resideo Gas Conversion Kits Installation Guide

396221, 396221-1, 396221-3 and 396222,
396222-2 Gas Conversion Kits
FOR VR82, VR83, AND SV9 SERIES OF SINGLE STAGE
COMBINATION GAS CONTROLS

INSTALLATION INSTRUCTIONS

APPLICATION

The 396221, 396221-1, and 396221-3 LP Conversion Kit changes VR82, VR83, and SV9 series of single-stage combination gas controls from regulated natural gas to regulated LP gas. The 396222 and 396222-2 Natural Gas Conversion Kit changes VR82, VR83, and SV9 series of single-stage combination gas controls from regulated LP gas to regulated natural gas. Kits include a plastic pressure regulator adjustment screw, spring, and conversion label.
To use this kit, make sure that the gas control is single-stage and is equipped with a standard or slow opening pressure regulator (VR82xx, VR83xx, SV9xx A, H, K, M, S, and T).
NOTE: Step regulator valves, convertible regulator valves, two-stage valves, and SV9570 valves cannot be converted with this kit.
INSTALL ATION
When Installing this Product…

1.  Read these instructions carefully. Failure to follow instructions can damage the product or cause a hazardous condition.
2. Check ratings given in instructions and on the product to make sure the product is suitable for your application.
3.  The installer must be a trained, experienced service technician.
4.  After installation is complete, use these instructions to check out product operation.

WARNING
Fire or Explosion Hazard.
Can cause property damage, serious injury or death.
Follow these warnings exactly:

1. Disconnect power supply before wiring to prevent electrical shock or equipment damage.
2. To avoid the dangerous accumulation of fuel gas, turn off the gas supply at the appliance service valve before starting the installation and perform a Gas Leak Test after completion of installation.
3.  Use only your hand to turn the gas control knob or switch. Never use any tools. If the gas control knob or switch will not operate by hand, then a qualified technician should replace the gas control. Force or attempted repair may result in fire or explosion.
4.  Change main and pilot burner orifices to meet appliance manufacturer specifications.

To convert from one gas to another:

1.  Turn off the gas supply at the appliance service valve.

2. Remove metal regulator cap screw and plastic pressure regulator adjusting screw. Refer to Fig. 1–3.

3.  Remove the existing spring.

4.  Insert the replacement spring. Refer to Fig. 4. THERMOCOUPLE CONNECTION AND RED RESET BUTTON ON STANDING PILOT MODELS ONLY.
   Fig. 1. Top view of VR82xx, VR83xx, A, H, K, and M combination gas controls. Fig. 2. Top view of VR8205S, T combination gas controls. 396221, 396221-1, 396221-3 AND 396222, 396222-2 GAS CONVERSION KITS Fig. 3. Top view of VR8215S, T combination gas controls. REUSE EXISTING METAL CAP SCREW. Fig. 4. Conversion kit installation in the regulator.
   

5.  Install the new plastic pressure regulator adjustment screw.

6. Check and adjust the regulator setting using a manometer or by clocking the gas meter. See Check and Adjust Gas Input and Burner Ignition section.

7.  Replace metal regulator cap.
   NOTE: Reuse the existing metal cap screw.

8.  Mount conversion label on the gas control.

9. Install the gas control and appliance according to appliance manufacturer instructions.
   START-UP
   Gas Control Knob and Switch Settings
   OFF: Prevents pilot and main burner gas flow.

PILOT (On standing pilot controls only): Permits pilot burner gas flow when the red knob is held down or thermocouple current is above power unit dropout value.
ON: Permits gas flow into gas control. Pilot burner gas is controlled as in the PILOT position for standing pilot and intermittent pilot systems. Main burner gas flow is controlled by a thermostat and automatic valve operators.

Perform Gas Leak Test
WARNING
Fire or Explosion Hazard.
Can cause property damage, serious injury or death.
Check for gas leaks with soap and water solution any time work is done on a gas system.
Gas Leak Test

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

**Light Pilot (Standing Pilot Models)**

1. Turn the gas control knob clockwise to OFF. Wait five minutes to dissipate any unburned gas. Smell for gas around the appliance near the floor. Do not relight the pilot flame if you smell gas.
2. Turn the gas control knob counterclockwise to PILOT. Push down and hold the knob while lighting the pilot flame.
3.  Hold down the gas control knob for about one minute, then release.
   a. If the pilot flame goes out, turn the gas control knob clockwise to OFF and repeat steps 1 through 3.
   b. If the pilot flame remains lit, turn the gas control knob counterclockwise to ON.
   Turn on System (Intermittent and Direct Ignition Systems)
   Rotate the gas control knob counterclockwise **to ON or slide the gas control switch to ON.
   Turn on Main Burner
   Follow appliance manufacturer instructions or adjust thermostat setting to call for heat.
   Adjust Pilot Flame**
   The pilot flame should envelop 3/8 to 1/2 in. (10 to 13 mm) of the thermocouple or igniter-sensor tip. Refer to Fig. 5. To adjust pilot flame:

1. Remove pilot adjustment cap screw. Refer to Fig. 1.
2. Turn the inner adjustment screw clockwise to decrease or counterclockwise to increase the pilot flame.
3. Always replace cap screw after adjustment and tighten firmly to safeguard proper operation.

