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

8

F

ig.

 8.

 T

y

p

ica

l w

ir

ing con

nect

ions

 f

o

2

4

 v

o

lt

 con

tr

o

in

 i

n

te

rm

it

ten

t i

gni

ti

on

 s

yst

em

 w

it

h

 S8

6

00.

ST

ARTUP AND CHECKOUT

W

ARNIN

G

Fi

re

 o

r E

x

pl

os

io

n

 H

a

z

a

rd

.

C

a

n cau

se pr

op

er

ty

 d

a

m

a

ge

, sev

er

e i

n

ju

ry

 

o

r de

at

h.

1

.

D

o

 not

 f

o

rc

e

 t

he gas con

tr

ol

 kn

ob on t

h

appl

ia

n

c

e.

 U

s

onl

y yo

ur

 ha

nd 

to

 t

u

rn

 t

h

e g

a

cont

ro

l knob

. N

e

ver

 us

a

n

y t

o

o

ls.

2

.

If

 t

he kno

b does not

 oper

at

e by hand

, t

h

cont

ro

l shou

ld

 be r

epl

aced by a qua

lif

ied 

ser

vi

ce t

e

chn

ic

ian.

G

as Co

n

tr

o

l Kn

ob

 Sett

in

gs

G

a

co

nt

ro

l knob set

ti

ng

ar

e as f

o

llow

s:

O

F

F:

 P

revent

s pi

lo

a

nd m

a

in

 gas f

low

 t

h

ro

u

gh t

h

cont

ro

l.

O

N

: Pe

rm

its

 g

a

s

 to

 fl

o

w

 in

to

 t

h

e

 c

o

n

tro

l b

o

d

y. Un

d

e

cont

ro

of

 t

h

e

 t

her

m

o

st

at

 an

d i

n

te

rm

it

te

n

pi

lo

m

o

dul

e,

 

gas can f

low

 t

o

 t

he pi

lo

a

nd m

a

in

 bu

rn

e

rs

.

N

O

TE

:

C

o

n

tr

ol

s ar

e

 sh

ip

p

ed w

it

h

 t

he gas con

tr

ol

 kn

ob 

in

 t

he O

N

 posi

ti

on.

Tu

rn On S

ystem

R

o

ta

te

 t

h

e gas cont

ro

l knob

 co

unt

er

cl

oc

kw

is

e

  t

o

 

ON

.

Turn

 On Main

 Burne

r

Fo

llow

 app

liance m

anu

fa

c

tur

er

 i

n

st

ru

ct

io

n

s

 o

r t

u

rn

 u

p

 

ther

m

o

st

at

 t

o

 cal

fo

r heat

.

Perfo

rm Gas L

eak Test

W

ARNIN

G

Fi

re

 o

E

x

pl

osi

on

 H

a

zar

d.

C

a

n

 c

a

use

 p

ro

p

er

ty

 dam

ag

e,

 se

ver

in

ju

ry

 

or

 d

eat

h.

Per

fo

rm

 G

a

s Leak T

e

st

 ever

y t

im

e

 w

o

rk

 i

s

 done

 

on a gas syst

em

.

IM

PO

RT

AN

T

D

o

 not

 sp

ra

so

ap and w

a

te

r sol

ut

ion on

 t

he 

ga

co

nt

ro

l.

 D

o

 no

t use an excess

iv

e am

oun

t of

 

soa

a

nd w

a

te

s

o

lu

ti

on t

o

 per

fo

rm

 t

h

g

a

leak 

te

st

. The

se can dam

ag

the con

tr

ol

.

Gas L

eak

 Tes

t

1.

P

a

in

t pi

pe co

nnect

io

ns ups

tr

eam

 of

 t

h

e gas c

ont

ro

w

it

h

 r

ich so

ap a

nd w

a

te

r sol

ut

io

n.

 Bub

bl

e

s

 i

ndi

c

a

te

 

a gas

 l

eak.

2.

If

 a l

e

ak 

is

 det

ect

ed,

 t

ig

h

ten t

h

e

 p

ipe

 con

nect

io

ns.

3.

