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®
Replacing Control Valve
Series:
200209 – 450000
LP Gas
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Tools required: • # 2 Phillips screw driver • 8mm open end wrench • 9mm open end wrench • 10mm open end wrench • 12mm open end wrench • 5/8” open end wrench • 3/4” open end wrench • 7/16” nut driver or wrench (series 235000-450000) • Locking pliers • Leak test solution • Ratchet • 9/16” socket • Extension 7.5” in length • Penetrating oil • Leak test solution 1 part liquid soap and 3 parts water. DANGERS and Cautions 1
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Steps 1-5 1. T urn your LP gas tank off, unscrew regulator and remove LP gas tank. 2. Remove the dome. 3. Remove the access panel and the igniter wire, set aside 4. Disconnect the gas line. 5. Remove the 4 screws that hold the engine to the post and remove the engine. Replacing Control Valves Series 200209 – 450000 LP Gas 404121 1 Replacing Control Valves Series 200209 – 450000 LP Gas 404121 2
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Step 6 Remove emitter screen: A. 200209, 200308, 200605 – remove the 4 screws using a Phillips screw driver that attach the emitter to the emitter bottom, with the screws removed, remove the emitter. B. 230000-235000, 450000 – you will need to use the ratchet with an extension along with the 9/16” socket and remove the nut and washer in the bottom of the emitter. There are 3 bolts that attach the emitter to the em
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Step 7 1. Disconnect the burner supply tube from the control valve, using a 5/8” open end wrench. Note: There is a brass nut on the top of the control valve. You must remove the brass nut. 2. Remove the 2 screws on either side of the emitter bottom. Note: 230000 and 235000 do not have these screws. 3. Remove the burner by pulling it up. Be careful not to damage the wires on the pilot assembly. Replacing Control
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Step 8 1. Disconnect the pilot supply tube using the #10mm open end wrench. Note: You may need to use the #12mm open end wrench to hold the pilot orifice. 2. Remove the 2 screws that hold the pilot assembly to pilot bracket. 3. Remove the pilot assembly. Replacing Control Valves Series 200209 – 450000 LP Gas 404121 5 Replacing Control Valves Series 200209 – 450000 LP Gas 404121 6
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Step 9 Disconnect the thermal-couple 1. Remove the screw from the access panel on the rear of the valve housing. 2. Remove the access panel. 3. Using the #8 mm open end wrench remove the nut with wires coming out of it. Note: When reinstalling the nut to the back of the control valve finger tighten plus a 1⁄4 turn. Do not overtighten. 4. Remove the tip switch bracket on the front of the valve housing by removin
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Step 10 Disconnect the control valve 1. Remove the brass nut that holds the control valve in the valve housing using the 3/4” open end wrench 2. Remove the control valve from the valve housing 3. Remove the pilot supply tube using a #12 mm open end wrench. Replacing Control Valves Series 200209 – 450000 LP Gas 404121 7 Replacing Control Valves Series 200209 – 450000 LP Gas 404121 8
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Step 11 Re-install pilot supply tube and the control valve: 1. Connect the pilot supply tube to the control valve 2. Place the control valve into the valve housing. Secure the valve with the brass nut and tighten. Replacing Control Valves Series 200209 – 450000 LP Gas 404121 7 Replacing Control Valves Series 200209 – 450000 LP Gas 404121 8
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Step 12 Reinstall the thermal-couple: 1. Attach the thermal-couple to the back of the control valve in the valve housing. Finger tighten plus a 1/4 turn with the #8mm open end wrench. 2. Reinstall the small access panel on the back of the valve housing Replacing Control Valves Series 200209 – 450000 LP Gas 404121 9 Replacing Control Valves Series 200209 – 450000 LP Gas 404121 10
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Step 13 1. Slide the burner assembly into the valve housing. 2. Attach the burner supply tube to the top of the control valve. Do not over tighten. 3. Tighten the two screws that hold the burner in place. Replacing Control Valves Series 200209 – 450000 LP Gas 404121 9 Replacing Control Valves Series 200209 – 450000 LP Gas 404121 10
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Step 14 1. Attach the pilot to the pilot bracket. 2. Connect the pilot supply tube to the pilot. Replacing Control Valves Series 200209 – 450000 LP Gas 404121 11 Replacing Control Valves Series 200209 – 450000 LP Gas 404121 12
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Step 15 200209, 200308, 200605 1. Attach the emitter to the valve housing, using 3 screws. 2. Secure. 230000 - 450000 1. Place the spacer ring on the burner stud. 2. Insert the burner stud through the bottom of the emitter. Secure with washer and nut. Do not fully tighten. 3. Align the holes of the emitter with the valve housing, and secure with screws. 4. Tighten nut inside emitter. Replacing Control Valves Ser
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Steps 16-19 16. Attach the engine to the post 17. Burner Connections 1. Make sure the regulator valve and hose connections are securely fastened to the burner and the tank. 2. If your unit was assembled for you, visually check the connection between the burner pipe and orifice. Make sure the burner pipe fits over the orifice. WARNING: Failure to inspect this connection or follow these instructions could cause
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® ® For assistance call 1.800.762.1142. For assistance call 1.800.762.1142. Step 20 - IMPORTANT Perform leak check. WARNING FOR YOUR SAFETY If you smell gas - 1. Shut off gas to appliance. 2. Extinguish any open flame. 3. If odor continues, immediately call your gas supplier or your fire department. 1. Do not operate if gas leak is present. Gas leaks may cause a fire or explosion. 2. You must follow all leak-checking procedures before operating. To prevent fire or explosion hazard when test
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® For assistance call 1.800.762.1142. Tank/Gas Line Connection 1. Make 2-3 oz. of leak solution by mixing one part liquid dishwashing soap with three parts water. X 2. Make sure control knobs are off. 3. T urn LP gas tank ON at valve. X X 4. Spoon leak chec k solution at all “x” locations X 5. If any bubbles appear turn LP gas tank OFF, reconnect and re-test. If you continue to see X bubbles after several attempts, disconnect LP gas source and contact 1.800.762.1142 for assistance. 6. I
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Blue Rhino Global Sourcing, LLC 104 Cambridge Plaza Drive, Winston-Salem, NC 27104 USA 1.800.762.1142, www.bluerhino.com © 2004 Blue Rhino Global Sourcing, LLC All Rights Reserved. ® Endless Summer is a registered trademark of Blue Rhino Global Sourcing, LLC All Rights Reserved. ® Blue Rhino is a registered trademark of Ferrellgas, L.P. All Rights Reserved. 23004500RCV-IS-100
