Honeywell Ignition Module (PDF)

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S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K Intermittent Pilot Gas Ignition Control INSTALLATION INSTRUCTIONS

APPLICATION The 8600 family of ignition controls provide ignition sequence, flame monitoring and safety shutoff for intermittent pilot gas fired heating appliances. These controls provide flame sense and operating sequences suitable for the application. Table 1 describes the main features of each available model. Table 1. Intermittent Pilot Ignition Models. Valve Current Trial for Ignition Rating Prepurge Pilot Sequence @ 24 Vac Timing Ignition Type

Model

IgniterSensor Type

S8600B

Separateb

1.0 A Pilot and 1.0 A Main

None

15 or 90 seconds, as ordered

S8600C

Separate

1.0 A Pilot and 1.0 A Main

None

15 or 90 Continuous Spark and pilot gas ON until lightoff or trial for ignition ends. If seconds, Retry pilot fails to light, pilot gas and spark OFF (100% shutoff). After as ordered 5 minute delay, a new trial for ignition is initiated. This sequence continues until lightoff or “Call for Heat” is removed.

S8600H Combinationc 1.0 A Pilot and 1.0 A Main

None

15 or 90 seconds, as ordered

S8600M Combination

1.0 A Pilot and 1.0 A Main

None

15 or 90 Continuous Spark and pilot gas ON until lightoff or trial for ignition ends. If seconds, Retry pilot fails to light, pilot gas and spark OFF (100% shutoff). After as ordered 5 minute delay, a new trial for ignition is initiated. This sequence continues until lightoff or “Call for Heat” is removed.

S8610B

Separate

1.0 A Pilot and 2.0 A Main

None

15 or 90 seconds, as ordered

S8610C

Separate

1.0 A Pilot and 2.0 A Main

None

15 or 90 Continuous Spark and pilot gas ON until lightoff or trial for ignition ends. If seconds, Retry pilot fails to light, pilot gas and spark OFF (100% shutoff). After as ordered 5 minute delay, a new trial for ignition is initiated. This sequence continues until lightoff or “Call for Heat” is removed.

S8610H Combination

1.0 A Pilot and 2.0 A Main

None

15 or 90 seconds, as ordered

S8610M

1.0 A Pilot and 2.0 A Main

None

15 or 90 Continuous Spark and pilot gas ON until lightoff or trial for ignition ends. If seconds, Retry pilot fails to light, pilot gas and spark OFF (100% shutoff). After as ordered 5 minute delay, a new trial for ignition is initiated. This sequence continues until lightoff or “Call for Heat” is removed.

1.0 A Pilot and 2.0 A Main

30 seconds

Separate

S8670D Combination

15 or 90 seconds, as ordered

®

Lockout

Lockout

Lockout

Lockout

Lockout

Ignition Sequence Descriptiona Spark and pilot gas ON until lightoff or trial for ignition ends. If pilot fails to light, pilot gas and spark OFF (100% shutoff), and lockout. Cycle “Call for Heat” to restart ignition sequence.

Spark and pilot gas ON until lightoff or trial for ignition ends. If pilot fails to light, pilot gas and spark OFF (100% shutoff), and lockout. Cycle “Call for Heat” to restart ignition sequence.

Spark and pilot gas ON until lightoff or trial for ignition ends. If pilot fails to light, pilot gas and spark OFF (100% shutoff), and lockout. Cycle “Call for Heat” to restart ignition sequence.

Spark and pilot gas ON until lightoff or trial for ignition ends. If pilot fails to light, pilot gas and spark OFF (100% shutoff), and lockout. Cycle “Call for Heat” to restart ignition sequence.

After prepurge, spark and pilot gas ON until lightoff or trial for ignition ends. If pilot fails to light, pilot gas and spark OFF (100% shutoff), and lockout. Cycle “Call for Heat” to restart ignition sequence.

Automatic Ignition Systems ANSI Z21.20

69-1954-01

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL Table 1. Intermittent Pilot Ignition Models. (Continued)

Model

IgniterSensor Type

Valve Current Trial for Ignition Rating Prepurge Pilot Sequence @ 24 Vac Timing Ignition Type

Ignition Sequence Descriptiona

S8670E Combination

1.0 A Pilot and 2.0 A Main

30 seconds

15 or 90 Continuous After prepurge, spark and pilot gas ON until lightoff or trial for seconds, Retry ignition ends. If pilot fails to light, pilot gas and spark OFF as ordered (100% shutoff). After 5 minute delay, a new trial for ignition is initiated. This sequence continues until lightoff or “Call for Heat” is removed.

S8670J

Separate

1.0 A Pilot and 2.0 A Main

30 seconds

15 or 90 seconds, as ordered

S8670K

Separate

1.0 A Pilot and 2.0 A Main

30 seconds

15 or 90 Continuous After prepurge, spark and pilot gas ON until lightoff or trial for seconds, Retry ignition ends. If pilot fails to light, pilot gas and spark OFF as ordered (100% shutoff). After 5 minute delay, a new trial for ignition is initiated. This sequence continues until lightoff or “Call for Heat” is removed.

Lockout

After prepurge, spark and pilot gas ON until lightoff or trial for ignition ends. If pilot fails to light, pilot gas and spark OFF (100% shutoff), and lockout. Cycle “Call for Heat” to restart ignition sequence.

a

If established flame is lost, all models restart ignition trial. Separate: two rod; remote flame sensing. c Combination: one rod; local flame sensing. b

All models provide: • • • • •

Natural or LP gas. Pilot burner ignition using a high voltage spark. Flame rectification circuit to monitor flame presence. Monitoring of 24 Vac, pilot, and main gas valve. LED indicator for flame presence/strength and system status/errors. • Connections for flame reading via standard microammeter. • Optional: Alarm Output dry contacts (Lockout models Only).

