e 7 f

o

in

s

e

rt

ion i

n

to

 cont

ro

l or

 adap

te

rs

D

o

 not

 t

h

re

a

d

 

pi

p

e

 t

o

o

 f

a

r.

 V

a

lv

e di

st

o

rt

io

n

 o

r m

a

lf

un

ct

ion can 

re

sul

t i

th

e

 pi

pe i

s

 i

n

ser

te

d t

o

o

 de

epl

y.

T

a

bl

7

.  NP

T Pi

pe Thr

e

a

d Len

gt

h (

in.

).

4.

 App

ly

 a m

oder

at

e am

ount

 of

 go

od qual

it

y pi

pe

 

com

po

und (

do not

 use T

e

fl

on

 t

ape

) onl

to

 t

he 

pi

pe,

 l

eav

in

g

 t

w

o

 en

d t

h

read

s b

a

re

O

n

 LP 

in

st

al

la

ti

on

s,

 use a com

pou

nd r

e

si

st

ant

 t

o

 LP

 g

a

s.

 

S

ee Fig

. 4.

5.

R

e

m

o

ve t

he seal

s over

 t

h

c

ont

ro

l i

n

le

t and out

le

t i

ne

cessar

y.

6

.

C

onne

ct

 t

he pi

pe t

o

 t

he con

tr

ol

 in

le

t an

d out

le

t.

 U

s

a w

ren

ch on t

h

s

quar

e ends

 of

 t

h

co

nt

ro

l.

 I

f a 

fl

an

ge i

s

 use

d,

 pl

ace t

h

e w

rench

 on

 t

he f

lan

ge 

ra

th

e

r th

a

n

 o

n

 th

e

 g

a

s

 c

o

n

tr

o

l. Re

fe

r to

 F

ig

5

 

an

d

6

.

C

o

n

n

ec

t Pilo

t G

a

s

 Tu

bin

g

1.

C

u

tubi

ng t

o

 t

he des

ir

ed l

e

n

g

th

 a

nd bend

 a

s

 

ne

cessar

y f

o

r r

out

in

g

 t

o

 t

h

p

ilo

t bu

rn

e

r.

 D

o

 not

 

m

a

ke sha

rp

 be

nds or

 d

e

fo

rm

 t

h

e t

u

b

ing

. D

o

 no

be

nd 

th

e t

ubi

ng 

at

 t

h

e

 ga

s co

nt

ro

af

te

th

e

 

com

pr

es

si

on

 nu

is

 t

igh

te

n

ed,

 b

e

cause

 t

h

is

 ca

re

sul

t i

n

 g

a

s l

e

a

k

age at

 t

he con

nect

io

n.

2.

S

quar

e of

f and

 r

e

m

o

ve

 bu

rr

s f

rom

 t

h

e

nd of

 t

he 

tubi

ng.

3.

U

n

scr

ew

 t

he br

ass com

pr

essi

on f

it

ti

ng f

rom

 t

h

pi

lo

t out

le

t (

F

ig

. 6)

. Sl

ip

 t

he f

it

ti

ng over

 t

h

tubi

ng 

an

d s

lid

out

 of

 t

h

e w

a

y.

 S

ee 

Fi

g.

 7.

N

O

T

E

:

W

he

re

p

laci

ng a cont

ro

l,

 cut

 of

the ol

com

pr

es

si

on

 f

it

ti

ng 

an

d r

e

p

lace

 w

it

h

 t

h

com

pr

es

si

on

 f

it

ti

n

g

 pr

ovi

d

ed on t

he co

m

b

in

a

ti

on 

ga

s co

nt

ro

l.

 N

e

ver

 use 

th

e o

ld 

com

pr

essi

on 

fi

tt

ing bec

ause i

t m

a

n

o

t pr

ovi

de a gas-

ti

gh

sea

l.

 

4.

P

u

sh t

h

tu

b

ing i

n

to

 t

he pi

lo

t gas t

a

ppi

ng on t

h

ou

tl

et

 en

d o

the 

cont

ro

unt

il i

t bo

tt

om

s.

 Wh

ile

 

ho

ld

ing t

h

e t

u

b

ing

 al

l t

he w

a

y

 i

n

sl

id

e

 t

he f

it

ti

ng 

in

to

 p

lace

 an

d e

ngag

th

e

 t

h

reads

th

en 

tu

rn

 un

ti

fi

ng

er

 t

ig

h

t.

 T

ig

h

te

n one m

o

re

 t

u

rn

 w

it

h

 a

 w

re

n

ch,

 

bu

t do not

 over

ti

ght

en

.

