HONEYWELL Controls And HVAC Accessories Manual L0210045
User Manual: HONEYWELL HONEYWELL Controls and HVAC Accessories Manual HONEYWELL Controls and HVAC Accessories Owner's Manual, HONEYWELL Controls and HVAC Accessories installation guides
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INTERMn'TENTPILOT MODULES
$8600, S86_10,$8660, $8670
APPLICATION
These ignitionmodules provide ignitionsequence, flame
monitoring and safety shutoff for intermittent pilot central
furnaces and heating appliances. $8600 and $8660 models provide up to 1,0 A pilot and 1.0 A main valve current
rating. $8610 and $8670 provide up to 1.0 A pilot and 2.0
A mainvalve current rating. Minimum ambient temperature
TABLE 1--1NTERMII-rENT
MODEL
$8600A,
$8610A
$8600F,
$8610F
$8600B,
$8610B
$8600H,
$8610H
$8600M
IGNITERSENSOR
TYPE
TYPE
OF GAS
Separate
Natural
rating is -40" F [-40° C]. Maximum ambient rating is +175 °
. F [+79° C] for $8600, $8660 and for $8610, $8670 used
with 1.0 A or less main valve. Maximum ambient ratingfor
$8610, $8670 used with 1.0 to 2.0 A main valve is + 165° F
[+74° C]. See Table I for a summary of other differences
between models.
PILOT IGNITION MODULES.
100
PERCENT
SHUTOFF
LOCKOUT
TIMING
None
No
No
Spark on until pilot
lightoIf or manual
shutoff; pilot vatve
open until manual
shutdown.
Natural
or LP
None
Yes, at
lockout
15 or 90
Natural
or LP
None
Spark on until
lightoff or lockout;
pilot valve closes
on lockout.
Spark and pilot gas
on until shutoff.
After 5 min. rain,
PREPURGE
TIMING
Combination
Separate
Combination
Combination
Yes, at 90
sac. max.
sec. max.,
as ordered
No,
continuous
retry
$8660D,
$8670D
Combination
Natural
or LP
45 sec.
Yes, at
lockout
15or
90
Sec. max.,
as ordered
IGNITION
SEQUENCE a
(6 min. nora.) delay,
ignition starts again.
Ignition, wait, retry
repeats until pilot
lightsor system is
shut down manually.
Ignition trial follows
prepurge; spark on
until lightoffor
lockout; pilot valve
closes on lockout.
a If established flame is lost, all models restart ignition trial.
PLANNING
THE INSTALLATION
Intermittent pilot systems are used on a wide variety of
central heating equipment and on heating appliances such
as commercial cookers, agricultural equipment, industrial
heating equipment and pool heaters. Some of these applications may make heavy demands on the controls, either
because offrequent cycling, or because of moisture, corrosive chemicals, dust or excessive heat in the environment.
In these situations, special steps may be required to prevent nuisance shutdowns and premature control failure.
These applications require Honeywell Residential Division
Engineering review; contact your Honeywell Sales Representative for assistance.
FREQUENT CYCLING
These controls are designed for use on space heating
appliances that typically cycle 3 to 4 times an hour during
the heating season and not at all duringthe cooling season.
In an applicationwith significantlygreater cycling rates and
closerto year-round use, we recommend monthly checkout
because the controls may wear out more quickly.
WATER OR STEAM CLEANING
Once a module or gas control has been wet, it may
operate unreltablyand must be replaced. If the appliance is
J.A.
11-89
likely to be cleaned with water or steam, the controls and
associated widng shouldbe covered sowater or steam flow
cannot reach them. The controls should be high enough
above the bottom of the cabinet so they wilt not be subject
tofloodingor splashingduring normalcleaning procedures.
If necessary, shield the controls to protect them from
splashing water. A NEMA 4 enclosure is recommended for
the ignition module; see the Electronic Ignition Service
Manual, form 70-6604.
HIGH HUMIDITY OR DRIPPING WATER
Over time, dripping water or high ambient humiditycan
create unwanted electrical paths on the module circuit
board, causing the moduleto fail. Neverinstall an appliance
where water can drip on the controls.
In addition, high ambient humidity can cause the gas
control to corrode, and finally to fail.
Wherethe appliance may be installed in a humid atmosphere, makesure air circulationaround the module and gas
control is adequate to prevent condensation. It's also important to regularly check out the system. A NEMA 4
enclosure may be needed; see the Electronic Ignition
Service Manual, form 70-6604.
Form Number 69-0463
Cfrloneywell Inc. 1989.
CORROSIVE
CHEMICALS
Corrosive
chemicals
canalsoattack
themodule
andgas
control
andeventually cause a failure. Where chemicals
may be used routinely for cleaning, make sure the cleaning
solution cannot reach the controls. Where chemicals are
likely to be suspended in air, as in some industrial and
agricuifural applications, protect the ignition module from
exposure with a NEMA 4 enclosure; see the Electronic
Ignition Service Manual, form 70.6604.
DUST OR GREASE ACCUMULATION
Heavy accumulation of dust or grease may cause the
controls to marfunction. Where dust or grease maybe a
problem, provide covers for the module and the gas control
that will limit environmental contamination. A NEMA 4
enclosure is recommended for the ignitionmodule; see the
Electronic Ignition Service Manual, form 70-6604.
HEAT
The controlscan be damaged by excessively high temperatures. Make sure the maximum ambient temperature
at the control locations will not exceed the rating of the
control, if the appliance normally operates at very high
temperatures, insulation, shielding,and air cimulatldn may
be necessary to protect the controls. Proper insulation or
shielding should be provided by the appliance manufacturer; make sure adequate air circulation is maintained
when the appliance is installed.
INSTALLATION
WHEN INSTALLING THIS IGNITION SYSTEM...
1. Read these instructions carefully. Failure to follow
them could damage the components or cause a hazardous
condition.
2. Check the ratings given inthe instructionsand on the
components to make sure they are suitable for your application.
3. Installer must be a trained, experienced service technician.
4.After installation is complete, check out component
operation as provided in these instructions.
FIRE OR EXPLOSION HAZARD.
CAN CAUSE SERIOUS INJURY OR DEATH.
1. The ignition module can malfunction If It gets
wet, leading to accumulation of explosive gas.
Never Install where water can flood, drip or
condense on module.
• Never try to use a module that has been
wet--replace It.
2. Liquefied petroleum (LP) gas is heavier than
air and will not vent upward naturally.
Do not light pilot or operate electric
switches, lights, or appliances until you are
sure the applisnce area Is free of gas.
1. Disconnect power supplybstora beginningwiring
to prevent electrical shock or equipment damage.
2. If a new gas control is to be installed, turn off gas
supply before starting installation. Conduct Gas
Leak Test according to gas control manufacturer's instructions after the gas control is installed.
3. If module must be mounted near moisture or
water, provide suitable waterproof enclosure.
PERFORM PREINSTALLATION SAFETY INSPECTION
The preinstallation checks described in ANSI Standard
Z21.71 on page 19 mustbe done before the replacement
module is installed. If a condition which could result in
unsafe operation isdetected, the appliance should be shut
off and the owner advised of the unsafe condition. Any
potentially unsafe condition must be corrected before proceeding with the installation.
Maintenance Requirements In Severs Environments
Regular preventive maintenance is important in any application,but especially so in commercial cooking, agricul.
tural, and industrial applications because:
In many such applications, particularly commercial
cooking, the equipment operates 100,000-200,000
cycles per year. Such heavy cycling can wear outthe
gas control in one to two years, A normal forced air
furnace, for which the controls were originally intended, typically operates less than 20,000 cycles
per year.