SPECIFICATIONS Control Voltage: 24V (18-30 Vac) 50/60 Hz Current Draw: 0.1 A plus valve load @ 24Vac Trial for Ignition: 15 or 90 seconds (depends on model) Prepurge: See Table 1. Ignition Sequence: See Table 1. Retry Delay: 5 minutes (C, M, E, and K models only) Flame Failure Response Time: 2 seconds maximum LED: The green status LED provides system status, error codes, and flame strength indication when in run mode. Gas Control: Honeywell models VR8204 and VR8304 Operating Temperature: Minimum ambient temperature rating is -40°F (-40°C). Maximum ambient rating for S8600 used with 1.0A main valve is 175°F (79°C). Maximum ambient rating for S8610 and S8670 used with 2.0A main valve is 165°F (74°C). Relative humidity: 0% to 95% noncondensing

PLANNING THE INSTALLATION

WARNING

Fire or Explosion Hazard. Can cause severe injury, death or property damage. 1. Plan the installation as outlined below. 2. Plan for frequent maintenance as described in the Maintenance section.

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 of frequent 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 special Honeywell review; contact your Honeywell Sales Representative for assistance. Review the following conditions that can apply to your specific installation and take the precautionary steps suggested.

Frequent Cycling These controls are designed for use on appliances that typically cycle three to four times an hour only during the heating season. In year-round applications with greater cycling rates, the control can wear out more quickly; perform a monthly checkout.

Water or Steam Cleaning If the control gets wet, replace it. If the appliance is likely to be cleaned with water or steam, protect (cover) the controls and wiring from water or steam flow. Mount the controls high enough above the bottom of the cabinet so they do not get wet during normal cleaning procedures. Use a NEMA 4 enclosure for the ignition control. 69-1954—01

2

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL

High Humidity or Dripping Water

WARNING

Dripping water can cause the control to fail. Never install an appliance where water can drip on the controls.

Electrical Shock Hazard. Can cause severe injury, death or property damage. Disconnect power supply before beginning wiring or making wiring connections to prevent electrical shock or equipment damage.

In addition, high ambient humidity can damage the control. If the appliance is in a humid atmosphere, make sure air circulation around the controls is adequate to prevent condensation. Also, regularly check out the system. A NEMA 4 enclosure is recommended for the ignition module.

CAUTION

Corrosive Chemicals

1. If a new gas control is to be installed, turn off the gas supply before starting installation. Conduct a Gas Leak Test according to the gas control manufacturer instructions after the gas control is installed. 2. Wiring errors can cause improper appliance operation and dangerous conditions such as bypassing safety features.

Corrosive chemicals can attack the module and gas control, eventually causing a failure. If chemicals are used for routine cleaning, make sure they do not reach the controls. Where chemicals are suspended in air, as in some industrial or agricultural applications, use a NEMA 4 enclosure for the ignition module.

Dust or Grease Accumulation Heavy accumulations of dust or grease can cause controls to malfunction. Where dust or grease can be a problem, provide covers for the module and the gas control to limit contamination. A NEMA 4 enclosure is recommended for the ignition module.

CAUTION

Equipment Damage Hazard. Water can cause equipment damage or malfunction. If the module must be mounted near water or moisture, provide suitable waterproof enclosure.

Heat Excessively high temperatures can damage controls. Make sure the maximum ambient temperature at the control does not exceed the rating of the control. If the appliance operates at very high temperatures, use insulation, shielding, and air circulation, as necessary, to protect the controls. Proper insulation or shielding should be provided by the appliance manufacturer; verify proper air circulation is maintained when the appliance is installed.

Maintenance Requirements in Severe Environments Regular preventive maintenance is important in any application.

WARNING Fire or Explosion Hazard. May cause severe injury, death or property damage. Do not attempt to take the module apart or to clean it. Improper reassembly and cleaning may cause unreliable operation.

INSTALLATION When Installing This Product… 1. 2. 3. 4.

Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition. Check the ratings given in these instructions to make sure the control is suitable for your application. Installer must be a trained, experienced service technician. After installation is complete, check out operation as provided in these instructions.

WARNING Fire or Explosion Hazard. Can cause severe injury, death or property damage. 1. The module can malfunction if it gets wet, leading to accumulation of explosive gas. — Never install where water can flood, drip or condense on the 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 naturally vent upward. — Do not operate electric switches, lights, or appliances until you are sure the appliance area is free of gas.

Maintenance frequency must be determined individually for each application. Some considerations are: • Cycling frequency. Appliances that may cycle more than 20,000 times annually should be checked monthly. • Intermittent use. Appliances that are used seasonally 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 modules to deteriorate more rapidly, the system should be checked more often. Any module should be replaced if it 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 “Planning the Installation” are recommended regardless of checkout frequency.

Location The mounting location must provide: — Good, clear access to the field wiring terminals.

3

69-1954—01

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL — Operating ambient temperatures between -40°F and 175°F (-40°C and 79°C); (165°F [74°C] for S8610 and S8670 models). — Relative humidity below 95% noncondensing. — Protection from water, steam or corrosive chemicals that are used to clean the appliance. — Protection from dripping water, such as from an overfilled humidifier or from condensation. — Protection from dust or grease accumulation.

Mount the 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 pilot burner. Ambient temperature at the module must be within the range listed under Operating Temperature, on page 2. The module must be protected from water, moisture, corrosive chemicals and excessive dust and grease.

IMPORTANT 1. As shown in the wiring diagrams, a common ground is required on: aThe pilot burner mounting bracket, and bThe 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 flame current sensitivity. 2. Make sure the transformer has adequate VA. The ignition module requires at least 0.1 A at 24 Vac. Add the current draws of all other devices in the control circuit, including the 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 2.4 VA (for the ignition module). The result is the minimum transformer VA rating. Use a Class II transformer if replacement is required.

Mount the module with the terminals down to protect them from dripping water and dust. As an alternative, it can also be mounted with the terminals on either side.

CONNECT IGNITION CABLE Use Honeywell ignition cable or construct an ignition cable that conforms to suitable national standards such as Underwriters Laboratories Inc. See Table 2 and Table 3.