5.

C

onne

ct

 t

he ot

h

e

e

nd of

 t

he t

u

bi

n

g

 t

o

 t

h

e pi

lo

bu

rn

er

 acco

rd

in

g

 t

o

 t

h

e

 p

ilo

t bur

ne

r m

anuf

act

ur

er

’s

 

in

s

tr

u

c

tio

n

s

.

F

ig.

 4.

  Us

m

o

der

at

e am

ou

nt

 o

f pi

pe

 co

m

pou

nd.

Pi

pe

 

Si

z

e

Thr

ea

d P

ipe 

th

is

 A

m

o

unt

M

a

x

im

u

m

 D

e

pt

h Pi

pe ca

b

e

 In

s

e

rte

d

 in

to

 C

o

n

tr

o

l

3/

8

9

/1

6

3

/8

1/

2

3

/4

1/

2

3/

4

1

3/

1

6

3/

4

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

TU

B

ING

GAS

SUPPLY

HORIZONTAL

DROP

3 IN.

(76 MM)

MINIMUM

RISER

M3077

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.

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).

M3075B

PIPE

VR

8104

, VR

820

A

N

D VR

8304

 I

N

T

E

R

M

IT

TEN

T PI

LO

T CO

M

B

IN

A

T

IO

N

 G

A

S CO

N

T

R

O

L

S

5

69-1

225—4

Fi

g.

 1.

 T

op vi

ew

 o

f co

nver

ti

bl

p

ressu

re

 r

e

g

u

la

to

r c

a

p.

Ins

tall Ada

pters To

 Contro

l

If

 a

dapt

er

s a

re 

bei

ng 

in

st

al

le

d

 on

 t

h

e co

nt

ro

l,

 m

ount

 t

hem

 

a

s

 fo

llo

ws

:

Fl

a

n

g

e

s

1.

C

h

oose t

he appr

op

ri

at

fl

ange f

o

yo

ur

 ap

pl

ic

at

io

n

.

2.

R

e

m

o

ve t

h

e

 se

al

 over

 t

h

g

a

s cont

ro

l i

n

le

o

out

le

t.

3.

M

a

ke sur

e t

h

a

t t

he O

-r

ing

 i

s

 f

it

ted i

n

 t

he gr

oove

 of

 

th

fl

ange.

 I

f t

h

e

 O

-r

ing i

s

 no

t at

ta

ched or

 i

s

 

m

issi

ng,

 d

o

 n

o

t use

 t

he 

fl

an

ge.

4.

Wi

th

 t

h

e O

-r

ing 

fa

ci

ng 

th

e

 co

nt

ro

l,

 al

ig

n t

he 

scr

ew

 

hol

es on t

h

g

a

s cont

ro

l w

it

h

 t

he hol

es i

n

 t

he 

fl

ang

e.

 I

n

ser

and

 t

ig

h

te

n t

he 

scr

ew

s pr

ov

ided

 w

it

h

 

th

fl

ange.

 See

 F

ig.

 2.

 T

ight

en t

he scr

e

w

s t

o

 2

5

 

in

c

h

-pound

o

f t

o

rq

ue t

o

 pr

ovi

de a gas-

ti

gh

t seal

.

Bu

shi

ng

s

1.

R

e

m

o

ve t

h

e

 se

al

 over

 t

h

c

ont

ro

l i

n

le

o

r out

le

t.

2.

App

ly

 a m

oder

at

e am

ount

 of

 go

od qual

it

y pi

p

e

 

com

pou

nd t

o

 t

he bu

shi

n

g

leavi

ng t

w

o en

d t

h

re

a

d

bar

e.

 O

n

 an LP

 i

n

st

al

la

ti

o

n

, use

 com

p

ound t

hat

 i

s

 

re

si

st

ant

 t

o

 LP

 g

a

s.

 D

o

 not

 u

s

T

e

fl

on 

tape.

3.

In

ser

t t

he bushi

ng i

n

 t

he con

tr

ol

 an

c

a

re

fu

lly 

th

re

ad 

th

e

 p

ipe

 i

n

to

 t

he 

bus

hi

n

g

 u

n

ti

ti

gh

t.

 

C

o

m

p

le

te

 t

h

in

st

ru

ct

ions

 be

lo

w

 f

o

r i

n

st

al

ling t

h

e pi

pi

ng,

 

in

s

tal

ling t

he cont

ro

l,

 c

onnec

ti

ng t

h

p

ilo

t ga

tubi

ng and

 

th

w

ir

ing.

