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 ignitionmodulesprovideignitionsequence, flame

monitoring and safety shutoff for intermittent pilot central

furnaces and heating appliances. $8600 and $8660 mod-

els provide up to 1,0 A pilot and 1.0 A main valve current

rating. $8610 and $8670 provide up to 1.0 A pilotand 2.0

A mainvalve current rating. Minimum ambient temperature

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.

TABLE 1--1NTERMII-rENT PILOT IGNITION MODULES.

IGNITER- 100

SENSOR TYPE PREPURGE PERCENT LOCKOUT IGNITION

TYPE OF GAS TIMING SHUTOFF TIMING SEQUENCE a

Separate Natural None No No

MODEL

$8600A,

$8610A

$8600F,

$8610F

$8600B,

$8610B

$8600H,

$8610H

$8600M

$8660D,

$8670D

Combination

Separate

Combination

Combination

Combination

Natural

or LP

Natural

or LP

Natural

or LP

None

None

45 sec.

a If established flame is lost, all models restart ignition trial.

Yes, at

lockout

Yes, at 90

sac. max.

Yes, at

lockout

15 or 90

sec. max.,

as ordered

No,

continuous

retry

15or 90

Sec. max.,

as ordered

Spark on until pilot

lightoIf or manual

shutoff;pilot vatve

open until manual

shutdown.

Spark on until

lightoffor lockout;

pilotvalve closes

on lockout.

Spark and pilotgas

on until shutoff.

After 5 min. rain,

(6 min. nora.) delay,

ignition starts again.

Ignition, wait, retry

repeats untilpilot

lightsor system is

shutdown manually.

Ignition trial follows

prepurge; spark on

until lightoffor

lockout;pilot valve

closes on lockout.

PLANNING THE INSTALLATION

Intermittent pilotsystems 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 appli-

cations may make heavy demands on the controls, either

because offrequent cycling, orbecause of moisture, corro-

sive chemicals, dust or excessive heat in the environment.

In these situations, special steps may be required to pre-

vent nuisance shutdowns and premature control failure.

These applications require Honeywell Residential Division

Engineering review; contact your Honeywell Sales Repre-

sentative 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 allduringthe cooling season.

In an applicationwith significantlygreater cycling rates and

closerto year-round use,we recommend monthlycheckout

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 mustbe replaced. If the appliance is

likely to be cleaned with water or steam, the controls and

associated widngshouldbe covered sowater orsteam flow

cannot reach them. The controls should be high enough

above the bottom of the cabinet so they wilt not be subject

tofloodingorsplashingduring 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 highambient 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 maybe installed ina humidatmos-

phere, makesure aircirculationaroundthe module and gas

control is adequate to prevent condensation. It's also im-

portant to regularly check out the system. A NEMA 4

enclosure may be needed; see the Electronic Ignition

Service Manual, form 70-6604.

J.A.

11-89 Form Number 69-0463

Cfrloneywell Inc. 1989.

CORROSIVECHEMICALS

Corrosivechemicalscanalsoattackthemoduleandgas

controlandeventually 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 industrialand

agricuifural applications, protect the ignition module from

exposure with aNEMA 4 enclosure; see the Electronic

IgnitionService 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 coversfor the module and the gas control

that will limit environmental contamination. A NEMA 4

enclosure is recommended for the ignitionmodule;see the

Electronic IgnitionService Manual, form 70-6604.

HEAT

The controlscan be damaged by excessively hightem-

peratures. 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 aircimulatldnmay

be necessary to protect the controls. Proper insulation or

shielding should be provided by the appliance manufac-

turer; 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 orcause a hazardous

condition.

2. Check the ratings given inthe instructionsand on the

components to make sure they are suitable for your appli-

cation.

3. Installer must be a trained, experienced service tech-

nician.

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 shockor equipment damage.

2. If anew gas control is to be installed, turn off gas

supply before starting installation. Conduct Gas

Leak Test according to gas control manufac-

turer's instructions after the gas control is in-

stalled.

3. If module must be mounted near moisture or

water, provide suitable waterproof enclosure.

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 in-

tended, typically operates less than 20,000 cycles

per year.

•Exposure to water, dirt, chemicals, and heat can

damage the moduleor thegas control and shutdown

the control system. A NEMA 4 enclosure can reduce

exposure to environmental contaminants. See Elec-

tronic Ignition Service Manual, form 70÷6604.

The maintenance program shouldincluderegular check-

out 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 mustbe 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 be-

fore the next use.

•Consequence of unexpected shutdown.Where the

cost of an unexpected shutdown wouldbe 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.

PERFORM PREINSTALLATION SAFETY INSPECTION

The preinstallation checks described inANSI 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 pro-

ceeding with the installation.

Maintenance Requirements In Severs Environments

Regular preventive maintenance is important in any ap-

plication,but especially so in commercial cooking, agricul.

tural, and industrialapplications because:

Any control should be replaced if if does not perform

properly on checkout or troubleshooting. In addition, re-

place any module if it is wet or looks like it has ever been

wet. Protective enclosures as outlinedunder "Planningthe

installation"are recommended regardless of checkoutfre-

quency.