• Exposure to water, dirt, chemicals, and heat can
damage the moduleor the gas control and shut down
the control system. A NEMA 4 enclosure can reduce
exposure to environmental contaminants. See Electronic Ignition Service Manual, form 70÷6604.
The maintenance program shouldincluderegular checkout of the system as outlined under Checkout, page 11.
FIRE OR EXPLOSION HAZARD
MAY CAUSE PROPERTY DAMAGE, SEVERE
INJURY OR DEATH
Do not attempt to take the module apart or to clean
it. Improper reeasembly and cleaning may cause
unreliable operation.
Maintenance frequency must be determined individ ually
for each application. Some considerations are:
Cyc/ing frequency. Appliances that may cycle more
than 20,000 times annually should be checked
monthly.
• /ntermittentuse.Appliancasthatareusedssasonally
should be checked before shutdown and again before the next use.
• Consequence of unexpected shutdown. Where the
cost of an unexpected shutdown would be high, the
system should be checked more often.
• Dusty, wet, or corrosive environment, Since these
environments can cause the controls to deteriorate
more rapidly, the system should be checked more
often.
Any control should be replaced if if does not perform
properly on checkout or troubleshooting. In addition, replace any module if it is wet or looks like it has ever been
wet. Protective enclosures as outlined under "Planningthe
installation"are recommended regardless of checkout frequency.
MOUNT IGNITION MODULE
Select a location close enough to the burner to allow a
short (3 ft. [0.9 m] max.), direct cable route to the igniter.
Ambient temperature at the module must be within the
range listed under APPLICATION, page 1. The module
must be protected from water, moisture, corrosive chemicals and excessive dust and grease.
Werecommend
mounting the modulewith the terminals
down to protect them from dripping water and dust. It can
also be mounted with the terminals on either side. DO NOT
MOUNT with terminals pointing up. Fasten securely with
four No. 6-32 machine or No. 8 sheetmetal screws.
Cable must be no longerthan 36 in.[0.9 m], To construct
a cable, fit one end of ignitioncable with 1/4 in. diameter
Rajah connector receptacle and the other with a 1/4 in.
female quick connect. Protect both ends with insulated
boots.
MOUNT THE SYSTEM CONTROLS
Mount any required controls, such as the gas control,
spark igniter, flame sensor, thermostat, limit and transformer according to manufacturer's instructions.
NOTE: The cable must notrun in continuous contact with a
metal surface or spark voltage will be greatly reduced.
Use ceramic or plastic standoff insulators as required.
To install:
1. Connect one end of the cable to the male quick
connect SPARK terminal on the ignition module.
2. Connect the other end of the cable to the igniter or
igniter-sensor stud on the pilot burner/igniter-sensor.
WIRE THE SYSTEM
1. Check the wiring diagram furnished by the appU.
ance manufacturer, if available, for circuits differing from the wiring hookups shown. Carefutly
follow any special instructions affecting the general procedures outlined below.
2. Disconnect the power supply before making wiring connections to prevent etactrica/ shock or
equipment damage.
Connect Vent Damper
The DSOB Vent Damper can be used with all ignition
modules, althoughthe Molex plugprovidedon some modules
simplifies wiring connections when used with the D80D
Plug-in Vent Damper. Once a module with vent damper
plug has powered a vent damper circuit, if cannot be used
in a gas system withouta vent damper. A non-replacaable
fuse inthe module blowson initialpower-up. Once thisfuse
has blown the module won't work unless the vent damper
is connected.
To connect the plug-in model to D80D:
t. Remove the plugfrom the terminal striponthe ignition
module case and discard.
2. Usingthe wiringharness supplied, insertthe matching
pin plug into receptacle on case and other end to vent
damper.
To connect the DSOS, follow the wiring diagrams supplied with the vent damper or see Fig. 7 for typical connections.
IMPORTANT
t, As shown in the wiring diagrams, a common
ground is required on:
a. The pilot burner mounting bracket, and
b. The GND(BURNER) terminal on the ignition
module. Failure to use the GND(BURNER) terminal may result in intermittent loss of spark and/or
loss of ffame current sensitivity.
2. Make sure the transformer has edequate VA. The
ignition modute requires at least 0.2 A at 24 Vac.
Add the current draws of all other devices in the
control circuit, includingthe pilot and main valves
in the gas control,and multiply by 24 to determine
the total VA requirement of these components.
Add this total to 4.8 VA (for the ignition module).
The result is the minimum transformer VA rating.
Use a Class II transformer if replacement is required.
Connect Ignition Module
1. Connect remaining system components tothe ignition
module terminals as shown in the appropriate wiring diagram, Figs. I to 10.
• Fig. 1 is a basic circuit for a heating only atmos- .
pheric burner with S8600F,H,M; S8610F, H;
$8660D or $8670D.
• Fig. 2 shows S8600F,H,M; S8610F,H with vent
damper plug in a heating only atmospheric burner
system with D60D vent damper. Neveruse a vent
damper in an LP gas system or in a fan-assisted
combustion system.
• Figs. 3 and 4 show S8600A,B; S8610A,B with
separate sensor and igniter, with and without the
D60D vent damper.
• Figs.5-1O showS8600F, H,M;S6610F, H;S8660D;
and $8670D in avariety of systems, with alternate
connections for modules with vent damper plug.
Remember, however, that a vent damper should
not be used in an fan-assisted combustion system
oran LPgas systemand thatthe vent damper plug
must notbe removed excapttoconnect the module
to a DSOD with the plug-in cable. S8600A,B;
$8610A,B can be substituted inthese drawings by
simplyconnecting the igniterand sensoras shown
in Figs. 3 and 4.
2. Refer to heating appliance manufacturer's instructions for wiring auxiliary controls.
3. Adjust thermostat heat anticipator to match system
current draw. The current draw equals the total current required for the ignition module (0,2 A) plus the gas control
and any other auxiliary equipment in the control circuit.
Connect Ignition Cable
Use Honeywell ignition cable or construct an ignition
cable that conformsto suitable national standards such as
Underwriters Laboratories Inc. See Tables 2 and 3.
TABLE 2---HONEYWELL PREASSEMBLED
CABLES, UL STYLE 3257).
_ABLE
3ART
_IUMBER
394800-30
LENGTH
30 in.
MODULE
END
114 in: quick
connect,
insulated
394801-30
30 in.
1/4 in. quick
connect,
insulated
IGNITION
IGNITER
END
Rajahconnector receptacle,
90 dag. rubber
boot
Rajahconnector receptacle,
straight rubber
boot
TABLE 3--RECOMMENDED
IGNITION CABLE FOR
FIELD ASSEMBLY.
:ABLE
rYPE
JL Style 3217
JL Style 3257
VOLTAGE
RATING (rms)
10,000
10,00O
TEMPERATURE
RATING
C
F
150
302
250
484
Connect Gee Control
Use No 18 gauge solid or stranded wire. Use 1/4 in.
female quick connects for module connections. Connect to
gas control terminals as shown in wiring diagrams, using
terminals appropriate to the gas control.
3
69-0463
and the 24V terminal on the module. To change out a
module with "I'H-R, TH-W terminals:
1. Remove the wires from the 25V(2) and TH-R termi.
nals on the old module. Connect these two wires with a
soldedess connector.