IMPORTANT Do not mount with terminals facing up.

.

Table 2. Honeywell Pre-assembled Ignition Cables (UL Style 3257). CABLE PART NUMBER

LENGTH

394800-30

30 inches

1/4 inch quick Rajah connector connect, receptacle, 90 insulated degree rubber boot

394801-30

30 inches

1/4 inch quick Rajah connector connect, receptacle, straight insulated rubber boot

MODULE END

PILOT BURNER

Table 3. Recommended Ignition Cable for Field Assembly.

M29897

Fig. 1. Incorrect Mounting (Model S8600M shown). Fasten securely with four No. 6-32 machine or No. 8 sheet metal screws.

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.

Wire the System

CABLE TYPE

VOLTAGE RATING (rms)

TEMPERATURE RATING

UL Style 3217

10,000

302°F (150°C)

UL Style 3257

10,000

484°F (250°C)

Cable must be no longer than 36 in. (0.9 m). Solid conductor cable recommended. To construct a cable, fit one end of ignition cable 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. NOTE: The cable must not run in continuous contact with a metal surface or spark voltage will be greatly reduced. Use ceramic or plastic standoff insulators as required. Resistive spark cable reduces spark voltage and may impact appliance performance.

CAUTION

To install:

Equipment Damage Hazard. Disconnect power supply before beginning wiring or making wiring connections to prevent electrical shock or equipment damage.

(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.

All wiring must comply with local codes and ordinances. See Fig. 2 and Table 4 for proper wiring connections.

CONNECT IGNITION MODULE NOTE: Refer to Fig. 2 and Table 4 for the location of each connection. 69-1954—01

4

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL Connect remaining system components to the ignition module terminals as shown in the appropriate wiring diagram. • Fig. 3 is a basic circuit for the H and M models used in heating systems with atmospheric burners. • Fig. 4 shows the basic circuit for the B and C models with separate sensor and igniter in a heating system with atmospheric burners. • Fig. 5—8 show typical circuits for power assisted combustion applications and two-stage gas control with power assisted combustion applications.

Table 4. Wiring Connection Descriptions. Connector Label

Size

Description

MV

1/4 inch

Main Valve connection

MV/PV

1/4 inch

Common terminal for gas valve

PV

1/4 inch

Pilot Valve connection

BRN GND

1/4 inch

Burner Ground

MAKE FLAME SENSE CONNECTION

24V GND

1/4 inch

Return path to transformer

For B, C, J, and K models: These models have remote flame sensing (two rod). Connect the flame sensor wire from the Pilot burner/ igniter to the SENSE connector on the ignition module.

24V

1/4 inch

24 Vac (“Call for Heat”)

ALARM1

3/16 inch Alarm connection (optional for B, H, D, and J models only)

For H, M, D, and E models: These models have local flame sensing (single rod). The spark lead carries the flame signal.

ALARM2

3/16 inch Alarm connection (optional for B, H, D, and J models only)

METER (μA)

Ammeter Connection for ammeter probes probes for measuring flame current in μAmp DC.

SENSE

3/16 inch Flame Sensor (B, C, J, and K models Only)

SPARK

1/4 inch

GROUND CONTROL SYSTEM The igniter, flame sensor and ignition module must share a common ground with the pilot burner. Use thermoplastic insulated wire with a minimum rating of 221°F (105°C) 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.

2.

3.

Fit one end of the ground wire with a female 1/4 in. quick-connect terminal and connect it to the male quick-connect BRN GND terminal on the ignition module. Strip the other end of the wire and fasten it under the pilot burner bracket mounting screw. If necessary, use a shield to protect the ground wire from radiant heat. The pilot burner serves as the common grounding area. If there is not good metal-to-metal contact between the pilot burner and ground, run a lead from the pilot burner to ground.

High voltage sparking electrode

GND 24V MV MV/PV PV (BRN) GND

24V

ALARM2

S8600 H,M; S8610 H,M ALARM1

CONNECT GAS CONTROL Use 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.

SPARK

3 PILOT

COM

MAIN VALVE

4

1ST 2ND OPERATOR OPERATOR THERMOSTAT

DUAL VALVE COMBINATION GAS CONTROL

2

LIMIT CONTROLLER

PILOT BURNER/ IGNITER-SENSOR

PILOT BURNER GROUND

L1 L2 (HOT) 1

PILOT GAS SUPPLY

NOTE: Earth ground is not required.

1

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

2

ALTERNATE LIMIT CONTROLLER LOCATION.

3

MAXIMUM CABLE LENGTH 3 FT. [0.9 M].

4

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

M29899

Fig. 3. S8600 H,M; S8610 H,M; connections in a heating system with an atmospheric burner. SPARK

SENSE

MV MV/PV

PV BRN/GND 24V GND

24V

ALARM2 (OPT) ALARM1 (OPT)

M29898

Fig. 2. Ignition Module wiring connection locations (Model S8610B shown). 5

69-1954—01

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL

S8600 B,C; S8610 B,C

GND 24V MV MV/PV PV (BRN) GND

SPARK

24V

ALARM2

SENSE

ALARM1

ALARM2

24V

ALARM1

S8600 H,M; S8610 H,M; S8670 D,E

GND 24V MV MV/PV PV (BRN) GND

SPARK

3

3 PILOT

MAIN VALVE

COM

PILOT

THERMOSTAT

1ST 2ND OPERATOR OPERATOR

COM

DUAL VALVE COMBINATION GAS CONTROL

2

GROUND

R 2ND OPERATOR

1ST OPERATOR

AIR PROVING SWITCH

MAIN VALVE STAGE 2 MAIN VALVE THERMOSTAT STAGE 1 W2

W1

2

TWO STAGE DUAL VALVE COMBINATION GAS CONTROL

PILOT BURNER/ IGNITERSENSOR

COMBUSTION AIR BLOWER RELAY

SENSOR 1 L2

4 PILOT BURNER/ IGNITER

LIMIT CONTROLLER

GROUND

PILOT BURNER GROUND PILOT GAS SUPPLY

4

L1 (HOT) LIMIT CONTROLLER

PILOT GAS SUPPLY

L1 L2 (HOT)

1

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

2

ALTERNATE LIMIT CONTROLLER LOCATION.