Check and Adjust Gas Input and Burner Ignition

WARNING
Fire or Explosion Hazard.
Can cause property damage, serious injury, or death.

1. Do not exceed input rating stamped on appliance nameplate, or manufacturer-recommended burner orifice pressure for size orifice(s) used. Make certain the primary air supply to the main burner is properly adjusted for complete combustion. Follow appliance manufacturer
   instructions.

2. IF CHECKING GAS INPUT BY CLOCKING GAS
   METER:
   a. Make sure that the only gas flowing through the meter is for the appliance being checked.
   b. Make certain that other appliances are turned off with their pilot flames extinguished (or deduct their gas consumption from the meter reading).
   c. Convert flow rate to Btuh as described in form 70-2602, Gas Controls Handbook, and compare to Btuh input rating on the appliance nameplate.

3.  IF CHECKING GAS INPUT WITH MANOMETER:
   a. Be sure the gas control knob or switch is in the off position before removing the outlet pressure tap plug to connect the manometer (pressure gauge).
   b. Shut off the gas supply at the appliance service valve, or for LP gas, at the gas tank, before removing the outlet pressure tap plug and before disconnecting the manometer and replacing the outlet pressure tap plug.
   c. Perform the Gas Leak Test at the outlet pressure tap plug.
   Checking Gas Pressure Using Meter Clocking Method

NOTE : Use this method when the manometer is not available or when manifold pressure is not specified in. WC (kPa) by the burner
manufacturer.

1.  Make sure that the only gas flowing through the meter is for the appliance being checked.

2. Make certain that other appliances are turned off with their pilot flames extinguished (or deduct their gas consumption from the meter reading).

3.  Turn gas control knob or switch to ON position.

4. To obtain an accurate outlet pressure reading, cycle the main burner on and off several times to stabilize the pressure regulator diaphragm.

5.  Using a watch with a second hand, carefully clock the gas meter to determine the time per revolution. Use Table 1 to determine the exact main burner gas flow rate in cubic feet per hour (cfh).
   a. For one ft3 per revolution gas meter dials, use Table 1 directly.3
   b. For 1/2 ft per revolution gas meter dials:
   (1) Determine the time for two dial revolutions
   (2) Use Table 1 directly.
   c. For two ft3 per revolution gas meter dials:
   (1) Determine the time for one complete dial revolution.
   (2) Divide time by two.
   (3) Use Table 1 directly.

6.  Compare actual input with burner manufacturer-recommended input (stamped on burner nameplate). To convert Btuh rating to cfh (m3/hr) use the following formula:
   Input Rating in BTUh = (cfh) x (the BTU content of the gas)

7.  If necessary, adjust the pressure regulator to match the appliance rating.
   a. Remove metal pressure regulator adjustment cap screw.
   b. Using a screwdriver, turn the inner plastic adjustment screw clockwise to increase or counterclockwise to decrease gas pressure to the main burner.
   c. Always replace the metal cap screw and tighten firmly to prevent gas leakage.

8.  Turn gas supply back on to other appliances and relight all pilot flames according to appliance manufacturer instructions.

9.  Proceed to the Checkout section.

Checking Gas Pressure Using a Manometer (Pressure Gauge)

1.  Turn the gas control knob to PILOT for standing pilot systems or turn gas control knob or slide switch to OFF for intermittent and direct ignition systems.

2.  Remove outlet pressure tap plug from gas control and connect a pressure gauge. Refer to Fig. 1–3.

3.  Turn gas control knob or slide gas control switch to ON position.

4. To obtain an accurate outlet pressure reading, the main burner must be cycled on and off several times to stabilize the pressure regulator diaphragm.

5.  Light main burner and read pressure gauge.

6. If necessary, adjust the pressure regulator to match the appliance rating.
   a. Remove metal pressure regulator adjustment cap screw.
   b. Using a screwdriver, turn the inner plastic adjustment screw clockwise to increase or counterclockwise to decrease gas pressure to the main burner.
   c. Always replace the metal cap screw and tighten firmly to prevent gas leakage.

7.  Turn the gas control knob to PILOT for standing pilot systems or turn gas control knob or slide switch to OFF for intermittent and direct ignition systems.

8.  Remove pressure gauge and replace outlet pressure tap plug and metal pressure regulator cap screw.

9. Proceed to the Checkout section.

CHECKOUT

1. Make certain the primary air supply to the main burner is properly adjusted for complete combustion at the final pressure regulator setting. The main burner must light reliably under all conditions.
2. Place the system in operation and observe through at least one complete cycle to assure all controls are operating properly.
3. If manometer (pressure gauge) method is used, perform Gas Leak Test at outlet pressure tap plug.
4.  Apply the conversion label in the conversion kit to the gas control, heating appliance, and any other controls to show the conversion to a new type of gas.

Table 1. Converting Gas Flow Rate.

69-1564EF-03

www.resideo.com

Resideo Technologies, Inc.
1985 Douglas Drive North, Golden Valley, MN 55422
1-800-468-1502
69-1564EF—03 M.S. Rev. 03-20 | Printed in the United States

© 2020 Resideo Technologies, Inc. All rights reserved.
This product is manufactured by Resideo Technologies, Inc. and its affiliates.

References

• Smart Home Solutions in EMEA | Resideo

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