2.Tag and remove the remaining wires from the old
module.
3. Remove the old module and mountthe new one inthe
same location.
4. Reconnect the remaining wires as shown in Table 4.
5. Increase the thermostat anticipator setting by 0.2 A.
Ground
ControlSystem
Theigniter,
flamesensor
andignition
module must
share a common ground with the main burner. Use thermoplasticinsulated wire with a minimum ratingof 105° C [221 °
F] for the ground wire; asbestos insulation is not acceptable. If necessary, use a shield to protect the wire from
radiant heat generated by the burner. Connect the ground
wire as follows:
1.Fit one end of the ground wire with a female 114in.
quick-connect terminal and connect it to the male quickconnect GND(BURNER) terminal on the ignitionmodule.
2. Strip the other end of the wire and fasten it under the
igniter bracket mounting screw, ff necessary, use a shield
to protect the ground wire from radiant heat.
3. The burner serves as the common grounding area. ff
the re isnotgood metal-to-metal contactbetween the burner
and ground, run a lead from the burner to ground.
TABLE ,S--TERMINAL CROSS REFERENCE.
TERMINAL ON
TERMINAL ON
OLD MODULE:
NEW MODULE:
25 V (1)
TH-W
MV
MV/PV
PV
GND (Burner)
NOTE: "Earth" ground is not required.
REPLACING MODULE WITH TH-R; TH-W TERMINALS
On modules that do not have a vent damper plug, the
thermostat must be connected between the transformer
S8600F_1_; Se610F,H;_
24 V (GND)
24 V
MV
MV/PV
PV
GND (Burner)
se6700
OUAL VALVEcoMBINATION
GASCONTROL
_1
POWER SUPFI.Y.
PROVIDE DISCONNECT
MEANS ANO OVERLOAD
PROTECTION
AS REG4JIREO.
_1 ALTERNATELIMITcoNTR(X.LER L_-,ATiON.
,_ u_IMu_ c,_u_LENO_3_Io.om].
._
CONTROLSIN 24V CtRCUrr MUST NOT SE IN GROUNOLEG TO TRANSFORMER,
/_
FOR MOOULE
WiTH TH-W TERMINAL
AND VENT OAMPER PLUG, CONNECT
24V OPEN. co NOT REMOV_ _NT DAMRER PLUG,
Fig. 1--S8600F,H,M;
S8610F, H; $8660D; $8670D connections
4
I_'IE RMO6TAT
TO TH-W.
LEAVE
MII7_
In a heating system with an atmospheric burner
$8_OOF.H,M;Sl_ lff:,H
GNO
MV MV/PV PV (BURNER)
PILOT
24V
GND 24V TH-W
A_ VENT
DAMPER
PLUG
VALVE
1ST
SPARK
W(B[NG
_1
X
°i
DUAL VALVECOMBINATION
GAS CONTROL
;,"
/_
i m_
080DVENT
CONTROLLER
Lt
LIMIT
Q348,Q3_,Q361!
Q345, Q346.
_
IGNITER.SENSOR
PILOTBURNEP,/ (
_
_-
PILOT
BURNER _
GROUND
---JILL2
pILOT GAS
SUPPLY
POWERSUPPLY. PROVIO_OISCONNECT MEANSAND OVERLOADPROTECTIONAS REDUIREO.
/_
ALTERNATE UMrTCONTROLLER LOCATION.
Z_ MAXIMUM CASL_ LENGTH3 K (0.9 m].
CONTROLSIN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER.
REMOVE PLUGONLY F USING VENT DAMPER, GUSEBLOWS ON STARTUP WHEN PLUG L_REMOVED;
THEN MODULEWIt.LOPERATE ONLY WHEN VENT DAMPER 15CONNECTED.
M,17r_
Fig. 2--S8600F, H,M; $8610F, H with a vent damper plug in a heating system with an atmospheric burner and a D80D
vent damper.
S8600A.B;S8610A,B
GNO
MV MV/PV PV (BURNER)
IST
_ERATOR
,_
24V
TH.W
GND 24V (OPT)
E
VENT
OAMPER
PLLK:itOPT) SENSE
SPARK
eM TA'
_Lwrr
IGNITE
_
GROUND
CONTROLLER
PILOT GAS
SUPPLY
Z_ POWER SUPPLY. PROVIOE DISCONNECT MEANSAND OVERLOADPROTECTION AS REDUIRED,
L_ ALTERNATE LIMITCONTROLLER LOCATION.
MAXIMUMCASLE LENO1_ 3" [0"9mi._
CONTROLS IN 24V CIRCUIT MUST ROT BE IN GROUND LEG TO TRANSFORMER.
L_ FOR MOOOLEVclTHTH-W TERMINAL AND VENT OAMPERPLUG, CONNECT IHERMO6TAT ]O
TH-W. LEAVE 24V OPEN. CO NOT REMOVEVENT DAMPERPLUG.
1,11m
Fig. 3--S8600A,B;
S8610A,B connections in a heating system with an atmospheric burner.
5
69-O463
S86EOA,B;S861OA,B
VENT
DAMPER
24V
GND
I
F
OND
24V
TH.W
PLUG
/5_
[][
SENSE
SPARK
__j
MAIN
VALVE
L
PILOT
__ _
RATOR
RATOR
I
3UAL VALVE COMBfNATION
3AS CONTROL
SENSOR
LIMIT
CONTROLLER
GROUND
IGNITER_
_
PILOT GAS
POWER SUPPLY.
Z_I ALTERNATE
Z_
MAXIMUM
Z_
CONTROLS
REMOVE
PROVIDE
DISCONNECT
LIMff CONTROLLER
CABLE LENGTH
IN 24V CIRCUrT
MEANS AND OVERLOAD
PROTECTION
AS REQUIRED.
LOCATION,
3 ff {0.9 mJ.
MUST NOT BE IN GROUNO
LEG TO TRANSFORMER.
PLUG ONLY IF USING VENT DAMPER
fat rise
Fig. 4---S8600A,B; S8610A,B with vent damper plug In an atmospheric burner heating system with a D80D vent
damper.
S86COF_I.M;
58610F.H;
24V
III
MV
MV/PV
PV
_
GNO
TH.W
24V
DAMPER
(OPT)
L_
PLUG (OPT}
SPAR
VENT
F
i I
L..J
MAIN
I VALVE
PILOT
$86700
i °l -I--r-}r-i D
(BURNER)
I±
fL
$86600;
AIR
)_H_RMOSTAT
PROVING
DUAL VALVE COMBINATION
GAS CONTROL
COMBUSTION
AIR BLOWER
_RELAY
PILOT
0345. 0346,
0348, Q362, G381
{HOT)_
BURNER
GROUND
COMBUSTION
AIR BLOWER
MOTOR
PILOT BURNER/
IGNiTER.SENSOF
POWER
i'_
SUPPLY.
ALTERNATE
MAXIMUM
Fig. _S8600F,H,M;
L2
/_
PROVIOE
DISCONNECT
LIMIT CONTROLLER
MEANS AND OVERLOAD
Lt
(HOT)
PROTECTION
AS REOUIREO.
LQUATION.
CABLE LENGTH 3 ft 10,9 4.
/_
COflTROLB
/_
FOR MODULE WITH TH.W TERMINAL AND VENT DAMPER PLUG, CONNECT
TH-W. LEAVE 24V OPEN. DO NOT REMOVE VENT OAMPER PLUG.