 M

a

ke

 su

re

 t

he l

e

ak t

e

st

 you per

fo

rm

 on

 t

he 

cont

ro

l af

te

r com

pl

et

in

g

 t

he i

n

st

a

lla

ti

on i

n

cl

ud

es l

e

a

k

 

te

st

ing t

h

e adap

te

rs

 and scr

ew

s.

 I

f you use

 a

 w

re

n

ch on 

th

v

a

lv

e

 af

te

the f

lang

es ar

in

st

al

led,

 use t

he w

rench

 

onl

y o

n

 t

h

e

 f

la

nge,

 n

o

t on

 t

he 

cont

ro

l.

 See

 F

ig.

 5.

F

ig.

 2.

  Fi

rm

ly f

ast

en f

la

nge t

o

 val

ve,

 but

 

do no

t ove

rt

ight

en

 s

c

re

w

s

.

Lo

c

a

ti

on

Th

e com

bi

nat

io

n

 g

a

s cont

ro

l i

s

 m

ount

ed i

n

 t

h

e appl

ia

nce 

ves

ti

bul

o

n

 t

h

e

 ga

m

a

n

if

o

ld

. I

f t

h

is

 i

s

 a r

e

pl

a

c

em

ent

 

ap

pl

ic

at

io

n

, m

ount

 t

h

e

 g

a

c

ont

ro

l i

n

 t

he sam

e l

o

ca

ti

on 

as t

he ol

d

 co

nt

ro

l.

Lo

cat

the com

bi

nat

io

n gas cont

ro

l w

h

er

it

 ca

nnot

 b

e

 

af

fe

ct

ed by st

ea

m

 cl

eani

ng,

 hi

gh

 h

u

m

idi

ty

, or

 dr

ippi

n

g

 

w

a

te

r,

 cor

ro

si

ve che

m

ical

s,

 dus

t or

 g

re

a

se accum

ul

at

io

n

 

or

 excessi

ve hea

t.

 T

o

 a

ssur

e pr

oper

 oper

at

io

n,

 f

o

llow

 

these

 gu

id

e

lin

es:

L

o

c

a

te

 g

a

s

 c

o

n

tro

l in

 a

 we

ll-v

e

n

tila

te

d

 a

re

a

.

M

oun

t gas cont

ro

l hi

gh enou

gh above

 cab

in

e

t bot

to

m

 

to

 avoi

e

x

posu

re

 t

o

 f

loodi

ng or

 spl

a

shi

n

g

 w

a

te

r.

A

ssur

e t

h

e

 am

bi

ent

 t

e

m

p

e

rat

ur

does

 no

excee

d t

he 

am

bi

ent

 t

e

m

p

e

ra

tur

e r

a

ti

ng

fo

e

a

ch com

pon

ent

.

C

over

 gas cont

ro

l i

f appl

ia

nce i

s

 cl

e

aned

 w

it

h

 w

a

te

r,

 

st

eam

o

r chem

ic

al

s

 or

 t

o

 av

oi

d du

st

 and

 gr

ea

se 

acc

um

ul

a

ti

on.

A

voi

d

 l

o

cat

in

g g

a

cont

ro

w

h

er

e e

x

posur

to

 

cor

ro

si

ve 

chem

ic

al

 f

u

m

e

s o

dr

ip

pi

n

g

 w

a

te

r a

re

 l

ikel

y.

Instal

l Piping 

to Con

trol

A

ll 

pi

pi

ng m

u

st

 com

pl

y w

it

h

 l

o

cal

 cod

es and or

di

nance

or

 w

it

h

 t

he N

a

ti

onal

 Fuel

 G

a

s C

ode (

A

N

S

Z

223.

1,

 

N

F

P

A

 N

o

. 5

4

),

 w

h

ic

he

ver

 a

ppl

ie

s.

 T

ubi

ng 

in

s

tal

la

ti

on 

m

u

st

 c

o

m

p

ly

 w

it

h

 a

ppr

oved

 st

and

ar

ds 

and 

pr

act

ic

e

s

.

1.

U

s

new

pr

oper

ly

 r

eam

e

d

 p

ipe

 t

hat

 i

s

 f

ree 

fr

o

m

 

chi

ps.

 I

f t

ubi

ng 

is

 use

d,

 m

a

ke

 sur

the 

ends

 ar

squ

ar

e,

 de

bur

red and cl

ean.

 Al

l t

ubi

ng bend

s m

u

st

 

be

 sm

oo

th

 an

d w

it

hou

def

or

m

a

ti

on

.

2.

R

un pi

p

e

 or

 t

ubi

ng t

o

 t

he cont

ro

l.