Li

ght

 t

h

e

 m

a

in

 bur

ner

. S

tan

c

lea

r of

 t

he m

a

in

 

bu

rn

er

 w

h

ile l

ight

in

g

 t

o

 pr

event

 i

n

ju

ry

 caused

 f

rom

 

hi

dde

n l

eaks

 t

hat

 c

oul

d

 ca

use 

fl

ashb

ack 

in

 t

he 

ap

pl

iance

 ve

st

ibul

e.

 

4.

Wi

th

 t

he m

a

in

 bu

rn

er

 i

n

 o

per

at

io

n

, pai

nt

 t

he pi

pe 

jo

in

ts

 (

incl

udi

ng ad

apt

er

s)

 an

d t

h

e

 c

ont

ro

l i

n

le

t and 

ou

tl

et

 w

it

h

 r

ich 

soap

 an

d w

a

te

r s

o

lu

ti

on.

5.

If

 ano

th

er

 l

eak i

s

 det

ect

ed,

 t

ight

en t

he adap

te

scr

ew

s,

 j

o

in

ts

, a

nd 

pi

p

e

 conne

ct

ions.

6

.

R

epl

ace t

h

e par

t i

f a 

leak can

not

 b

e

 s

top

ped.

Chec

k and Ad

just Pilo

t Flame

Th

pi

lo

t f

lam

e

 sho

ul

d

 en

vel

op 

3/

8

 t

o

 1/

2 i

n

. (

1

0

 t

o

 13 

m

m

of

 t

he t

ip of

 t

he 

ig

ni

te

r-

s

ensor

. Se

e F

ig.

 9

If

 t

he 

pi

lo

fl

am

e i

s

 sm

al

l or

 l

a

zy

th

e

 i

n

le

t gas pr

essu

re

 m

a

y be t

oo 

lo

w

, or

 t

he pi

lo

o

ri

fi

c

e m

a

y be par

ti

al

ly

 cl

o

gged

. C

h

eck 

an

re

p

a

ir

 as necess

ar

y.

 I

th

e

 pi

lo

t f

lam

e i

s

 har

d and

 

no

is

y,

 t

he i

n

le

t gas pr

essur

e m

a

y be t

o

h

igh

. The

 g

a

con

tr

ol

 h

a

s a

 p

ilo

adj

ust

m

ent

 m

e

ch

ani

sm

 t

o

 r

e

duce 

the 

pi

lo

t f

low

 i

f nec

essar

y.

 I

f pi

lo

t adj

u

s

tm

en

t i

s

 ne

cessar

y,

 

pr

oce

ed as f

o

llo

w

s:

1.

R

e

m

o

ve pi

lo

t adj

u

s

tm

en

t cove

r scr

ew

. See

 F

ig.

 6.

2.

Th

e pi

lo

ad

ju

st

m

ent

 i

s

 shi

pped at

 t

h

e

 f

u

ll pi

lo

g

a

fl

ow

 r

a

te

. T

u

rn

 t

h

inne

r adj

ust

m

ent

 scr

ew

 

cl

ockw

is

e

  

if

 t

he i

n

le

pr

es

sur

is

 t

o

o

 hi

gh.

 

T

u

rn

 t

he i

n

ner

 a

d

ju

st

m

e

n

t scr

ew

 cl

ockw

is

e

 

to

 de

cr

e

a

se o

r c

ount

er

cl

o

ckw

is

e  

to

 in

cr

eas

pi

lo

t f

lam

e.

3.

R

epl

ace t

h

e cover

 s

c

re

w

 af

te

r t

h

a

d

ju

st

m

e

n

t t

o

 

pr

eve

nt

 ga

leaka

ge.

Fi

g.

 9

. Pr

o

p

er

 f

lam

e adj

us

tm

e

n

t.

MV

MV/PV

PV

GND

(BURNER)

24V

GND

24V

SPARK

S8600

POWER SUPPLY.  PROVIDE DISCONNECT MEANS 

AND OVERLOAD PROTECTION AS REQUIRED.

ALTERNATE LIMIT CONTROLLER LOCATION.

MAXIMUM WIRE LENGTH 3 ft [.9 m].  