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 chemi-

cals and excessive dust and grease.

Werecommendmounting the modulewith theterminals

down to protect them from dripping water and dust. It can

alsobe 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 trans-

former according to manufacturer's instructions.

WIRE THE SYSTEM

1. Check the wiring diagram furnished by the appU.

ance manufacturer, ifavailable, for circuits differ-

ing from the wiring hookups shown. Carefutly

follow any special instructionsaffecting the gen-

eral procedures outlined below.

2. Disconnect the power supply before making wir-

ing connections to prevent etactrica/ shock or

equipment damage.

IMPORTANT

t, As shown in the wiring diagrams, a common

ground is required on:

a. The pilotburner mounting bracket, and

b. The GND(BURNER) terminal on the ignition

module. Failure to use the GND(BURNER) termi-

nal may result in intermittent loss of spark and/or

loss of ffame current sensitivity.

2. Make sure the transformer hasedequate VA. The

ignitionmodute requires at least 0.2 A at 24 Vac.

Add the current draws of all other devices in the

control circuit, includingthe pilotand main valves

inthe 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 resultis the minimum transformer VA rating.

Use aClass II transformer if replacement is re-

quired.

Connect Ignition Cable

Use Honeywell ignition cable or construct an ignition

cable that conformsto suitable national standards such as

Underwriters Laboratories Inc. See Tables 2and 3.

TABLE 2---HONEYWELL PREASSEMBLED IGNITION

CABLES, UL STYLE 3257).

_ABLE

3ART

_IUMBER

394800-30

LENGTH

30 in.

30 in.

394801-30

MODULE

END

114 in:quick

connect,

insulated

1/4 in. quick

connect,

insulated

IGNITER

END

Rajahconnec-

tor receptacle,

90 dag. rubber

boot

Rajahconnec-

torreceptacle,

straight rubber

boot

TABLE 3--RECOMMENDED IGNITION CABLE FOR

FIELD ASSEMBLY.

TEMPERATURE

:ABLE VOLTAGE RATING

rYPE RATING (rms) C F

JL Style 3217 10,000 150 302

JL Style 3257 10,00O 250 484

NOTE: The cable must notrun incontinuous contact with a

metal surface or spark voltage willbe 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 studon the pilotburner/igniter-sensor.

Connect Vent Damper

The DSOB Vent Damper can be used with all ignition

modules, althoughthe Molex plugprovidedon somemodules

simplifies wiring connections when used with the D80D

Plug-in Vent Damper. Once amodule with vent damper

plug has powered a vent damper circuit, if cannot be used

ina 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 plugfromtheterminal 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 sup-

plied withthe vent damper or see Fig. 7 for typical connec-

tions.

Connect Ignition Module

1. Connect remaining system components tothe ignition

module terminals as shown in the appropriate wiring dia-

gram, Figs. I to 10.

•Fig. 1 is a basic circuitfor 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 pluginaheating only atmospheric burner

system withD60D 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 inavariety of systems, with alternate

connections for modules with vent damper plug.

Remember, however, that a vent damper should

not be usedinan fan-assisted combustion system

oran LPgas systemand thatthe vent damper plug

mustnotbe removed excapttoconnect themodule

to a DSOD with the plug-in cable. S8600A,B;

$8610A,B canbe substitutedinthese drawingsby

simplyconnecting theigniterand sensoras shown

in Figs. 3 and 4.

2. Refer to heating appliance manufacturer's instruc-

tions for wiring auxiliary controls.

3. Adjust thermostat heat anticipator to match system

current draw. The current draw equals the total current re-

quired for the ignitionmodule (0,2 A) plus the gas control

and any other auxiliary equipment in the control circuit.

3

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.

69-0463

GroundControlSystem

Theigniter,flamesensorandignition module must

share a common ground withthe main burner. Use thermo-

plasticinsulatedwire witha minimum ratingof 105°C[221 °

F] for the ground wire; asbestos insulation is not accept-

able. If necessary, use ashield 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 afemale 114in.

quick-connect terminal and connect it to the male quick-

connect GND(BURNER) terminal onthe 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, runa lead fromthe burner to ground.

NOTE: "Earth" ground is not required.

REPLACING MODULE WITH TH-R; TH-W TERMINALS

On modules that do not have avent damper plug, the

thermostat must be connected between the transformer

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 oldmodule 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.

TABLE ,S--TERMINAL CROSS REFERENCE.