3

MAXIMUM CABLE LENGTH 3 FT. [0.9 M].

4

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

M29900

Fig. 4. S8600 B,C; S8610 B,C connections with remote flame sensing in a heating system with an atmospheric burner.

COMBUSTION AIR BLOWER MOTOR

L1 L2 (HOT) 1

1

1

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

2

ALTERNATE LIMIT CONTROLLER LOCATION.

3

MAXIMUM CABLE LENGTH 3 FT. [0.9 M].

4

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

M29902

Fig. 6. S8600 H,M; S8610 H,M; S8670 D,E connections in a heating system with a two-stage gas control and power-assisted combustion.

ALARM2

24V

ALARM1

GND 24V MV MV/PV PV (BRN) GND

24V

ALARM2

GND 24V MV MV/PV PV (BRN) GND

S8600 H,M; S8610 H,M; S8670 D,E

ALARM1

S8600 B,C; S8610 B,C; S8670 J,K

SENSE

SPARK

SPARK 3

3 PILOT

COM

AIR PROVING SWITCH

MAIN VALVE

1ST 2ND OPERATOR OPERATOR

L1 L2 (HOT) 1

2 COMBUSTION AIR BLOWER RELAY

PILOT BURNER GROUND PILOT GAS SUPPLY

4

SENSOR 4

COMBUSTION AIR BLOWER MOTOR L2 L1 (HOT)

2

ALTERNATE LIMIT CONTROLLER LOCATION.

3

MAXIMUM CABLE LENGTH 3 FT. [0.9 M].

4

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

GROUND

LIMIT CONTROLLER COMBUSTION AIR BLOWER MOTOR L2 L1 (HOT) 1

PILOT GAS SUPPLY

1

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

L1 L2 (HOT) 1

PILOT BURNER/ IGNITER

LIMIT CONTROLLER

1

M29901

Fig. 5. S8600 H,M; S8610 H,M; S8670 D,E connections in a heating system with power-assisted combustion.

69-1954—01

1ST 2ND OPERATOR OPERATOR DUAL VALVE COMBINATION GAS CONTROL

COMBUSTION AIR BLOWER RELAY

THERMOSTAT

AIR PROVING SWITCH

MAIN VALVE

COM

2

DUAL VALVE COMBINATION GAS CONTROL

PILOT BURNER/ IGNITER-SENSOR

THERMOSTAT

PILOT

1

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

2

ALTERNATE LIMIT CONTROLLER LOCATION.

3

MAXIMUM CABLE LENGTH 3 FT. [0.9 M].

4

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

M29903

Fig. 7. S8600 B,C; S8610 B,C; S8670 J,K connections with remote flame sensing in a heating system with power-assisted combustion.

6

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL

Step 2: Verify control system ground. 24V

ALARM2

GND 24V MV MV/PV PV (BRN) GND

ALARM1

S8600 B,C; S8610 B,C; S8670 J,K

SENSE

SPARK

3

PILOT

COM

1ST OPERATOR

GROUND

AIR PROVING SWITCH

MAIN VALVE STAGE 2 MAIN VALVE THERMOSTAT STAGE 1 R

2ND OPERATOR

W2

SENSOR

W1

2

PILOT BURNER/ IGNITER

TWO STAGE DUAL VALVE COMBINATION GAS CONTROL

The igniter, flame sensor, and ignition module must share a common ground with the main burner. Use thermoplastic insulated wire with a minimum rating of 221°F (105° C) for the ground wire; asbestos insulation is not acceptable. If the temperature at the wire could exceed 221°F (105°C), use a shield to protect the wire from radiant heat generated by the burner. Connect the ground wire as follows:

GROUND

COMBUSTION AIR BLOWER RELAY

a. Fit one end of the ground wire with a female 1/4 in. quick-connect terminal and connect it to the male quick-connect GND (BURNER) terminal on the ignition module. b. Strip the other end of the wire and fasten it under the igniter bracket mounting screw. If necessary, use a shield to protect the ground wire from radiant heat. c. The burner serves as the common grounding area. If there is not good metal-to-metal contact between the burner and ground, run a lead from the burner to ground.

PILOT GAS SUPPLY

4

LIMIT CONTROLLER 1 L1 L2 (HOT)

L1 L2 (HOT) 1

COMBUSTION AIR BLOWER MOTOR

1

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

2

ALTERNATE LIMIT CONTROLLER LOCATION.

3

MAXIMUM CABLE LENGTH 3 FT. [0.9 M].

4

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

M29904

Fig. 8. S8600 B,C; S8610 B,C; S8670 J,K connections with remote flame sensing in a heating system with a two-stage gas control and power-assisted combustion.

CHECKOUT

NOTE: Earth ground is not required.

Step 3: Review Normal Operating Sequence and Module Specifications. a. See “Operation” on page 8 and “Specifications” on page 2.

Check out the gas control system: • At initial installation of the appliance. • As part of regular maintenance procedures. Maintenance intervals are determined by the application. See “Planning the Installation” on page 2 for more information. • As the first step in troubleshooting. • Any time work is done on the system.

WARNING

Step 4: Reset the Module. a. Turn the thermostat to its lowest setting. b. Wait one minute. As you do the remaining steps, watch for points where operation deviates from normal. Refer to the Troubleshooting guide on page 15 to correct problems.

Step 5: Check Safety Shutoff Operation. a. Turn gas supply off. b. Set thermostat or controller above room temperature to call for heat. c. Watch for spark at pilot burner either immediately or following prepurge. See device label. d. Time spark from start to shutoff. See device label. e. On all continuous retry models, wait 5 minutes. Ignition sequence should start again followed by shutoff after 90 seconds maximum. f. Open manual gas cock and make sure no gas is flowing to pilot or main burner. g. Set thermostat below room temperature and wait one minute before continuing.