IN 24V CIRCUIT MUST NOT BE IN GROUND
LEG TO TRANSFORMER.
THE RMOSTAT TO
$8610F, H; $8660D; S8670D connectlbns In a heating system with power-assisted combustion.
$86(X_: J4,M; S8610F.H;
GNO
MV MV/PV PV (BURNER)
S_;
S867¢0
/_
24V
GNO
24V
TH-W
VENT
DAMPER
(OPT)
PLUG(OPT)
SPARK
7
r--1
I
ICOM
• PILOT
r
)ERATOR
VALVE
MAIN
_O
ROUND
I
I
I
I
STAGE 2
MAIN
VALVE
TAGE 1 r_
)
-_OSTAT
OPERATOR
Q_5,0_6,
TWO STAGE OUAL VALVE
COMBINATION
GAS CONTROL
O348,0362.
Q_IP_OT
SURNE_
COMSUSTIO$_
IGNITERSENSOR
AIR BLOWER
RELAY
PIL
T
BU
_ER
UNO
PILOT GAS
SUPPLY
LINIT
CONTROLLER
L1
/_L1
(HO'_
L2
L2
COMSUSTK)N
AiR
BLOWER
MOTOR
(HO'n
_
POWERSUPPLY. P ROV_IE OI._2ONNECTMEANS AND O_'ERLOAOPRO'I_CTION AS REOULRE_
_
AL'_RN_E
z_
MAX=MUMC,_LE LENGTH 3, Io.9 ml.
z_
CONTROLS IN 24V CIRCUIT MUST NOT BE IN GRG4JNOLEG TO TRANSFORMER.
,,_
FORMODULE WITHTH-WTERMINALANOVENTDAMPERPLUG,
24V OPEN. OO NOT REMOVE VENT DAMPER PLUG.
LIMtT_NIL_U.E
R L_T_N.
CONN_CTIHERMO_TATTO
TH-W. LEAVE
MIt7_
Fig. 6--S8600F, H,M; $8610F, H; $8660D; $8670D connections In a heating system with a two-stage gas controi and
power-assisted combust on.
7
69-0463
S8600f:,H.M;
S861(IF,H;
$86600;
S_700
DUAL VALVE COMBINATION
GAB CONTROL
Q345. O'J46,
Q3,48, Q362, (3381
PILOT BURNBRI
IGNITER-SENSOF
z/_
POWER SUPPLY.
i_
ALTERNATE
PROVIDE
DISCONNECT
MEANS AND OVERLOAD
PROTECTION
AS REQIJIRED.
LIMIT CONTROLLE R LOCATION.
MAXIMUM CABLE LENGTH2 ft 10.9m_.
Z_l CONT ROIS fN 24V CIRCUIT
MUST NOT BE IN GROUND LEG TO TRANSFORMER.
1/_ FOR MOOULEWITH TH*W TERMINALANDVENT DAMPER PLL_I. CONNECT _
TH-W. LEAVE 2,1VOPEN. DO NOT REMOVEVENT DAMPERPLUG.
Z_
Fig. 7IS8600F,H,M;
damper.
COLORS REFER TO WIRE HARNESS,
IF USED.
RMOSTATTO
Mlll10e
S8610F,H; S8660D; S8670D in a heating system with an atmmlpherlc burner and a DSOB vent
8
_,H
J_; S8610F,H;
$86r=00; S_700
24V
THW"
• _
GNO 24V (OPT)
VENT
DAMPER
PLUG(OPT)
r'----1
SPARK
kJ
&
MAIN
VALVE
I
DUN. VALVECOMSkNATION
GAS CONTROL
THERMOSTAT
LI
GO4e,Q_2.
QO81PILOT
BURRER/
IGNITERSENSOR
AIR BLOWER
MOTOR
GROUND
PILOTGAS
SUPPLY
COMBUSTION
AIR BLOWER
RELAY
AIR PROVING
SWITCH
=RESSURE
30NTROLLER
_
FAN
POWERSUPPLY. PROVIOE DISCONNECT MEANSAND OVERLOAOPROTECTION AS FIEQUIRED.
Z_I ALTERNATELIMITCONTROLLERLOCATION.
Z_ MAXIMUM C*'mLE LENGTH 3 a [0.9 m].
CONTROLSIN 24V CIRCUIT MUST NOT BE'IN GROUNDLEG TO TRANSFORMER.
Mlt_
.,_ FOR MOOULIEWI"R.ITH-W TERMINAL AND VENT DAMPERPLUG. CONNECT THERMOSTAT TO
TH-W. LEAVE 24V OPEN, OO NOT REMOVIEVENT DAMPER PLUG.
Fig. 8--S8600F,H,M; S8610F,H; $8660D; S8670D connections in s heating.cooling system with power-assisted
combustion.
9
69-0463
SS_OOF_I,M; S8_10_,H;
$8660D;
S86700
DUAL VALVE COMBINATION
GAS CONTROL
O8OO
BLACK
L1
FAN
MOTOR
L2
/_
POWER SUPPLY, PROVID_ OISCONNECT MEANSAND OVERLOAD PROTECTIONAS REQUIRED.
L_ CUT PLUGOFF MODULE ENC OF DeOOWIRE HARNESS,CONNECTt.EAOWIRECOLORSAS SHOWN,
L_ MAXIMUM CABLELENGTH3 It [0,9 m].
L_ FOR MOOULEW1THTH-W TERMINALANO VENT OAMPER PLUG, CONNECTTHERMOSTATTO TH-W.
LEAVE _4V OPEN, DO NOT REMOVEVENT DAMPERPLUG.
L_ LEAVE TP-Z ANDZoWJUMPERS IN PLACE,
MII I_e
Fig. 9---S8600F, H,M; S861 OF, H; S8660D; S8670D connection s In a hydronlc heating sytem with a D80D vent dam per.
10
Se6OOF,H.M;
S86tOF,H; S8660D; BN700
Z_
MV
MV/PV
PV
GND
24V
(BURNER]
GND
24V
TH,W
VENT
OAMPER
(OPT)
PLUG(OPT)
SPARK
F'i
I
I
I
MAIN
VALVE
L8100
IECO
DUAL VALVE COMBINATION
ICONTROLLER
GAS CONTROL
A
L1
L2
(HOT)
Q345, 0346,
Q348, 0362.
038
PILOT BURNER/
IGN]TER-S_NSOR
PILOT GAS
SUPPLY
POWER SUPPLY.
PROVIDE
DISCONNECT
Z_
MAXIMUM CABLE LENGTH
•_
CONTROLS
Z_
FOR MODULE WITH TH-W TERMfNAL
TH-W
IN 24V CIRCUIT
LEAVE 24V OPEN.
MEANS AND OVERLOAD
PROTECTION
AS REQUIRED.
3 It [0.g m].
MUST NOT BE IN GROUND
LEG TO TRANSFORME
AND VENT DAMPER PLUG. CONNECT
DO NOT REMOVE
R.
THERMOSTAT
TO
VENT DAMPER PLUG.
M117_
Fig. 10-.-S8600F,H,M;
S8610F,H; $8660D; $8670D connections In a commercial water heater control system.
CHECKOUT
Check out the gas control system:
• At initial installationof the appliance.
• As part of regular maintenance procedures. Maintenance intervals are determined by the application.
See PLANNING THE INSTALLATION, page 1, for
more information.
• As the first step in troubleshooting.
• Any time work is done on the system.