 I

f t

u

b

ing

 i

s

 u

s

ed,

 

ob

ta

in

 a t

u

b

e

-t

o-

pi

pe cou

pl

ing t

o

 co

nnect

 t

h

e

 

tubi

ng t

o

 t

he cont

ro

l.

3.

In

st

al

l a

 se

di

m

e

n

tr

ap

 i

n

 t

h

e

 su

ppl

y l

ine

 t

o

 t

h

c

o

nt

ro

l.

 S

e

e

 F

ig.

 3

.

PRESSURE 

REGULATOR 

CAP

M11678

NA

T

NAT

LP

L P

NA

T

NAT

OR

OTHER SIDE

OF CAP

M9046

VALVE OUTLET

FLANGE

9/64 INCH HEX SCREWS (4) 

DO NOT OVERTIGHTEN SCREWS.  TIGHTEN TO 

25 INCH-POUNDS.

1

1

Summary of Contents for B Series

Page 1: ...al Designed and Manufactured in Accordance with ASME Code Section IV Heating Boilers E T L Listed ASME Code Construction and Stamped Photo shown may vary from actual model Model B_G Series Gas Fired C...

Page 2: ...site http www ajaxboiler com Email info ajaxboiler com Ace Boiler Inc formerly Ace Buehler Inc is a division of Ajax Boiler Inc ACE BOILER INC E T L Listed Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q...

Page 3: ...e the heater so that leakage from tank or connections will be directed to a floor drain and will not damage adjacent area or lower level floors 2 The minimum clearance between a heater and a storage t...

Page 4: ...is measured downstream of the gas pressure regu lator Do not exceed the maximum gas pressure specified on the rating plate 4 A trap drip leg must be installed upstream of the gas pressure regulator 5...

Page 5: ...P OP Check Valve Pressure Relief Valve Pressure Temp Gauge Primary Operational Aquastat Unit Circulation Pump System Recirculation Pump Check Valve Pilot Safety Relay Ground Hi Limit Aquastat Control...

Page 6: ...STANDARD FOR CSD 1 G 22225 N A HEADER COMB GAS VALVE SHUT OFF VALVE PILOT LINE PILOT LINE TYP COMB GAS VALVE TYP HEADER SHUT OFF VALVE B2 THRU B8 INDOOR OUTDOOR CSD 1 GAS TRAIN FOR MODELS B11 THRU B1...

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Page 8: ...CONTROLS AND GAS TRAIN GAS FIRED COPPER FIN CONE COIL WATER HEATERS HEAVY DUTY INDUSTRIAL WATER HEATERS MINI PACK SEMI INSTANTANEOUS WATER HEATERS PACKAGED STORAGE WATER HEATERS CLEAN STEAM BOILERS AS...

Page 9: ...and accept the product when received as conforming to their purchase order specifications and approved drawings All claims for non conformance errors shortages etc must be made within 10 days after re...

Page 10: ...4 United States Tel 714 437 9050 Fax 714 437 9060 http www ajaxboiler com mail ajaxboiler com June 2010 Ace Heating Solutions LLC ACE Heating Solutions LLC 2701 S HARBOR BLVD SANTA ANA CA 92704 PHONE...

Page 11: ...060 http www ajaxboiler com mail ajaxboiler com February 2007 ACE Heating Solutions LLC 2701 S HARBOR BLVD SANTA ANA CA 92704 PHONE 714 540 2230 FAX 714 540 2239 www aceheatingllc com Ace Heating Solu...

Page 12: ...anta Ana California 92704 United States Tel 714 437 9050 Fax 714 437 9060 http www ajaxboiler com mail ajaxboiler com ACE Heating Solutions LLC 2701 S HARBOR BLVD SANTA ANA CA 92704 PHONE 714 540 2230...

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Page 16: ...es at very high temperatures insulation shielding and air circulation may be necessary to protect the controls Proper insulation or shielding should be provided by the appliance manufac turer make sur...

Page 17: ...o ground NOTE Earth ground is not required To connect the D80B follow the wiring diagrams sup plied with the vent damper or see Fig 8 for typical connec tions Connect Ignition Module 1 Connect remaini...

Page 18: ...T DAMPER PLUG OPT 5 2ND OPERATOR 1ST OPERATOR PILOT COM MAIN VALVE DUAL VALVE COMBINATION GAS CONTROL Fig 2 S8610F H S8670D in a heating system with an atmospheric burner 5 TABLE 4 TERMINAL CROSS REFE...