TERMINAL ON TERMINAL ON

OLD MODULE: NEW MODULE:

25 V (1) 24 V (GND)

TH-W 24 V

MV MV

MV/PV MV/PV

PV PV

GND (Burner) GND (Burner)

S8600F_1_; Se610F,H;_ se6700

OUALVALVEcoMBINATION

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 GROUNOLEGTO TRANSFORMER,

/_ FOR MOOULE WiTH TH-W TERMINAL AND VENT OAMPER PLUG, CONNECT I_'IE RMO6TAT TO TH-W. LEAVE

24V OPEN. co NOT REMOV__NT DAMRERPLUG, MII7_

Fig. 1--S8600F,H,M; S8610F, H; $8660D; $8670D connections In a heating system with an atmospheric burner

4

$8_OOF.H,M;Sl_ lff:,H

A_ VENT

GNO 24V DAMPER

MV MV/PV PV (BURNER) GND 24V TH-W PLUG SPARK

X

PILOT VALVE

1ST

DUAL VALVECOMBINATION

GAS CONTROL

W(B[NG _1

°i

;," 080DVENT

im_ LIMIT

/_ CONTROLLER Lt

Q345, Q346. _- GROUND

Q348,Q3_,Q361! _PILOT BURNER _ ---JILL2

PILOTBURNEP,/ ( _

IGNITER.SENSOR pILOTGAS

SUPPLY

POWERSUPPLY. PROVIO_OISCONNECT MEANSAND OVERLOADPROTECTIONAS REDUIREO.

/_ ALTERNATEUMrTCONTROLLER LOCATION.

Z_ MAXIMUMCASL_ LENGTH3 K(0.9m].

CONTROLSIN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER.

REMOVE PLUGONLY F USING VENT DAMPER, GUSEBLOWS ON STARTUP WHENPLUG L_REMOVED;

THEN MODULEWIt.LOPERATE ONLY WHENVENT 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

,_ VENT

GNO 24V TH.W OAMPER

MV MV/PV PV (BURNER) GND 24V (OPT) PLLK:itOPT) SENSE

IST E eM TA'

_ERATOR

_Lwrr

IGNITE _GROUND CONTROLLER

PILOT GAS

SUPPLY

SPARK

Z_ POWER SUPPLY. PROVIOEDISCONNECT MEANSAND OVERLOADPROTECTIONAS REDUIRED,

L_ ALTERNATELIMITCONTROLLER LOCATION.

MAXIMUMCASLE LENO1_ 3" [0"9mi-

._ CONTROLS IN 24V CIRCUIT MUST ROT BEIN 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

IOND

__j

LMAIN

PILOT _ _ _ VALVE

RATOR RATORI

3UAL VALVE COMBfNATION

3AS CONTROL SENSOR

IGNITER_ _

PILOT GAS

GROUND

S86EOA,B;S861OA,B

VENT

24V DAMPER

GND 24V TH.W PLUG /5_ SENSE

F [][

LIMIT

CONTROLLER

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

SPARK

Z_I ALTERNATE LIMff CONTROLLER LOCATION,

Z_ MAXIMUM CABLE LENGTH 3ff {0.9 mJ.

Z_ CONTROLS IN 24V CIRCUrT MUST NOT BE IN GROUNO LEG TO TRANSFORMER.

REMOVE 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; $86600; $86700

III i °l

MV MV/PV PV (BURNER)

fL _MAIN

PILOT IVALVE

DUAL VALVE COMBINATION

GAS CONTROL

L_ VENT F i I

24V TH.W DAMPER

GNO 24V (OPT) PLUG (OPT} SPAR

-I--r-}r-i D

L..J

I± AIR

PROVING

COMBUSTION

AIR BLOWER

_RELAY

)_H_RMOSTAT

PILOT {HOT)_ COMBUSTION

AIR BLOWER

0345. 0346, BURNER MOTOR L2 Lt

0348, Q362, G381 GROUND (HOT)

PILOT BURNER/ /_

IGNiTER.SENSOF

POWER SUPPLY. PROVIOE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REOUIREO.

i'_ ALTERNATE LIMIT CONTROLLER LQUATION.

MAXIMUM CABLE LENGTH 3 ft 10,9 4.

/_ COflTROLB IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER.

/_ FOR MODULE WITH TH.W TERMINAL AND VENT DAMPER PLUG, CONNECT THE RMOSTAT TO

TH-W. LEAVE 24V OPEN. DO NOT REMOVE VENT OAMPER PLUG.

Fig. _S8600F,H,M; $8610F, H; $8660D; S8670D connectlbns In aheating system with power-assisted combustion.

$86(X_: J4,M; S8610F.H; S_; S867¢0

GNO

MV MV/PV PV (BURNER)

/_ VENT

24V TH-W DAMPER

GNO 24V (OPT) PLUG(OPT)

r--1

III

I I

MAIN

ICOM _O MAIN VALVE

VALVE STAGE 2

•PILOT rROUND TAGE 1 r_ -_OSTAT

)ERATOR OPERATOR

TWO STAGE OUAL VALVE

COMBINATION GAS CONTROL

COMSUSTIO$_

AIR BLOWER

RELAY

Q_5,0_6,

O348,0362.