GAS LEAK TEST: Paint pipejoints with rich soap and water
solution. Bubbles indicate gas leak. Tighten joints to stop
leak. Recheck with soap and water.
STEP 2: Review Normal Operating Sequence and Module
Specifications.
[] See OPERATION, page 12, and APPLICATION,
page 1.
STEP 3: Reset the Module.
E3 Turn the thermostat to itslowest setting.
[] Wait one minute.
Asyou do Steps 4 and5, watch for/mints where operation
deviates from normal. Refer to Troubleshooting Chart to
correct problem.
FAILURE TO HEED THESE WARNINGS MAY
CAUSE FIRE OR EXPLOSION WITH PROPERTY
DAMAGE, INJURY, OR LOSS OF MFE.
1. If you smell gas or suspect a gas leak, turn off
gas at manual service valve and evacuate the
building. Do not try to light any appliance, do
not touch any electrical switch or telephone in
the building until you are sure no spilled gas
remains.
2. Gas leak test must be done as described In
Steps I and 5 below on Initial Installation and
any time work Is done Involving the gas piping.
STEP 4: Check Safety Shutoff Operation.
This step applies to lockout and continuous retry modules
only.
[] Turn gas supply off.
[] Sat thermostat or controller above room temperature to
call for heat.
[] Watch for spark at pilot burner either immediately or
following prapurga. Sea device label.
[] Time spark from start to shutoff, Sea device label.
On $8600M, wait 6 rain, nom. Ignition sequence should
start again followed by shutoff after 90 sac. max.
[] Open manual gas cock and make sure no gas is flowing
to pilot or main burner.
[] Set thermostat below room temperature and wait one
minute before continuing.
STEP 1: Perform Visual Inspection.
i-1 With power off, make sure all wiring connections are
clean and tight.
E3 Turn on power to appliance and ignition module.
IS] Open manual shutoff valves in the gas line to the
appliance.
O Do gas leak test ahead of gas control if piping has been
disturbed.
STEP 5: Check Normal Operation.
O Set thermostat or controller above room temperature to
call for heat.
11
69-0463
[] Make sure pilot lights smoothly when gas reaches the
pilot burner,
[] Make sure main burner lights smoothly without flashback.
[] Make sure burner operates smoothly without floating,
lifting, or flame rol_outto the furnace vestibule or heat
buildup in the vestibule.
[] If gas line has been disturbed, complete gas leak test.
GAS LEAK TEST: Paint gas control gasket edges and all
pipe connectionsdownstream of gas control, includingpilot
tubing connections, with rich soap and water solution.
Bubbles indicate gas leaks. Tighten joints and screws or
replace component to stop gas leak. Recheck with soap
and water,
[_ Turn thermostat or controller below room temperature.
Make sure main burner and pilot flames go out.
OPERATION
Module operation can be conveniently divided into two
phases for $8600, $8610 and three for $8660, $8670. The
phases are
• Prepurge (S8660, S8670only)
• Trial for ignition (all models)
• Mainburneroperation(allmodels)
PREPURGE ($8660,$8670 ONLY)
When the $8660 is used in a fan-assisted combustion
system, the combustionair blower starts on a call for heat.
On proof of airflow, the air proving switch closes and
energizes the $8660, $8670. When the module is used in
an atmospheric system, the call for heat energizes the
module.
In either case, the module first initiates a 45 sac. delay
to allow system prepurge. Afterprepurge, the module starts
the pilot ignition sequence.
Figs. 11 and 12 summarize the normal operating sequences of the modules.
START
STAGE 1
TRIALFOR
IGNIIT_N
SM006.H Ntet 15¢4gO14ml system
;386108,H kld_ ouq;mutt be
manudlyreset.
Slle00M
_
90 NC.I Systemshutsoff;
_
5 minuce=n_. (6 mi_._es
_),
rn_
mtattl Uiallor
_:
igriti_ _al. s_.
wsh
or eal hx he_ endt.
a Shutollno_,=uttie'_l i= =l=w,pedon modute
STAGE 2
MAIN BURNER
• S_*kgeeemto,
on.
• seooad
v_e em_or(e_a)
OPERATION
l
"4_'*)FLAI_ C_JRRENT_O
k_Fl_€_=_
T_'OSTATt_l_u.F._
I
END
Fig. 11_,
58610 normal operating sequence.
12
ix,_r _
TRIAL FOR IGNITION
Pilot Ignition
Followingprepurge timing ($8660, $8670), or on the call
for heat ($8600, $8610), the module energizes the first
main valve operator, The first main valve opens, which
allows gas to flow to the pilot burner• At the same time, the
electronic sparkgenerator in the module produces an over
10,000 volt spark pulse output. The voltage generates a
spark at the igniter (S8600A,B; $8610A,B) or igniter-sensor
(S8600F,H,M; S8610F,H; $8660; $8670) that lights the
pilot.
If the pilot does not light, or the pilot flame current is not
at least 1.0 _A and steady, the module will not energize the
second (main) valve and the main burner will not light.
S8600A,F; $8610A.F will continue to spark as long as the
thermostat calls for heat, or until the pilot lights.
perature for one minute or by turning off power to the
module for one minute,
Safety Shutoff with Continuous Retry ($8600M)
The $8600M provides 100 percent gas shutoff,followed
by retry for ignition.Operation on ignitionfailure is the same
as lockout modules, exceptthat a timer starts timing immediately following shutoff. Six minutes nora. (five minutes
rain.) after shutoff, the module restarts the ignition sequence. The ignitiontrial, shutoff,wait sequence continues
until either the pilot lights or the thermostat is set below
room temperature to and the call for heat. The module can
also be reset by settingdown the thermostatlor one m inute,
MAIN BURNER OPERATION
When the pilotflame is established, a flame rectification
circuitiscompleted between the sensorand burnerground.
The flame sensing circuit in the module detects the flame
current, shuts off the spark generator and energizes the
second main valve operator. The second main valve opens
and gas flows to the main burner, where it is ignited by the
pilot burner, On tockout models, the flame current also
holds the safety lockout timer in the reset (normal) operating condition.
When the callfor heat ends, bothvalve operators are deenergized, and both valves in the gas control close.
Safety Lockout (S8600B,H; S8610B,H; $8660D; $8670D)
These modules provide 100 percent shutoff and safety
lockout. A timer in these models starts timing the moment
the trial for ignition starts. Ignition sparkcontinues only until
the timed trial for ignition period ends. Then the module
goes into safety lockout. Lockout de-energizes the first
mainvalve operator and closes the first main (pilot)valve in
the gas control, stopping pilotgas flow. The control system
must be reset by setting the thermostat below room tem-
START
STAGE
1
PREPURGE
STAGE
2
TRIAL FOR IGNITION
_Lo#,.o_t_
is
_
oamodus.
• Spark ger_a_x off.
• Secondvak_ _rat_x
_,_
LAME CURRENT
(main)
SENSED
i
i
STA_ E 3
SyStem shuts o/I. mSIKIs when powe, i_
mslored,
MAIN BURNER
OPERATION
.,_
Module monitors _
€_,rne
AIN BURNER oPeRAllON
cutront•
PILOT FLAME FNLURE
Maln valve closss.
• S8670 slam Irbl lot ilpi_ion.
VMvesdose. _k_ and mmn
END
THERMO6TAT
bume,s
Are of/, SATISRED
Fig. 12--58660,
J
Mtt71A
$8670 normal operating sequence.