Fire or Explosion Hazard. Failure to heed these warnings may cause fire or explosion with property damage, injury, or loss of life. 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 the steps below on initial installation and any time work is done involving the gas piping.

Step 1: Perform Visual Inspection. a. With power off, make sure all wiring connections are clean and tight. b. Turn on power to appliance and ignition module. c. Open manual shutoff valves in the gas line to the appliance. d. Perform Gas Leak Test ahead of gas control if piping has been disturbed.

Step 6: Check Normal Operation. a. Set thermostat or controller above room temperature to call for heat. b. Make sure pilot lights smoothly when gas reaches the pilot burner. c. Make sure main burner lights smoothly without flashback. d. Make sure burner operates smoothly without floating, lifting, or flame rollout to the furnace vestibule or heat buildup in the vestibule. e. Perform a gas leak test in the appliance.

GAS LEAK TEST (UPSTREAM OF GAS CONTROL) Paint the gas control gasket edges and all pipe connections upstream of the gas control with a rich soap and water solution. Bubbles indicate gas leaks. Tighten the joints and screws or replace component to stop gas leak. Recheck with soap and water solution. 7

69-1954—01

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL GAS LEAK TEST (DOWNSTREAM OF GAS CONTROL) Paint the gas control gasket edges and all pipe connections downstream of the gas control, including the pilot tubing connections, with a rich soap and water solution. Bubbles indicate gas leaks. Tighten the joints and screws or replace component to stop gas leak. Recheck with soap and water solution. f.

Turn the thermostat or controller below the room temperature. Make sure the main burner and pilot flames go out.

OPERATION Module operation can be conveniently divided into two phases for the S8600 and S8610 and three phases for the S8670. The phases are: • Prepurge (S8670 models only)—See Fig. 10 • Trial for ignition (all models) • Main burner operation (all models) Fig. 9-10 summarize the normal operating sequences of all the models.

Prepurge (S8670 models Only) When an S8670 model is used in a fan-assisted combustion system, the combustion air blower starts on a call for heat. On proof of airflow, the air proving switch closes and energizes the S8670. When this model is used in an atmospheric system, the “Call for Heat” energizes the module. In either case, the module first initiates a 30 second delay to allow system prepurge. After prepurge, the module starts the trial for pilot ignition sequence.

Trial for Pilot Ignition On a “Call for Heat” (and after prepurge on S8670 models), the module energizes the spark source and the pilot valve relay simultaneously. The pilot valve opens, allowing gas to flow to the pilot burner for the ignition trial time. The spark lights the pilot flame when pilot gas is present. A flame rectification circuit confirms the presence of the pilot flame, shuts off the spark source, and energizes the main valve relay.

69-1954—01

The S8600 family uses a two-level pilot flame proving sequence. When a sufficient flame current is sensed, the spark is turned OFF. However, the pilot flame must generate a higher level of flame current to energize the main valve. This approach assures a stable pilot flame to support reliable burner lightoff. If the pilot flame is weak or unstable, the spark may turn back ON. However, the trial for pilot ignition will not exceed the stated ignition trial time

Main Burner Operation When the main valve opens, gas flows to the main burner where it is lit by the pilot flame. There is a short flame stabilization period as the main valve opens to allow the pilot flame to stabilize as the main gas lights. The system is now in the run mode with the presence of the pilot flame continuously monitored by the flame rectification circuit. If the pilot flame goes out, the control senses loss of pilot flame and shuts off both the pilot valve relay and the main valve relay. Flow of gas to pilot and main burners stops as the valves close.

FAILED TRIAL FOR PILOT IGNITION Lockout Models—S8600B,H; S8610B,H; S8670D,J Lockout models provide a single trial for pilot ignition sequence. If the pilot flame is not lit and sensed before the end of the ignition trial time, the control shuts off the pilot valve (100% shutoff) and goes to lockout. The control remains in lockout until power to the control is cycled by the system thermostat or by removing and restoring system power.

Continuous Retry Models—S8600C,M; S8610C,M; S8670E,J Continuous retry models provide multiple trials for ignition. If the pilot is not lit or sensed before the end of the trial for ignition time, the control shuts off the spark and pilot gas (100% shutoff). There is a 5 minute delay before another ignition sequence is initiated. The pattern of ignition sequence followed by a 5 minute delay continues until the pilot lights and is proved or the “Call for Heat” ends. The 5 minute delay time can be bypassed by cycling the system thermostat or removing and restoring system power.

8

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL

OPERATING SEQUENCE - STANDARD MODELS S8600 C, M; S8610 C, M = RETRY S8600 B, H; S8610 B, H = LOCKOUT IDLE (NOT POWERED)

“CALL FOR HEAT” RECEIVED FROM THERMOSTAT

WAIT FOR “CALL FOR HEAT” TO BE REMOVED

POWER TO MODULE AND SELF CHECK

ACTIVATE ALARM CONTACT(S) (OPTIONAL) RETRY DELAY (5 MINUTES)

A

TRIAL FOR IGNITION (TIMER STARTED)

FLAME PROVED?

NO

SPARK ON

OPEN PILOT GAS VALVE

CLOSE PILOT GAS VALVE

SPARK OFF

RETRY

RETRY OR LOCKOUT MODEL?

LOCKOUT

(BEFORE TRIAL FOR IGNITION TIMER EXPIRES) YES

SPARK OFF

OPEN MAIN GAS VALVE FLAME STABILIZATION (2 SECONDS) NO

RUN

“CALL FOR HEAT” ENDS?

NO

FLAME LOST?

CLOSE MAIN GAS VALVE AND PILOT GAS VALVE

YES

A

YES CLOSE MAIN GAS VALVE AND PILOT GAS VALVE M29905

Fig. 9. Normal Operating Sequence for Standard Models.