Q_IP_OT

SURNE_

IGNITER-

SENSOR

)

PIL T

BU _ER

UNO

PILOT GAS

SUPPLY

SPARK

7

LINIT

CONTROLLER

L1 L2 COMSUSTK)N

(HO'_ AiR BLOWER

/_L1 L2 MOTOR

(HO'n

_POWERSUPPLY. P ROV_IE OI._2ONNECTMEANS AND O_'ERLOAOPRO'I_CTION AS REOULRE_

_AL'_RN_E LIMtT_NIL_U.E RL_T_N.

z_ MAX=MUMC,_LE LENGTH 3, Io.9 ml.

z_ CONTROLS IN 24V CIRCUIT MUST NOT BE IN GRG4JNOLEG TOTRANSFORMER.

,,_ FORMODULE WITHTH-WTERMINALANOVENTDAMPERPLUG, CONN_CTIHERMO_TATTO TH-W. LEAVE

24V OPEN. OO NOT REMOVE VENT DAMPER PLUG. 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. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQIJIRED.

i_ ALTERNATE LIMIT CONTROLLE R LOCATION.

MAXIMUMCABLE LENGTH2 ft 10.9m_.

Z_l CONT ROIS fN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER.

1/_ FOR MOOULEWITHTH*W TERMINALANDVENT DAMPER PLL_I. CONNECT _ RMOSTATTO

TH-W. LEAVE2,1VOPEN. DO NOT REMOVEVENT DAMPERPLUG.

Z_ COLORS REFER TO WIRE HARNESS, IF USED. Mlll10e

Fig. 7IS8600F,H,M; S8610F,H; S8660D; S8670D in a heating system with an atmmlpherlc burner and a DSOBvent

damper.

8

_,H J_; S8610F,H; $86r=00; S_700

MAIN

VALVE

DUN. VALVECOMSkNATION

GAS CONTROL

THERMOSTAT LI

AIR BLOWER

MOTOR

COMBUSTION

AIR BLOWER

RELAY

AIR PROVING

SWITCH

=RESSURE

30NTROLLER

24V THW" _VENT

• DAMPER

GNO 24V (OPT) PLUG(OPT)

r'----1

kJ

I

GO4e,Q_2.

QO81PILOT

BURRER/ GROUND

IGNITER-

SENSOR PILOTGAS

SUPPLY

SPARK

&

Mlt_

FAN

_POWERSUPPLY. PROVIOEDISCONNECT MEANSAND OVERLOAOPROTECTIONAS FIEQUIRED.

Z_I ALTERNATELIMITCONTROLLERLOCATION.

Z_ MAXIMUMC*'mLELENGTH 3a [0.9m].

CONTROLSIN 24V CIRCUIT MUST NOT BE'IN GROUNDLEGTO TRANSFORMER.

.,_ FOR MOOULIEWI"R.ITH-W TERMINALAND VENT DAMPERPLUG. CONNECT THERMOSTATTO

TH-W. LEAVE 24V OPEN, OO NOT REMOVIEVENT DAMPER PLUG.

Fig.8--S8600F,H,M; S8610F,H; $8660D; S8670D connections in s heating.cooling systemwith 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 OVERLOADPROTECTIONAS REQUIRED.

L_ CUT PLUGOFF MODULE ENC OFDeOOWIRE HARNESS,CONNECTt.EAOWIRECOLORSAS SHOWN,

L_ MAXIMUMCABLELENGTH3 It [0,9m].

L_ FOR MOOULEW1THTH-W TERMINALANO VENT OAMPER PLUG,CONNECTTHERMOSTATTOTH-W.

LEAVE _4V OPEN, DO NOT REMOVEVENT DAMPERPLUG.

L_ LEAVE TP-Z ANDZoWJUMPERS IN PLACE, MIII_e

Fig. 9---S8600F, H,M; S861 OF, H; S8660D; S8670D connection s Ina hydronlc heating sytem with a D80D vent dam per.

10

Se6OOF,H.M; S86tOF,H; S8660D; BN700

GND

MV MV/PV PV (BURNER]

Z_ VENT

24V TH,W OAMPER

GND 24V (OPT) PLUG(OPT)

F'i

I I I

MAIN

VALVE

DUAL VALVE COMBINATION

GAS CONTROL

L8100

IECO

ICONTROLLER

SPARK

A

L1 L2

(HOT) Q345, 0346,

Q348, 0362. 038

PILOT BURNER/

IGN]TER-S_NSOR PILOT GAS

SUPPLY

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

Z_ MAXIMUM CABLE LENGTH 3 It [0.g m].

•_CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORME R.

Z_ FOR MODULE WITH TH-W TERMfNAL AND VENT DAMPER PLUG. CONNECT THERMOSTAT TO

TH-W LEAVE 24V OPEN. DO NOT REMOVE 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 controlsystem:

•At initial installationof the appliance.

•As part of regular maintenance procedures. Mainte-

nance 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.

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 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 ignitionmodule.

IS] Open manual shutoff valves in the gas line to the

appliance.

ODo gas leak test ahead of gas control if pipinghas been

disturbed.