13
69-0463
TROUBLESHOOTING
IMPORTANT
1. Thefoliowingserviceproceduresareprovldedas
a generalguide. Follow appliance manufacturer's
service instructions if available.
When performing th • following steps, do not touch
stripped end of Jumper or SPARK terminal. The
ignition circuit generates over 10,000 volts and
electrical shock can result.
2. On lockout and retry models, meter readings
between gas control and _nition module must be
taken within the trial for ignition period. Once the
ignition module shutsoff, lockout models must be
reset by setting the thermostat down for at least
one minute before continuing. On retry models,
wait for retry or reset at the thermostat.
D Energize the module and immediately touch one end of
the jumper firmly to the GN D terminal on the module. Move
the free end of the jumper slowly toward the SPARK
terminal until a spark is established.
[] Pull the jumper slowly away from the terminal and note
the length o! the gap when sparking stops. Check table
below.
3. If any component does not function properly,
make sure it iscorrectly installed andwired before
replacing it.
4. The ignitionmodule cannot be repaired. If it malfunctions,it must be replaced.
5. Only trained, experienced service technicians
should service intermittent pilot systems.
Pedorm the checkout on page 11 as the first step in
troubleshooting. Then check the appropriate troubleshooting guide (Fig. 14 or 15) and the schematic diagram (Figs.
16-17) to pinpointthe cause of the problem. I| troubleshooting indicates an ignition problem, see Ignition System
Checks below to isolate and correct the problem.
Followingtroubleshooting, pedorm the checkout proce.
dure (page 11) again to be sure system i,s operating
normafly.
ARC LENGTH
ACTION
No arc or arc less
than 1/8 in. [3 mm]
Checkexternatfuse, it provided.
Verify power at module input
terminal.
Replace module if fuse and
power ok.
Voltage output is okay.
Arc 1/8 in. [3 mm]
or longer.
STEP 4: Check pilot and main burner lighfoff.
Set the thermostat to call for heat.
[] Watchthepiiot burnerduringtheignitionsequence. See
if:
Ignition spark continues after the pilot is lit.
• The pilot lights and the spark stops, but main burner
does not light.
S8600B,H,M; S8610B, H; S8660D: SB670D on/y:The
pilotlights, the sparkstops andmain burnerlights, but
the system shuts down.
[] If so, ensure adequate flame current as follows.
Turn off furnace at circuit breaker or fuse box.
Clean the flame rod with emery cloth.
IGNITION SYSTEM CHECKS
STEP 1: Check ignition cable.
Make sure:
[] Ignition cable does not run in contact with any metal
sudeces.
O Ignition cable is no more than 36 in. [0.9 m] long.
[] Connections to the ignition module and to the igniteror
igniter-sensor are clean and tight.
[] Ignition cable provides good electrical continuity.
APPEARANCE
SMALLBLUE
FLAME
CAUSE
CH_CK FOR LACK OF GAS FROM:
e CLOGGI_00_IFtCE
FILTER
• CLOGGED PILOT FILTER
STEP 2: Check ignition system grounding. Nuisance shut.
downs are often caused by a poor or erratic ground.
[_ A common ground, usually supplied by the pilot burner
bracket, is required for the module and the pilot burner/
igniter-sensor.
• Check for good metal-to-metal contact between the
pilot burner bracket and the main burner.
• Check the ground lead trom the GND(BURNER)
terminal on the module to the pilot burner. Make sure
connections are clean and tight. If the wire is damaged or deteriorated, replace itwith No. 14-18 gauge,
moisture-resistant, thermoplastic insulated w_rswith
1050 C [221 = F] minimum rating.
-- Check the ceramic flame rod insulator for cracks
or evidence of exposure to extreme heat, which
can permitleakage toground.Replace p_iotburner/
igniter-sensor and provide shield if necessary.
-- If flame rod or bracket are bent out of position,
restore to correct position,
• LOW GAS SUPRLY PRESSURE
• P_LOTAD_JSTMENT AT
MINIMUM
LAZYYELLOW
FLAME
CHECK FOR LACK OF AIR FROM:
• LARGE ORIF1C_
• DIRT_ UNT SCRE_L IF USED
• DIR_f PRIMARY AIR
OFENING, IF THERE H; ONE
• PILOT ADJUSTMENT AT
MINIMUM
WAVINGBLUE FLAME
CH|CK FOR:
• EXCESSIVEDRAFTAT PILOT
LOCATION
• HECIRCULATINGPROOUCTS
OF COMBUSTION
NOISYLLFTINOBLOWINGFLAME
CHECK FOR:
• HIGH GAS PRESSURE
STEP 3: Check spark ignitioncircuit. You willneeda shorl
jumper wire made from ignition cable or other heavi_
insulated wire.
El Close the manual gas valve.
[] Disconnect the ignition cable at the SPARK terminal on
the module.
THiSF4JUtlEIS
CHAAACTImmTIGOF
MANUFACTUREDGAS
CHECKFOR:
* HIOHGAS PRESSURE
I * ORIFICETOOSMALL
l*.Iml
Fig, 13--F, xamples of unsatisfactory pilot flames,
14
justmentscrew on the gas control clockwise _
to
decrease or counterclockwise _
to increase pilot
flame. Following adjustment, always replace pilot
adjustment cover screw and tighten firmly to assure
proper gas control operation.
• Set thermostat below room temperature to end call
for heat.
O Recheck ignitionsequence as follows.
Reconnect ma(n valve wire.
Set thermostat to call for heat.
Watch ignitionsequence at burner.
If spark still doesn't stop after pilot lights, replace
ignition module.
If main burnerdoesn't lightor if main burner lightsbut
system locksout, check module, ground wire andgas
control as described in appropriate troubleshooting
chart, Fig, 14or 15.
Make sure electrical connections are clean and tight.
Replace damaged wire with moisture-resistant No.
18 wire rated for continuous duty up to 105° C [221 o
F].
Check forcracked ceramic insulator,whichcan cause
short to ground, and replace igniter-sensorif necessary.
At the gas control, disconnect main valve wire from
the TH or MV terminal.
Turn on power and set thermostatto callfor heat. The
pilot should light but the main burner will remain off
because the main valve actuator is disconnected.
Check the pilotflame, Make sure it is blue, steady and
envelops 3/8 to 1/2 in. [10 to 13 ram] of the flame rod.
See Fig. 13 for possible flame problems and their
•
•
CaUSeS.
•
If necessary, adjust pilotflame by turningthe pilot ad-
NOTE:
I
Before troubles hoollng, hum_lil_
_ yourN)' with the sl=ttup and ¢heckoul _ure.
TURN THERMOSTAT
Check line _*oltage p<)w_-, _ voltage Irlmsformer, (niit coni_olle=, thercr_stat {con(roht) and wiling. Also.
cheek ai_ p,(_ing m_v;tchon ¢orrb_mlion lit _owlmr syst_
(I u_*d) i_d 1hat *r_nl dl,'r_e_ (il umed) is open rand
end sw;lch is mado.
(CONTROLLER) TO CALL
FOR HEAT
START
_;
POWER
MODULE
TURN
GAS TO
SUPPLY
OFF.
I
(24V NOMINAL)
On modem w_h venl damper I_S. make sum vent damper
hal fbolbeen lea(ailed. I ken te rr_oved. Repta_ van1 d;zrt_t
check spark at module.
_.INITEP./SENSO
R GAP
SPARK
YES + ACROSS
i
r_
I
if neces=ary.
On otke_ mode_, replace module.
Spark okay?