9

69-1954—01

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL

OPERATING SEQUENCE - PREPURGE MODELS S8760 E, K = RETRY S8670 D, J = LOCKOUT IDLE (NOT POWERED)

“CALL FOR HEAT” RECEIVED FROM THERMOSTAT

WAIT FOR “CALL FOR HEAT” TO BE REMOVED

POWER TO MODULE AND SELF CHECK

ACTIVATE ALARM CONTACT(S) (OPTIONAL)

RETRY DELAY (5 MINUTES)

A PREPURGE (30 SECONDS) TRIAL FOR IGNITION (TIMER STARTED)

OPEN PILOT GAS VALVE

SPARK ON

FLAME PROVED?

NO

CLOSE PILOT GAS VALVE

RETRY

RETRY OR LOCKOUT MODEL?

SPARK OFF

LOCKOUT

(BEFORE TRIAL FOR IGNITION TIMER EXPIRES) YES

SPARK OFF

OPEN MAIN GAS VALVE FLAME STABILIZATION (2 SECONDS) NO “CALL FOR HEAT” ENDS?

RUN

NO

FLAME LOST?

YES

CLOSE MAIN GAS VALVE AND PILOT GAS VALVE

A

YES CLOSE MAIN GAS VALVE AND PILOT GAS VALVE M29906

Fig. 10. Normal Operating Sequence for Prepurge Models.

TROUBLESHOOTING

WARNING

Fire, Explosion, or Electrical Shock Hazard. Can cause severe injury, death or property damage. Do not attempt to modify the physical or electrical characteristics of this device in any way. Replace it if troubleshooting indicates a malfunction.

69-1954—01

10

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL IMPORTANT 1. The following service procedures are provided as a general guide. Follow appliance manufacturer’s service instructions if available. 2. Meter readings between the gas control and ignition control must be taken within the trial for ignition period. Once the ignition control shuts off, lockout models must be reset by setting the thermostat down for at least 30 seconds before continuing. On retry models, wait for retry or reset at the thermostat. 3. If any component does not function properly, make sure it is correctly installed and wired before replacing it. 4. The ignition module cannot be repaired. If it malfunctions, it must be replaced. 5. Only trained, experienced service technicians should service intermittent pilot systems. 6. After troubleshooting, check out the system again to be sure it is operating normally. General troubleshooting process is as follows: 1. 2. 3. 4. 5.

Refer to “LED Status and Troubleshooting” on page 12 for LED status codes. Perform the “Checkout” on page 7 as the first step in troubleshooting. Check the troubleshooting guide (Fig. 14) to pinpoint the cause of the problem. If troubleshooting indicates an ignition problem, see Ignition System Checks below to isolate and correct the problem. Following troubleshooting, perform the “Checkout” on page 7 again to be sure system is operating normally.

Ignition System Checks Step 1: Check ignition cable. Make sure: • Ignition cable does not run in contact with any metal surfaces. • Ignition cable is no more than 36 in. (0.9 m) long. • Connections to the ignition module and to the igniter or igniter-sensor are clean and tight. • Ignition cable provides good electrical continuity.

STEP 2: Check ignition system grounding. Nuisance shutdowns are often caused by a poor or erratic ground. A common ground is required for the module and the pilot burner bracket. • Check the ground circuit from 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 it with 14- to 18-gauge, moisture-resistant, thermoplastic insulated wire with 221°F (105°C) minimum rating. — If the flame rod or bracket is bent out of position, restore to correct position.

STEP 3: Check spark ignition circuit. You will need a short jumper wire made

from ignition cable or other heavily insulated wire. • Close the manual gas valve. • Disconnect the ignition cable at the SPARK terminal on the module.

WARNING Electrical Shock Hazard. Can cause severe injury, death or property damage. When performing the following steps, do not touch the stripped end of jumper or SPARK terminal. The ignition circuit generates over 10,000 volts and electrical shock can result. • Energize the module and immediately touch one end of the jumper firmly to the GND 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 of the gap when sparking stops. Check Table 5 below. Table 5. Arc Troubleshooting. Arc Length

Action

No arc or arc less Check external fuse, if provided. than 1/8 in. (3 mm) Verify power at the module’s input terminal. Replace control if fuse and power are okay. Arc 1/8 in.(3 mm) or longer

Voltage output is okay.

STEP 4: Check pilot and main burner lightoff. • Set the thermostat to “Call for Heat.” • Watch the pilot burner during the ignition sequence. See if: • Ignition spark continues after the pilot is lit. • The pilot lights and the spark stops, but main burner does not light. • S8600 B,H; S8610 B,H; S8670 D,J only: The pilot lights, the spark stops and main burner lights, but the system shuts down. • If so, ensure adequate flame current as follows. • Turn off appliance power at circuit breaker or fuse box. • Clean the flame rod with emery cloth. • Make sure electrical connections are clean and tight. Replace damaged wire with moistureresistant No. 18 wire rated for continuous duty up to 221°F (105°C). • Check for cracked ceramic insulator, which can cause short to ground, and replace ignitersensor if necessary. • At the gas control, disconnect main valve wire from the MV terminal. • Turn on power and set thermostat to call for heat. The pilot should light but the main burner will remain off because the main valve actuator is disconnected. • Check the pilot flame. Make sure it is blue, steady and envelops 3/8 to 1/2 in. (10 to 13 mm) of the flame rod. See Fig. 11 for possible flame problems and their causes.

11

69-1954—01

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL • If necessary, adjust pilot flame by turning the pilot adjustment screw on the gas control clockwise to decrease or counterclockwise to increase pilot flame. Following adjustment, always replace pilot adjustment cover screw and tighten firmly to assure proper gas control operation. • Set thermostat below room temperature to end call for heat.

CAUSE

APPEARANCE SMALL BLUE FLAME

CHECK FOR LACK OF GAS FROM: • CLOGGED ORIFICE FILTER

• Recheck ignition sequence as follows. • Reconnect main valve wire. • Set thermostat to call for heat. • Watch ignition sequence at burner. • If spark still doesn’t stop after pilot lights, replace ignition control. • If main burner doesn’t light or if main burner lights but system locks out, check the control, ground wire and gas control as described in “Troubleshooting” on page 10 and refer to the Troubleshooting Guide (Fig. 14).