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.

E3Turn 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.

STEP 4: Check Safety Shutoff Operation.

This step applies to lockout and continuous retry modules

only.

[] Turn gas supplyoff.

[] Sat thermostat or controllerabove 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 sureno gas is flowing

to pilot or main burner.

[] Set thermostat below room temperature and wait one

minute before continuing.

STEP 5: Check Normal Operation.

OSet thermostat orcontroller above roomtemperature to

call for heat.

11 69-0463

[] Make sure pilotlights smoothly when gas reaches the

pilotburner,

[] Make sure main burner lights smoothly without flash-

back.

[] Make sure burner operates smoothly without floating,

lifting, or flame rol_outto the furnace vestibule or heat

buildup inthe vestibule.

[] Ifgas linehas been disturbed, complete gas leak test.

GAS LEAK TEST: Paint gas control gasket edges and all

pipe connectionsdownstream of gascontrol, 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 controllerbelow room temperature.

Make sure main burner and pilot flames go out.

OPERATION

Module operation can be conveniently dividedinto two

phases for $8600, $8610 and three for $8660, $8670. The

phases are

• Prepurge (S8660, S8670only)

•Trial for ignition (all models)

• Mainburneroperation(allmodels)

Figs. 11 and 12 summarize the normal operating se-

quences of the modules.

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 allowsystem prepurge. Afterprepurge, the module starts

the pilotignition sequence.

START

STAGE 1

TRIALFOR

IGNIIT_N

STAGE 2

MAIN BURNER

OPERATION

l

END

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.

aShutollno_,=uttie'_l i= =l=w,pedon modute

"4_'*)FLAI_ C_JRRENT_O k_Fl_€_=_ ix,_r _

•S_*kgeeemto,on.

• seooadv_e em_or(e_a)

T_'OSTATt_l_u.F._ I

Fig. 11_, 58610 normal operatingsequence.

12

TRIAL FOR IGNITION

Pilot Ignition

Followingprepurge timing ($8660, $8670), or on thecall

for heat ($8600, $8610), the module energizes the first

main valve operator, The first main valve opens, which

allows gas to flowto 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 atthe igniter (S8600A,B; $8610A,B) or igniter-sensor

(S8600F,H,M; S8610F,H; $8660; $8670) that lights the

pilot.

Ifthe pilot does not light,or the pilotflame currentis not

at least 1.0 _A and steady, the module willnot 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 untilthe pilot lights.

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 sparkcontinuesonly 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 firstmain (pilot)valve in

the gas control, stopping pilotgas flow. The controlsystem

must be reset by setting the thermostat below room tem-

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

aslockout modules, exceptthat a timer startstimingimme-

diately following shutoff. Six minutes nora. (five minutes

rain.) after shutoff, the module restarts the ignition se-

quence. The ignitiontrial,shutoff,wait sequence continues

until either the pilot lights or the thermostat is set below

roomtemperature to and the call for heat. The module can

also be resetby settingdownthe thermostatlor one minute,

MAIN BURNER OPERATION

When the pilotflame is established, aflame 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 valveopens

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 inthe reset (normal) operat-

ing condition.

When thecallfor heat ends, bothvalve operatorsarede-

energized, and both valves in the gas controlclose.

START

STAGE 1

PREPURGE

STAGE 2

TRIAL FOR IGNITION

_Lo#,.o_t_ is

_oamodus.

STA_ E 3

MAIN BURNER

OPERATION

END

_,_ LAME CURRENT SENSED

•Spark ger_a_x off.

•Secondvak__rat_x (main)

.,_ AIN BURNER oPeRAllON

Module monitors _€_,rne

cutront•

THERMO6TAT SATISRED

VMvesdose. _k_ and mmn

bume,s Are of/,

ii

SyStem shuts o/I. mSIKIs when powe, i_

mslored,

PILOT FLAME FNLURE

Maln valve closss.

• S8670slam Irbl lot ilpi_ion.

J Mtt71A

Fig. 12--58660, $8670 normal operating sequence.

13 69-0463

TROUBLESHOOTING

IMPORTANT

1. Thefoliowingserviceproceduresareprovldedas

ageneralguide. Follow appliance manufacturer's

service instructionsifavailable.

2. On lockout and retry models, meter readings

between gas controland _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.

3. If any component does not function properly,

make sure itiscorrectlyinstalled andwiredbefore

replacing it.

4. The ignitionmodule cannot be repaired. If it mal-

functions,it must be replaced.

5. Only trained, experienced service technicians

should service intermittent pilotsystems.

Pedorm the checkout on page 11 as the first step in

troubleshooting. Then check the appropriate troubleshoot-

ingguide (Fig. 14 or 15) and the schematic diagram (Figs.

16-17) to pinpointthe cause of the problem. I| troubleshoot-

ing indicates an ignition problem, see Ignition System

Checks below to isolate and correct the problem.

Followingtroubleshooting,pedorm thecheckout proce.

dure (page 11) again to be sure system i,s operating

normafly.