YES
i
YES
i
+
• Ched_ ignition cabS, ground wifleg, ¢z,ral_¢ lesulet o( and gap, and co_.
• Check boot of the ignition eddie for ligr_
boo4 Iforil e_cQsslve tsrrIpetatum$.
of rne)'irlg or I_klleg.
Take Womcti_
a_ion to =hleld cable and
i
TURN GAS SUPPLY ON
• Check Ihat all manual 9a
i= _o€ blocked.
PILOT BURNER LIGHTS?
• Check elecltical
_r=_d_
• Check Ior 24 Vac _o'Js
r*p_a_ module.
YES
I
_
SPARR
PILOT
STOPS
IS LIT?
WHEN,, ,
ININININ_
MAIN BURNER LIGHTS?
YES
between module _1
PV.MVIPV
terra'all
pilot I_Jrner orilice
pilol opera(or or=gas _ntroL
on module. )' vof_
is okay. mplece gas oont¢¢_;_f not.
i
r
• Check (dll_l_l
I
are op4n. =u_0_y t...i>mg and pressures we good. ,rid
NOTE: )' Se_O0_.H;S_(IIC_.H goesink) Io(:k_, ttlll Sytle,'fl.For S86OOM.walt6 ram.norrtfor leiP( or
fete( syllem.
• Checkcominukly
of ignaio_cable and groundwire.
• Cleanitama rod.
• Ched_ele¢Idc=lconnect_s betweenflarn=rodandmodule.
• Ch*d_ lot _ad_d _tan,lc f_
rodin=ulator.
• CheckIhal piletflamecover=f_Tte rodand is =lead),and blue.
• Adjut( I_kX flern_.
• )' problem_iszs. mgle(:_module.
YES
_
v_
mNmN_I
conneo(_on$ belween module and gas cOnltoL it okay. replace gas o_tro_ Or gas _Ir_
opera(or. 24V_ _s
.Ched_lo,
MV.MWPV
tern,,_, itno_t=ge..,placernod,,k,.
_
i
I
i
.'esel Systom.
CALL
FOR RUNS
NEAT ENDS?
SYSTEM
UNTIL
• Check ¢onlinuity c4 ignlt .=*_ca_* and ground _m.
NOTE; If Stoun_ is poor or et tll_c, sh_tdowrs rna_'o¢_ur _siona_y
Ihe Irr, e of d'w.ckout.
rNrNr_
I
• Check
NOTE: Ihal
if Sit6OO_,H;
pilet if_e S84_$OB.H
covert ifame
goesrod
inlo
rand
Io_o_d.
is =te.tdy
tes41tsytlem.
w_d blue.
• it decks we okay. rep_
module.
eve,_ thigh
op_t a_ion is normal a(
For S86COM. wa_ 6 ram.._om, lot ml,-/or
YES
CALL FOR HEAT ENDS
SYSTEM SHUTS
OFF?
• Chld_ IOr ptOplt thetmo_tal ((_drolle_
• Rim_l
I
J
opera(ion.
MV lead al module; if valve Ck_=.
lech_¢k lempeeatum COnltolaf and _ting;
i( no(. rll_ace
gain ¢omro_.
ES,
!,
I
"_OJBLESHcoTING
ENOS
I RepN_ proo_dum
u_4NImubleft_
operation _mobt aln_.
Mt 17,1/,
Fig. 14---$8600, $8610 troubleshooting guide•
15
69-0463
START
TURN GAS SUPPLY OFF.
TURN THERMOSTAT
TO
CALL FOR HEAT
POWER
TO MODULE
(24V NOMINAL)
YES
45 SECOND
DELAY
YES ,
SPARK _ROSS
IGNiTER/SENSOR
GAP
Spark_y?
YES
TURN GAS SUPPLY ON
PILOT BURNER LIGHTS?
YES
SPARK STOFS WHEN
PILOT tS LIT?
YES
MNNBURNERL_HTS?
YES
SYSTEM RUNS UNTIL
CALL FOR HIEAT ENDS?
CALL FOR HEAT ENDS
SYSTEM
SHUTS OFF?
YES
TROUBLESNOOT_G
ENOS
Fig. 15--S8660, S8670 troubleshootingguide•
16
LI
LIMIT
ON.OFF
(HOT)
r.......
THERMOSTAT
OR
CONTROLLER
A
IP
_.m_
=1
r..... to--_ --,-o_-t-_
!
I
I
_
e- ............
!
24V
_
i
=
L2
:
I
,J
TRANSFORMER
L........................................
ARC
GAP
IGNITER
SENSOR
RUR_R
GROUND
MNN
1K1
IK2
_(2
)
---,_,-PILOT
//_
PO_R
SUPPLY,
/_
ALTERNATE
PROVIDE DISCONNECT
UMIT CONTROLLER
MEANS ANO OVERLOAD
PROTECTION
AS REQUIRE D.
LOCATION.
3K RELAY ON tOORERCIENTSHUTOFF MODELSONLY. ON NON-SHUTOFFMOOELS.PV AND MV
WIRED AS FOLLOWS.
TO 24v
I
TO 24V (GND)
_2:
[1K1'_ -
-
Fig. 16---Representative
11(2_+]
G
MAIN
_
- P-L'_O;
-VALVE
VALVE
_
_
.....
s
Q---'_
--
INTERNAL WIRING
- - - EXTERNAL WIR INO
M.+58
schematic for S8600F, H, M; S8610F,H. ,See Fig. 1 for hookup. $8660 and $8670 are simlla
excepl the timing circuit Includes a purge timer. See Fig. 6 for hookup.
17
69-0463
UMIT
ON-OFF
CONTROLLER SWITCH
[ .....
THERMOSTATOR
CONTROLLER
r .....
to
,,_
F _
_lI
*'_Ol- - - t -o-'_',L-o- -Ie -a
IIDI
I
I
!
_
-_I
L1
(HO]_ [.2
_1_ ,_Z_
,:
f
-J
24V
I TRANSFORMER
t. ........................................
ii
ARC
GAP
GROUND
2K2
3KI
./_ POWSRSUPFLy_ PROVIOE DISCONNECTklEAHS ANO OVERLOAD
PRGTECTION AS REQUJRIEO_
ALTERNATE LIMITCONTROJ=ER LOCATION_
/_ 3K RELAY ON 100 PERCENTSHUTOFF MOOELSONLY. ON NON-SHUTOFFMOOELS,PV ANO
MYWlREO AS FOLLOWS.
TO 24V
_K,,] ,,,
TO 24V (GNO)
!
Fig. 17.--Representative
'_
II
G"
- -p-_;V.VE _
--
INTERNALWIRING
--- S_ERN._W._G
schematic for S8600A,B; 58610A,B. See Fig. 3 for hookup.
18
ANSISTANDARDS
EXHIBIT A
RECOMMENDED PROCEDURE FOR SAFETY INSPECTION OF AN EXISTING
APPLIANCE INSTALLATION AS A PRELIMINARY STEP TO APPLYING
AN AUTOMATIC INTERMITTENT PILOT SYSTEM
The following procedure is intended as a guide to aid
!n determining that an appliance is properly installedand
=sIn a safe condition for continuing use.
This procedure is predicated on central furnace and
boiler installations equipped with an atmospheric gas
burner(s) end not of the direct vent type. It should be
recognized that generalized test procedures cannot anticipate all situations. Accordingly, in some cases, deviation from thisprocedure may be necessary to determine
safe operation of the equipment.
a. This procedure should be performed prior to any
attempt at modification of the appliance or the installation.
b. If it is determined there is a condition which could
result in unsafe operation, the appliance shouldbe
shut off and the owner advised of the unsafe condition.