CONTROLS IN 24V CIRCUIT MUST NOT BE IN 

GROUND LEG TO TRANSFORMER.

FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER 

PLUG, CONNECT THERMOSTAT TO TH-W.  LEAVE 

24V OPEN.  DO NOT REMOVE VENT DAMPER PLUG.

1

2

3

4

5

M9056

GROUND

PILOT GAS

SUPPLY

2

4

3

Q345, Q346,

Q348, Q362, Q381 

PILOT BURNER/

IGNITER-SENSOR

L1

(HOT)

1

L2

LIMIT 

CONTROLLER

THERMOSTAT

5

TH-W

(OPT)

VENT

DAMPER

PLUG 

(OPT)

5

GAS CONTROL

TERMINALS

PV

PV/MV

MV

SENSE

PROPER FLAME 

ADJUSTMENT

IGNITER-

SENSOR 

M3080A

3/8 TO 1/2 INCH

(10 TO 13 mm)

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

7

69-1

225—4

F

ig.

 5.

  Pr

op

er

 u

se of

 w

ren

ch on ga

c

ont

ro

w

it

h

 a

nd w

it

h

o

u

fl

ange

s.

Fi

g.

 

6

. T

op 

vi

ew

 o

gas

 c

ont

ro

l.

Fi

g.

 7.

 A

lw

ays

 u

se new

 c

o

m

p

re

s

s

io

n f

it

ti

n

g

.

Wi

ri

n

g

Fol

lo

w

 t

h

w

ir

ing i

n

st

ru

ct

io

n

s

 f

u

rn

is

hed by t

he appl

ia

nce 

m

anuf

act

ur

er

if

 ava

ilabl

e

or

 use

 t

he g

ener

al

 i

n

st

ru

ct

ions 

pr

ovi

d

ed bel

ow

. When t

hese i

n

st

ru

ct

ions di

ff

er

 f

rom

 t

he 

appl

ia

nce m

anuf

act

ur

er

, f

o

llow

 t

he appl

ia

nce 

m

anuf

act

ur

er

 i

n

st

ru

ct

ions.

A

ll w

ir

in

g

 m

u

s

com

pl

y w

it

h

 app

lic

abl

e

 e

lect

ri

cal

 codes 

an

d o

rd

ina

nces.

 

D

isco

nnect

 pow

er

 sup

pl

y

 be

fo

re

 m

a

ki

ng w

ir

ing 

con

nect

io

ns t

o

 pr

even

el

ect

ri

cal

 sho

ck o

eq

ui

pm

en

da

m

a

ge.

1.

C

heck 

the 

pow

er

 su

ppl

y

 r

a

ti

ng

 o

n

 t

he 

ga

s co

nt

ro

an

m

a

k

e

 s

u

re

 i

t m

a

tc

hes t

he avai

la

b

le supp

ly

In

st

al

a

 t

ransf

or

m

e

r,

 t

h

er

m

o

st

at

 and ot

her

 cont

ro

ls

 

as r

equi

red.

2.

C

onne

ct

 co

nt

ro

l ci

rc

ui

t t

o

 t

he g

a

s con

tr

ol

 t

e

rm

in

a

ls

S

ee Fig

. 8.

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

M3079

HI-LO 

ADJUSTMENT SCREWS 

(UNDER CAP)

REGULATOR

VENT COVER

INLET

INLET

OUTLET

M10968A

HI

LO

OUTLET

PRESSURE 

TAP

WIRING

TERMINALS (3)

INLET

PRESSURE TAP

PRESSURE REGULATOR

ADJUSTMENT

(UNDER CAP SCREW)

PILOT OUTLET

PILOT ADJUSTMENT

(UNDER CAP SCREW)

GAS

CONTROL

KNOB

TWO-STAGE 

PRESSURE

REGULATOR 

MODEL

GAS CONTROL

TIGHTEN NUT ONE TURN

BEYOND FINGER TIGHT.

FITTING BREAKS OFF AND CLINCHES 

TUBING AS NUT IS TIGHTENED.

TO PILOT

BURNER

M3076A

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...

Page 7: ......

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...

Page 13: ......

Page 14: ......

Page 15: ......

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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