IGNITION SYSTEM CHECKS

STEP 1: Check ignition cable.

Make sure:

[] Ignition cable does not run in contact with any metal

sudeces.

OIgnitioncable 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.

[] Ignitioncable provides good electrical continuity.

STEP 2: Check ignitionsystem grounding. Nuisance shut.

downs are often caused by a poor or erratic ground.

[_ A common ground, usually supplied by the pilotburner

bracket, is required for the module and the pilot burner/

igniter-sensor.

• Check for good metal-to-metal contact between the

pilotburner bracket and the main burner.

• Check the ground lead trom the GND(BURNER)

terminal onthe module to the pilot burner. Make sure

connections are clean and tight. If the wire is dam-

aged ordeteriorated, replace itwithNo. 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

canpermitleakage 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,

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 terminalon

the module.

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.

DEnergize the module and immediately touch one end of

the jumper firmly to the GN D terminal onthe module. Move

the free end of the jumper slowly toward the SPARK

terminal untila spark is established.

[] Pull the jumper slowly away from the terminal and note

the length o! the gap when sparking stops. Check table

below.

ARC LENGTH ACTION

No arc or arc less Checkexternatfuse, itprovided.

than 1/8 in. [3 mm] Verify power at module input

terminal.

Replace module if fuse and

power ok.

Arc 1/8 in. [3 mm] Voltage output is okay.

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 pilotlights 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.

APPEARANCE

SMALLBLUEFLAME

LAZYYELLOWFLAME

WAVINGBLUEFLAME

NOISYLLFTINOBLOWINGFLAME

CAUSE

CH_CK FOR LACK OF GAS FROM:

eCLOGGI_00_IFtCE FILTER

• CLOGGED PILOT FILTER

•LOW GAS SUPRLY PRESSURE

• P_LOTAD_JSTMENT AT

MINIMUM

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

CH|CK FOR:

•EXCESSIVEDRAFTAT PILOT

LOCATION

•HECIRCULATINGPROOUCTS

OF COMBUSTION

CHECK FOR:

•HIGH GAS PRESSURE

THiSF4JUtlEIS

CHAAACTImmTIGOF

MANUFACTUREDGAS

CHECKFOR:

*HIOHGAS PRESSURE

I* ORIFICETOOSMALL l*.Iml

Fig, 13--F, xamples of unsatisfactory pilot flames,

14

Make sure electrical connections are clean and tight.

Replace damaged wire with moisture-resistant No.

18 wire rated for continuousduty up to 105° C [221o

F].

Checkforcracked ceramic insulator,whichcancause

short to ground, and replace igniter-sensorif neces-

sary.

• At the gas control, disconnect main valve wire from

the TH or MV terminal.

Turn on power and set thermostatto callfor heat. The

pilotshould light but the main burner will remain off

because the main valve actuator is disconnected.

• Check the pilotflame, Make sureit 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.

•Ifnecessary, adjust pilotflame by turningthe pilot ad-

justmentscrew on the gas controlclockwise _to

decrease orcounterclockwise _ to increase pilot

flame. Following adjustment, always replace pilot

adjustment cover screw and tighten firmly to assure

proper gas controloperation.

•Set thermostat below room temperature to end call

for heat.

ORecheck ignitionsequence as follows.

Reconnect ma(nvalve wire.

Set thermostat to call for heat.

Watch ignitionsequence at burner.

If spark still doesn't stop after pilot lights, replace

ignitionmodule.

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.

START _;

ITURN GAS SUPPLY OFF.

TURN THERMOSTAT

(CONTROLLER) TO CALL

FOR HEAT

POWER TO MODULE

(24V NOMINAL)

YES + r_ I

iSPARK ACROSS

_.INITEP./SENSO R GAP

YES

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES _

I SPARR STOPS WHEN ININININ_PILOT IS LIT? ,, ,

YES

_ r

IMAIN BURNER LIGHTS?

YES _

i

ISYSTEM RUNS UNTIL

CALL FOR NEAT ENDS?

i

YES

CALL FOR HEAT ENDS

SYSTEM SHUTS OFF?

ES,!,

I"_OJBLESHcoTINGENOS

NOTE: Before troubles hoollng, hum_lil__yourN)' with the sl=ttup and ¢heckoul _ure.

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.

check spark at module.

Spark okay?

i

YES +

On modem w_h venl damper I_S. make sum vent damper

hal fbolbeen lea(ailed. Iken te rr_oved. Repta_ van1 d;zrt_t

if neces=ary.

On otke_ mode_, replace module.

• Ched_ ignition cabS, ground wifleg, ¢z,ral_¢ lesulet o( and gap, and co_.

• Check boot of the ignition eddie for ligr_ of rne)'irlg or I_klleg. Take Womcti_ a_ion to =hleld cable and

boo4 Iforil e_cQsslve tsrrIpetatum$.

i

•Check Ihat all manual 9a v_ are op4n. =u_0_y t...i>mg and pressures we good. ,rid pilot I_Jrner orilice

i= _o€ blocked.