LED Status and Troubleshooting

• CLOGGED PILOT FILTER • LOW GAS SUPPLY PRESSURE • PILOT ADJUSTMENT AT MINIMUM

LAZY YELLOW FLAME

The control has one LED used for flame sensing and system status:

CHECK FOR LACK OF AIR FROM: • DIRTY ORIFICE • DIRTY LINT SCREEN, IF USED • DIRTY PRIMARY AIR OPENING, IF THERE IS ONE • PILOT ADJUSTMENT AT MINIMUM

WAVING BLUE FLAME

CHECK FOR: • EXCESSIVE DRAFT AT PILOT LOCATION • RECIRCULATING PRODUCTS OF COMBUSTION STATUS LED

NOISY LIFTING BLOWING FLAME

CHECK FOR:

Fig. 12. Location of LED.

• HIGH GAS PRESSURE

HARD SHARP FLAME

M29907

THIS FLAME IS CHARACTERISTIC OF MANUFACTURED GAS CHECK FOR: • HIGH GAS PRESSURE • ORIFICE TOO SMALL

M2233B

Fig. 11. Examples of unsatisfactory pilot flames.

Table 6. Continuous Retry Models C, M, E, and K Only—Green LED Status Codes. Green LED Flash Codea

Indicates

Next System Action

Recommended Service Action

OFF

No “Call for Heat”

Not applicable

None

Flash Fast

Power up - internal check Not applicable

None

Heartbeat

Normal startup - ignition Not applicable sequence started (including prepurge)

None

4 Seconds ON then “x” flashes

Device in run mode. “x” = Not applicable flame current to the nearest μA.

None

2

5 minute Retry Delay Initiate new trial for ignition after retry delay - Pilot flame not detected completed. during trial for ignition

If system fails to light on next trial for ignition check gas supply, pilot burner, spark and flame sense wiring, flame rod contaminated or out of position, burner ground connection.

69-1954—01

12

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL Table 6. Continuous Retry Models C, M, E, and K Only—Green LED Status Codes. (Continued) Green LED Flash Codea

Indicates

Next System Action

Recommended Service Action

3

Recycle Initiate new trial for ignition. Flash code will remain If system fails to light on next trial for ignition, - Flame failed during run through the ignition trial until flame is proved. check gas supply, pilot burner, flame sense wiring, contamination of flame rod, burner ground connection.

4

Flame sensed out of sequence

If situation self corrects within 10 seconds, control Check for pilot flame. Replace gas valve if pilot returns to normal sequence. If flame out of flame present. If no pilot flame, cycle “Call for sequence remains longer than 10 seconds, control Heat.” If error repeats, replace control. will resume normal operation 1 hour after error is corrected.

6

Control Internal Error

Control remains in wait mode. When the fault corrects, control resumes normal operation.

Cycle “Call for Heat”. If error repeats, replace control.

7

Flame rod shorted to ground

Control remains in wait mode. When the fault corrects, control resumes normal operation.

Check flame sense lead wire for damage or shorting. Check that flame rod is in proper position. Check flame rod ceramic for cracks, damage or tracking.

8

Low secondary voltage supply

Control remains in wait mode. When the fault corrects, control resumes normal operation.

Check transformer and AC line for proper input voltage to the control. Check with full system load on the transformer.

a Flash

Code Descriptions: - Flash Fast: rapid blinking. - Heartbeat: Constant ½ second bright, ½ second dim cycles. - 4 second solid on pulse followed by “x” 1 second flashes indicates flame current to the nearest μA. This is only available in run mode. - A single flash code number signifies that the LED flashes X times at 2Hz, remains off for two seconds, and then repeats the sequence. Table 7. Lockout Models B, H D, and J Only—Green LED Status Codes.

Green LED Flash Codea

Indicates

Next System Action Not applicable

Recommended Service Action

OFF

No “Call for Heat”

None

Flash Fast

Power up - internal check

Not applicable

None

Heartbeat

Normal startup - ignition sequence started (including prepurge)

Not applicable

None

4 Seconds ON Device in run mode. “x” = flame Not applicable then “x” flashes current to the nearest μA.

None

2

Lockout - Failed trial for ignition Remain in lockout until “Call for Heat” is cycled. Check gas supply, pilot burner, spark and flame sense wiring, flame rod contaminated or out of position, burner ground connection.

3

Recycle - Flame failed during run

4

Flame sensed out of sequence If situation self corrects within 10 seconds, control returns to normal sequence. If flame out of sequence remains longer than 10 seconds, control will resume normal operation 1 hour after error is corrected.

Check for pilot flame. Replace gas valve if pilot flame present. If no pilot flame, cycle “Call for Heat.” If error repeats, replace control.

6

Control Internal Error

Cycle “Call for Heat”. If error repeats, replace control.

Initiate new trial for ignition. Flash code will remain through the ignition trial until flame is proved.

Control remains in wait mode. When the fault corrects, control resumes normal operation.

13

If system fails to light on next trial for ignition, check gas supply, pilot burner, flame sense wiring, contamination of flame rod, burner ground connection.

69-1954—01

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL Table 7. Lockout Models B, H D, and J Only—Green LED Status Codes. (Continued) Green LED Flash Codea

Indicates

Next System Action

7

Flame rod shorted to ground

Control remains in wait mode. When the fault corrects, control resumes normal operation.

8

Low secondary voltage supply Control remains in wait mode. When the fault corrects, control resumes normal operation.

Recommended Service Action Check flame sense lead wire for damage or shorting. Check that flame rod is in proper position.Check flame rod ceramic for cracks, damage or tracking. Check transformer and AC line for proper input voltage to the control. Check with full system load on the transformer.

a Flash

Code Descriptions: - Flash Fast: rapid blinking. - Heartbeat: Constant ½ second bright, ½ second dim cycles. - 4 second solid on pulse followed by “x” 1 second flashes indicates flame current to the nearest μA. This is only available in run mode. - A single flash code number signifies that the LED flashes X times at 2Hz, remains off for two seconds, and then repeats the sequence.