Page 19: ...9 0523 MV MV PV PV GND BURNER 24V GND 24V TH W VENT DAMPER PLUG SPARK 5 S8610A B POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION MAXIMUM C...

Page 20: ...TOR PILOT COM MAIN VALVE DUAL VALVE COMBINATION GAS CONTROL PILOT BURNER GROUND PILOT GAS SUPPLY 9 69 0523 Fig 8 S8610F H S8670D in a heating system with an atmospheric burner and a D80B Vent Damper L...

Page 21: ...23 Fig 10 S8610F H S8670D in a hydronic heating system with a D80D Vent Damper 2 MV MV PV PV GND BURNER 24V GND 24V TH W OPT VENT DAMPER PLUG OPT SPARK 4 S8610F H S8670D POWER SUPPLY PROVIDE DISCONNEC...

Page 22: ...ne as described in Steps 1 and 5 below on initial installation and any time work is done involving the gas pip ing STEP 3 Reset the Module Turn the thermostat to its lowest setting Wait one minute As...

Page 23: ...burner igniter sensor and provide shield if necessary If flame rod or bracket are bent out of position restore to correct position STEP 3 Check spark ignition circuit You will need a short jumper wire...

Page 24: ...ing the pilot adjustment screw on the gas control clockwise to decrease or counterclockwise to increase pilot flame Following adjustment always replace pilot adjustment cover screw and tighten firmly...

Page 25: ...V PV MV PV MAIN VALVE PILOT VALVE TO 24V GND TO 24V 3 3 Fig 17 Representative schematic for S8610F H See Fig 1 for hookup S8670 is similar except the timing circuit includes a purge timer See Fig 6 fo...

Page 26: ...water pumps are in operating condition b Test low water cutoffs automatic feed water controls pressure and temperature limit control lers and relief valves in accordance with the manufacturer s recomm...

Page 27: ...ntrol after compression nut has been tightened because this can result in gas leakage at connection 2 Square off and remove burrs from end of tubing 3 Push tubing into compression nut clearance hole u...

Page 28: ...ot flame 6 Always replace pilot adjustment cover screw and tighten firmly after completing adjustment to assure pro per operation Service WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEV...

Page 29: ...e would result in personal injury and or loss of prop erty it is the responsibility of the installer to add devices safety limit controls that protect against or systems alarm supervisory systems that...

Page 30: ...llation and adjustment CAUTION Check the installation for no flow switch operation Make appropriate adjustments to the sensitivity adjustment screw to be sure the switch restores fully at the desired...

Page 31: ...ls The thermostat or the fuse will be damaged DO NOT allow any flame to impinge on the regulator vent tubing if sup plied It may clog and cause gas valve malfunction DO NOT use the gas cock to adjust...

Page 32: ...or 6 for a typical connection diagram X XX UL INSTALLATION INSTRUCTIONS U S Registered Trademark Copyright 1995 Honeywell Inc All Rights Reserved L4008A B E L L6008A G H Aquastat Controllers APPLICATI...

Page 33: ...R IGNITION TRANSFORMER RA89A RELAY RA817A PROTECTORELAY CONTROL BURNER MOTOR 24V THERMOSTAT 2 1 3 4 T T 1 2 3 4 M8785 Fig 5 Typical oil fired hydronic heating system with domestic hot water SETTING Co...

Page 34: ...9 mm OD for both inlet and outlet Approval CE 0063AU1215 U S Registered Trademark Copyright 2000 Honeywell Inc All Rights Reserved INSTALLATION INSTRUCTIONS 69 1225 4 VR8104 VR8204 and VR8304 Intermit...

Page 35: ...mine if the pressure regulator setting factory set will meet the appliance manifold requirements after conversion NOTE Convertible pressure regulator models suffix letter R do not have field adjustabl...

Page 36: ...BINATION GAS CONTROLS 5 69 1225 4 Fig 1 Top view of convertible pressure regulator cap Install Adapters To Control If adapters are being installed on the control mount them as follows Flanges 1 Choose...

Page 37: ...hanism to reduce the pilot flow if necessary If pilot adjustment is necessary proceed as follows 1 Remove pilot adjustment cover screw See Fig 6 2 The pilot adjustment is shipped at the full pilot gas...

Page 38: ...eter 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 Make sure the g...

Page 39: ...Non Regulating On Off U Models Non regulating VR8204U Valves are designed for application in various parts of Europe where a separate distinct pressure regulator is required The VR8204U is similar to...

Page 40: ...f heater falls off this is usually a sign of lime in the coil The ACE coil will bang or knock if lim ing condition is severely restricting circulation Customers have reported operating ACE heaters and...

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