•Check elecltical_r=_d_ between module _1 pilol opera(or or=gas _ntroL

• Check Ior 24 Vac _o'Js PV.MVIPV terra'all on module. )' vof_ is okay. mplece gas oont¢¢_;_f not.

r*p_a_ module.

NOTE: )' Se_O0_.H;S_(IIC_.H goesink) Io(:k_, ttlll Sytle,'fl.For S86OOM.walt6 ram.norrtfor leiP( or

fete( syllem.

• Checkcominuklyof ignaio_cableand groundwire.

• Cleanitama rod.

• Ched_ele¢Idc=lconnect_s betweenflarn=rodandmodule.

• Ch*d_lot _ad_d _tan,lc f_ rodin=ulator.

•CheckIhalpiletflamecover=f_Tte rodand is =lead),and blue.

• Adjut( I_kXflern_.

• )'problem_iszs. mgle(:_module.

i

mNmN_I .Ched_lo,24V_ _s MV.MWPVtern,,_, itno_t=ge..,placernod,,k,.

•Check (dll_l_l conneo(_on$ belween module and gas cOnltoL it okay. replace gas o_tro_ Or gas _Ir_

opera(or.

rNrNr_ I NOTE: if Sit6OO_,H; S84_$OB.H goes inlo Io_o_d. tes41tsytlem. For S86COM. wa_ 6ram.._om, lot ml,-/or

.'esel Systom.

•Check ¢onlinuity c4 ignlt .=*_ca_* and ground _m.

NOTE; If Stoun_ is poor or ettll_c, sh_tdowrs rna_'o¢_ur _siona_y eve,_ thigh op_t a_ion is normal a(

Ihe Irr, eof d'w.ckout.

•Check Ihal pilet if_e covert ifame rod rand is =te.tdy w_d blue.

•it decks we okay. rep_ module.

• Chld_ IOrptOplt thetmo_tal ((_drolle_ opera(ion.

•Rim_l MV lead al module; if valve Ck_=. lech_¢k lempeeatum COnltolaf and _ting; i( no(. rll_ace

gain ¢omro_.

IRepN_ proo_dum u_4NImubleft_ operation _mobt aln_.

Fig. 14---$8600, $8610 troubleshooting guide•

I

i

I

J

Mt 17,1/,

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, S8670troubleshootingguide•

16

LI

LIMIT ON.OFF (HOT) L2

r....... :

! I

THERMOSTAT OR Ie-............ ,J

I !

CONTROLLER A _24V

_.m_ _ TRANSFORMER

IP =1 i =

r..... to--_ --,-o_-t-_ L........................................

ARC

GAP

IGNITER

SENSOR

RUR_R

GROUND

MNN

1K1 IK2 _(2 ---,_,--

PILOT

//_ PO_R SUPPLY, PROVIDE DISCONNECT MEANS ANO OVERLOAD PROTECTION AS REQUIRE D.

/_ ALTERNATE UMIT CONTROLLER LOCATION.

3K RELAYON tOORERCIENTSHUTOFFMODELSONLY. ON NON-SHUTOFFMOOELS.PV AND MV

WIRED AS FOLLOWS.

TO 24v TO 24V (GND)

MAIN _-- INTERNAL WIRING

I _2:[1K1'_ -11(2_+] G- P-L'_O;-VALVEVALVE __ - - - EXTERNAL WIR INO

-Q---'_ ..... sM.+58

)

Fig. 16---Representative schematic for S8600F, H, M; S8610F,H. ,See Fig. 1 for hookup. $8660 and $8670 are simlla

excepl the timing circuit Includesa purgetimer. See Fig.6 for hookup.

17 69-0463

L1

UMIT ON-OFF (HO]_ [.2

CONTROLLER SWITCH _1_ ,_Z_

..... :

[ ,

!f-J

THERMOSTATOR _24V

CONTROLLER ,,_ --

_ _ TRANSFORMER

F _lI I I

r ..... to *'_Ol- --t-o-'_',L-o- -Ie -a t. ........................................

IIDI I Iii

2K2 3KI

./_ POWSRSUPFLy_ PROVIOEDISCONNECTklEAHS ANO OVERLOAD

PRGTECTIONAS REQUJRIEO_

ALTERNATELIMITCONTROJ=ERLOCATION_

ARC

GAP

GROUND

/_ 3K RELAY ON 100 PERCENTSHUTOFF MOOELSONLY. ON NON-SHUTOFFMOOELS,PV ANO

MYWlREO AS FOLLOWS.

TO 24V TO24V (GNO) -- INTERNALWIRING

_K,,] !,,, '_II G" _--p-_;-V.VE --- S_ERN._W._G

Fig. 17.--Representative 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 conditionfor 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 an-

ticipate all situations.Accordingly, in somecases, devia-

tion 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 instal-

lation.

b. Ifit is determined there is a condition which could

result in unsafe operation, the appliance shouldbe

shut off and the owner advised of the unsafe condi-

tion.