The following steps should be followed in makingthe
safety inspection:
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers. If, after completing steps 7 through 12, it is believed sufficient combustion air is not available, refer to 1.3.4 of the National Fuel
Gas Code (Z223.1) for guidance.
8. Place in operation the appliance being inspected.
Follow the lightinginstructions. Adjust thermostat soappliance will operate continuously.
9_
a. Determine t hat the pilot isbu rning propedyand
that main burner ignition is satisfactory by interruptingand re-establishing the electrical supply to
the appliance in any convenient manner.
b. Determine manifold pressure in order to match
input after the new control is installed.
a.Visual/y determinethat main burner gas is burning properly; i.e., no floating, lifting or flashback.
Adjust the primary air shutter(s) as required,
b.lf appliance is equipped with high and low flame
controfor flame modulation, check for proper main
burner operation at low flame.
1. Conduct a Gas Leakage Test of the appliance
piping and control system downstream of the shutoff
valve in the supply line to the appliance.
2. Visually inspect the venting system for proper size
and horizontal pitch and determine there is no blockage
or restrictions, leakage or corrosion or other deficiencies
which could cause an unsafe condition.
11. Test for spillage at the draft hood relief opening
afler 5 minutes of main burner operation. Use a draft
gauge, the flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
3, Shut off all gas to the appliance and shut off any
other fuel-burning appliance within the same room. Use
the shutoff valve in the shutoff valve in the supply line to
each appliance.
12. Return doors, windows, exhaust fans, fireplace
dampers and all other fuel-burning appliances to their
previous conditions of use.
4. Inspect burners and crossovers for blockage and
corrosion.
13. Applicable only to warm air heating appliances.
Check both limit controller and fan controller for proper
operation, Limit controlleroperation can be checked by
temporarily disconnecting the electrical supply to the
blower motor and determiningthat the limitcontrol acts
to shut off the main burner gas.
5. Applicable only to warm air heating appliances. Inspect heat exchangers for cracks, openings or excessive corrosion,
6. Applicable only to boilers. Inspect for evidence of
water or combustion product leaks.
14. Applicable only to boilers:
a. Determine that the circulatingwater pumpsare
in operating condition.
b. Test lowwater cutoffs, automaticfeed controls,
pressure and temperature limitcontrols and relief
valves in accordance with the manufacturer's recommendations and instructionsto determine they
are in operating condition.
7, Insofar as is practical, close all building doors and
windows and all doors between the space in which the
appliance is located and other spaces of the building.
Turn on clothes dryers. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they will
EXHIBIT A OF ANSI STANDARD Z21.71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD
INSTALLATION
19
69-0463
EXHIBIT
B
PROCEDURE
FORINSTALLING
AUTOMA11C
INTERMITTENT
PILOT
SYSTEMS
Priortobeginning
thisprocedure,
apreliminary
examination
oftheappliance
andtheautomatic
intermittentpilotsystem
should
bemade
todetermine
thatthe
automatic
intermlttant
pilotsystem
can be properly
7. Make certain wiring connections are tight and
wires are positioned and secured sothey will notbe able
to contact high temperature locations.
applied to the appliance.
This procedure is intended as a guide to aid in safely
installing a listed automatic intermittent pilot system on
an existing listed appliance equipped with an atmospheric gas burner(s) and not of the direct vent type.
This procedure is based on the assumption that the
history of the specific installationhas been one of safe
and satisfactory operation,
This procedure is predicated on central furnace and
boiler installations,and itshouldbe recognized thatgeneralized procedures cannot anticipate all situations, Accordingly, in some cases, deviation from this procedure
may be necessary to determine safe operation of the
equipment.
The following steps shouldbe folicwed in making the
modifications:
8. Conduct a Gas Leakage Test of the appliance
piping and control system downstream of the shutoff
valve in the supply line to the appliance.
t. Perform a safety inspection of the existing appliance installation.See Exhibit A for a recommended procedure for such a safety inspection.
2. Shut off all gas and electricity to the appliance. To
shut offgas, use the shutoffvalve in the supplyline tothe
appliance. Do not use the shutoff valve which is prov_ed as pad of a combination control.
3. Install the automatic interrn_ent pilot system in
strictaccordance with the manufacturer's installationinstructions.
g. a. Adjust the thermostat to its highest temperature setting, and test manifold pressureand adjust
the pressure regulator to match original input as
required (refer to Exhibit A, step 9b).
b. Visually determine that main burner is burning
properly; i.e., no floating, lifting or flashback. Adjust the primary air shutter(s) as required.
10. If the appliance is equipped with high and low
flame control or flame modulation, check forproper main
burner operation at both high and low flame.
11. Determine that the pilot is igniting and burning
properly and that main burner ignition is satisfactory by
interrupting and re-establishing the electrical supply to
the appliance in any convenient manner. Make this determination with the appliance burner both cold and hot.
Perform this step as many times as is necessary to
satisfy yourself that the automatic intermittent pilot system is operating properly.
12. Test the pilot safety device (1) to determine if it is
operating properly, and (2) for turndown characteristics
accordingto the manufacturer's installationinstructions.
No adjustments should be made other than those recommended by the system manufacturer.
4. ,Turn on all gas and electricity to the appliance.
5. Determine that the appliance transformer has
adequate capacity by following the steps outlined below;
a. Compute the approximate current draw by adding
the current draw of the automatic intermittent pilot
system to (1) the current draw of the associated
valving, and (2) the current draw of any relays or
other devices operated by the transformer.
b. Multiplythetotalcurrentdrawasoomputedabova
by 24 V to determine the total VA (volt-ampere)
required.
c. The total VA (volt-ampere) required should be
equal to or less than the VA rating of the transformer.
d. If the total VA (volt-ampere) required is greater
than the VA ratingof the transformer, the transformer
must be replaced with a Class 2 transformer of
adequate rating.
6. Check the heat anticipator in the comfort thermostatto determine if if is property adjusted to the current
draw of the control system. Follow the thermostat
manufacturer's instructions.
13. Sequencatheappliancathroughatleastthreeoperating cycles.
14. Applicable only to furnaces. Check both the limit
controller and the fan controller for proper operation.
Limit Controloperation can be checked by blocking the
circulating air inlet or temporarily disconnecting the
electrical supply to the blower motor and determining
that the limit controller acts to shut off the main burner
gas.
15, Applicable only to boilers.
a. Oeterminethatthecirculatingwaterpumpsare
in operating condition.
b. Test low water cutoffs, automatic feed water
controls, pressure and temperature limit controllers and relief valves in accordance with the
manufacturer's recommendation to determine
they are in operating condition.
16. Add the labels (see 1.6.1-n
ance.
EXHIBIT B OF ANSI STANDARD Z21.71 FOR AUTOMATIC INTERMITTENT
INSTALLATION.
Honeywell Inc.
GoldenValley,MN
55422-4386
1885 DouglasDriveN.
and -o) on the appli-
PILOT IGNITION SYSTEMS FOR FIELD
InternationalSalesOfficesin all principalcitiesof the world Manufacturingin _
Australia,Canada,Finland,France,Germany,Japan,Mexico,Netherlands.
Spa n, Taiwan,UnitedK ngdom,U.S.A.
PRINTED IN U.S.A.
1
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