Flame Current Measurement Flame current of the device can be meaured using a standard micro-ammeter by simply inserting the meter probes into the holes labeled FLAME CURRENT, as shown in Fig. 13. — Flame current must be measured with pilot valve lit but no main gas flowing. — Disconnect MV leadwire from the control before measuring flame current. — Set meter to DC μAmp scale. — Ensure meter leads are positioned correctly [+/-].

NOTE: Trying to measure the pilot flame current in series with the wiring will not be accurate. Recommended Minimum Pilot Only Flame Current: • Must read steady 1 μAmp DC minimum. • Flame current should be 2 μAmp or greater for reliable appliance operation.

Golden Valley, MN 55422 Assembled in Mexico

90 Sec. Trial for Ignition ®

24V

C US ANSI Z21.20

24V

50043739-003 Rev. A

(GND)

PV

MV

MV/PV

Explosion Hazard. Can cause serious injury or death. This device can malfunction if it gets wet. Never try to use a device that has been wet - replace it.

S8600M Continuous Retry 24V, 60 Hz; PV=1A Max.; MV=1A Max.

GND

! WARNING

LED FLAME INDICATION: - 4 sec. pulse then 1 sec. flashes indicate flame current in uA: = 3 uA - Ensure 1 uA to avoid lockout

SPARK

002.3

LED FLASH CODES: (2) retry (3) recycle (4) flame out of sequence (6) internal error (7) flame rod shorted (8) low input voltage

DC

µA

+

FLAME CURRENT



STATUS

+

FLAME CURRENT



STATUS

M31297

Fig. 13. Measuring pilot flame current with micro-ammeter.

69-1954—01

14

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL

Troubleshooting Guide Refer to the following guide for troubleshooting (Fig. 14). START BEFORE TROUBLESHOOTING, FAMILIARIZE YOURSELF WITH THE STARTUP AND CHECKOUT PROCEDURES.

NOTE: “CALL FOR HEAT” 24 VAC SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONTROL.

TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER)TO “CALL FOR HEAT.”

POWER TO MODULE? (24 V NOMINAL)

NO

CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) IS MADE.

YES

30 SECOND PREPURGE DELAY?(S8670 ONLY)

NO

YES

SPARK ACROSS IGNITER/ SENSOR GAP?

REPLACE S8670

PULL IGNITION LEAD AND CHECK SPARK AT MODULE.

NO

SPARK OK?

REPLACE MODULE

NO YES CHECK IGNITION CABLE, GROUND WIRING, CERAMIC INSULATOR, AND SPARK GAP AND CORRECT. CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING. TAKE PROTECTIVE ACTION TO SHIELD CABLE AND BOOT FROM EXCESSIVE TEMPERATURES.

YES TURN GAS SUPPLY ON AND RECYCLE “CALL FOR HEAT.”

PILOT BURNER LIGHTS?

NO

YES

SPARK STOPS WHEN PILOT IS LIT?

NO

CHECK THAT ALL MANUAL GAS VALVES ARE OPEN, SUPPLY TUBING AND PRESSURES ARE GOOD, AND PILOT BURNER ORIFICE IS NOT BLOCKED (PILOT GAS FLOWING). CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL. CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF VOLTAGE IS OKAY, REPLACE GAS CONTROL. IF NOT, REPLACE MODULE. NOTE: IT MAY BE NECESSARY TO RECYCLE THE “CALL FOR HEAT” MORE THAN ONCE TO CLEAR THE PILOT SUPPLY TUBES OF AIR.

NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE “CALL FOR HEAT.” CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE. CLEAN FLAME ROD. CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE. CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR. CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE. ADJUST PILOT FLAME. IF PROBLEM PERSISTS, REPLACE MODULE.

YES

MAIN BURNER LIGHTS?

NO

CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF NO VOLTAGE, REPLACE MODULE. CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL INCLUDING SAFETY CONTROLS WIRED IN THE CIRCUIT. IF OKAY, REPLACE GAS CONTROL.

NO

NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE “CALL FOR HEAT.” CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE. NOTE: IF GROUND IS POOR OR ERRATIC, SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT. CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE. PILOT FLAME MUST NOT BE MOVING AROUND DUE TO OUTSIDE AIR FLOWS, ETC. ADJUST PILOT FLAME. CHECK GAS PRESSURE MEETS APPLIANCE SPECIFICATIONS WHILE APPLIANCE MAIN BURNER ON AND ALL OTHER GAS APPLIANCES ON THE SUPPLY ARE OPERATING AT FULL RATE. IF CHECKS ARE OKAY, REPLACE MODULE.

NO

CHECK FOR PROPER THERMOSTAT (CONTROLLER) OPERATION. REMOVE MV LEAD AT MODULE. IF VALVE CLOSES, RECHECK TEMPERATURE CONTROLLER AND WIRING. IF NOT, REPLACE GAS CONTROL.

YES

SYSTEM RUNS UNTIL “CALL FOR HEAT” ENDS? YES “CALL FOR HEAT” ENDS

SYSTEM SHUTS OFF? YES

REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED.

M29921

Fig. 14. Troubleshooting Guide. 15

69-1954—01

S8600B,C,H,M; S8610B,C,H,M; S8670D,E,J,K INTERMITTENT PILOT GAS IGNITION CONTROL

Automation and Control Solutions Honeywell International Inc. 1985 Douglas Drive North Golden Valley, MN 55422 Honeywell Limited-Honeywell Limitée 35 Dynamic Drive Toronto, Ontario M1V 4Z9 customer.honeywell.com

® U.S. Registered Trademark © 2010 Honeywell International Inc. 69-1954—01 M.S. Rev. 03-10 Printed in U.S.A.

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