The following steps should be followed in makingthe

safety inspection:

1. Conduct aGas Leakage Test of the appliance

piping and control system downstream of the shutoff

valve in the supply line to the appliance.

2. Visually inspectthe venting system for proper size

and horizontal pitchand determine there is no blockage

or restrictions, leakage orcorrosion orother deficiencies

which could cause an unsafe condition.

3, Shut off all gas to the appliance and shut off any

other fuel-burning appliance withinthe same room. Use

the shutoff valve in the shutoffvalve inthe supply line to

each appliance.

operate at maximum speed. Do not operate a summer

exhaust fan. Close fireplace dampers. If, after complet-

ingsteps 7through 12, it is believed sufficient combus-

tion air is not available, refer to 1.3.4 of the National Fuel

Gas Code (Z223.1) for guidance.

8. Place inoperation theappliance being inspected.

Follow the lightinginstructions. Adjust thermostat soap-

pliance will operate continuously.

9_ a. Determine t hatthe pilot isbu rning propedyand

that main burner ignition is satisfactory by inter-

ruptingand 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 burn-

ing 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.

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.

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.

5. Applicable only to warm air heating appliances. In-

spect heat exchangers for cracks, openings or exces-

sive corrosion,

13. Applicable only to warm air heating appliances.

Check both limit controller and fan controller for proper

operation, Limitcontrolleroperation 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.

6. Applicable only to boilers. Inspect for evidence of

water or combustion product leaks.

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 onclothes dryers. Turn on any exhaust fans, such

as range hoods and bathroom exhausts, so they will

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 withthe manufacturer's rec-

ommendations and instructionsto determine they

are in operating condition.

EXHIBIT A OF ANSI STANDARD Z21.71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD

INSTALLATION

19 69-0463

EXHIBITB

PROCEDUREFORINSTALLINGAUTOMA11CINTERMITTENTPILOTSYSTEMS

Priortobeginningthisprocedure,apreliminaryex-

aminationoftheapplianceandtheautomaticintermit-

tentpilotsystemshouldbemadetodeterminethatthe

automaticintermlttantpilotsystemcan be properly

applied to the appliance.

This procedure is intended as aguide to aid insafely

installinga listedautomatic intermittentpilotsystem on

an existing listed appliance equipped with an atmos-

pheric 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 satisfactoryoperation,

This procedure is predicated on central furnace and

boilerinstallations,and itshouldbe recognized thatgen-

eralized procedures cannot anticipate all situations,Ac-

cordingly, insome cases, deviation from this procedure

may be necessary to determine safe operation of the

equipment.

The following steps shouldbe folicwed inmaking the

modifications:

t. Perform a safety inspectionof the existing appli-

ance installation.See Exhibit Afora recommended pro-

cedure for such a safety inspection.

2. Shut off allgas and electricity to the appliance. To

shutoffgas, use the shutoffvalve inthe supplylinetothe

appliance. Do not use the shutoff valve which is pro-

v_ed as pad of acombination control.

3. Install the automatic interrn_ent pilot system in

strictaccordance withthe manufacturer's installationin-

structions.

4. ,Turnon all gas and electricity to the appliance.

5. Determine that the appliance transformer has

adequate capacity by following the steps outlined be-

low;

a. Compute the approximate current draw by adding

the current draw of the automatic intermittentpilot

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

equalto or less thanthe VA rating of thetransformer.

d. If the total VA (volt-ampere) required is greater

than the VA ratingofthe transformer,the transformer

must be replaced with a Class 2 transformer of

adequate rating.

6. Check the heat anticipator inthe comfort thermo-

statto determine if if is property adjusted to the current

draw of the control system. Follow the thermostat

manufacturer's instructions.

7. Make certain wiring connections are tight and

wires are positioned and secured sothey willnotbe able

to contact hightemperature locations.

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.

g. a. Adjust the thermostat to its highest tempera-

ture 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. Ad-

just the primary air shutter(s) as required.

10. If the appliance is equipped with high and low

flame controlorflame 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 de-

termination 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 sys-

tem 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 rec-

ommended by the system manufacturer.

13. Sequencatheappliancathroughatleastthreeop-

erating cycles.

14. Applicable only to furnaces. Check both the limit

controller and the fan controller for proper operation.

LimitControloperation can be checked by blockingthe

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 control-

lers 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 and -o) on the appli-

ance.

EXHIBIT B OF ANSI STANDARD Z21.71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD

INSTALLATION.

Honeywell Inc. InternationalSalesOfficesin allprincipalcitiesof the world Manufacturingin _

Australia,Canada,Finland,France,Germany,Japan,Mexico,Netherlands.

1885 DouglasDriveN. Spa n, Taiwan,UnitedK ngdom,U.S.A. PRINTED IN U.S.A. ql:_,i.rrt"is K=.:',

1

GoldenValley,MN 55422-4386