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APPLICATIONThe S8610U Universal Replacement Ignition Module isdesigned to provide easy field replacement of a wide range ofintermittent pilot ignition modules manufactured byHoneywell, Robertshaw, Johnson and others. The S8610UModule provides ignition sequence, flame monitoring, andsafety shutoff for intermittent pilot central furnaces, residentialboilers, and other heating appliances.
FEATURES• Provides up to 1.0A pilot and 2.0A main valve current
rating.
• System uses rectification principle for flame sensing.
• For use with separate igniter and sensor orcombination igniter-sensor. Q345, Q348, Q362, Q373or Q381 Igniter-sensor recommended as combinationigniter-sensor; Q179C with igniter and sensormounted on one bracket, or Q354 Sensor with Q345,Q348, Q362, Q373 or Q381 Igniter-sensorrecommended as separate igniter and sensor.
• Q3450/Q3480 Hot Surface Pilot hardware plugsdirectly into system control.
• Can be used on natural or LP gas; provides 100percent shutoff on ignition failure. Waits six minutesnominal following shutoff, then reinitiates the pilotignition sequence. The ignition trial-shutoff-wait cyclerepeats until the pilot lights or the call for heat ends.
• Replaces numerous Honeywell and competitormodules.
• Capacitive discharge spark output.
• Temperature rating is -40°F to 175°F (-40°C to 79°C)when used with 1.0A or less main valve; -40°F to 165°F(-40°C to 74°C) when used with 1.0 to 2.0A main valve.
Contents
Application........................................................................... 1Features .............................................................................. 1Specifications ...................................................................... 2Ordering Information ........................................................... 2Planning the Installation ...................................................... 4Installation ........................................................................... 6Startup and Checkout ......................................................... 15Maintenance........................................................................ 15Operation ............................................................................ 16Troubleshooting .................................................................. 17ANSI Standards .................................................................. 21
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—2 2
ORDERING INFORMATION
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to theTRADELINE® Catalog or price sheets for complete ordering number, or specify:1. SUPER TRADELINE® order number.
If you have additional questions, need further information, or would like to comment on our products or services, please write orphone:1. Your local Home and Building Control Sales Office (check white pages of your phone directory).2. Home and Building Control Customer Logistics
Honeywell Inc., 1885 Douglas Drive NorthMinneapolis, Minnesota 55422-4386
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9.International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France,Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
SPECIFICATIONSIMPORTANT
The specifications given in this publication do notinclude normal manufacturing tolerances. Therefore,units may not exactly match the listed specificationsAlso, units are tested and calibrated under closelycontrolled conditions, and some minor differences inperformance can be expected if those conditions arechanged.
SUPER TRADELINE® ModelsSUPER TRADELINE® models are selected and packaged forease of handling, ease of stocking, and maximum replacementvalue. SUPER TRADELINE® model specifications are thesame as those of standard models except as noted.
SUPER TRADELINE® Model Available:S8610U Universal Intermittent Pilot Module.
Electrical Ratings:Voltage: 24V, 60 Hz.Current Draw: 1A pilot valve, 2A main valve.Valve Contact Rating: 0.2A.
Trial for Ignition:90 seconds maximum, then 100% shutoff (pilot and maingas).
Continuous Retry:Five-minute minimum (six-minute nominal) delay if pilot failsto light during trial for ignition. After delay, trial for ignition isrepeated. This sequence (trial, delay, trial, delay) continuesuntil pilot lights or call for heat ends.
Spark Generator Output:13 kV peak at 25 pF load.
Thermostat Anticipator Setting:0.2A plus pilot valve rating plus main valve rating.
Ambient Temperature Rating:-40°F to +175°F (-40°C to +79°C) with main valve rated
1.0A or less.-40°F to +165°F (-40°C to +74°C) with main valve rated
1.0A to 2.0A.
Relative Humidity Rating:5 to 90% RH at 95°F.
Flame Failure Response Time:0.8 sec at 1.0 mA flame current.
Terminals:SENSE: 3/16 in. male quick connect.All Other Terminals Including Ignition: 1/4 in. male quick
connects. Molex plug for connection to HoneywellD80D or D892 Vent Damper.
Flame Current:1 uA minimum.
Mounting:Mounts in any position except with terminals up. However,recommended mounting position is with terminals down toprovide maximum protection from dripping water or dustaccumulation. Fasten with no. 6-32 machine or no. 8sheetmetal screws of appropriate length. See Fig. 1.
Underwriters Laboratories Inc. Component Recognized:File no. MH15564, Guide no. MCCZ2.
IAS Design Certified: C2030011.
Other System ComponentsThese modules provide operating control of an intermittentpilot system. Additional components required to complete thesystem must be ordered separately:• Dual valve combination gas control designed for
intermittent pilot.• Combination pilot burner/igniter-sensor or separate igniter
and sensor on pilot burner bracket.• Ignition cable.• Transformer.• 24V thermostat.• High limit and other auxiliary controls, as required.
Dual Valve Combination Gas Control:Any that meet current ratings listed below. VR8204,
VR8440 or VR8520 are recommended.S8610U: 1.0A pilot, 2.0A main valve.
Pilot Burner/Igniter-Sensor:See Table 1.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—23
2 (51)
M1123A
3-3/16(81)
2-5/8 (67)1/4(6)
3-15/16(100)
3-3/8(86)
1-1/32(26)
5-7/16 (138)
3-3/8 (86) (2)3/16(5)
(2)
3/16(5)
(2)
Fig. 1. Approximate ignition module dimensions in in. (mm).
Table 1. Pilot Burner/Igniter-Sensors.
Ignition Cable:Use Honeywell preassembled cable, see Table 2, orassemble locally. Use the cable recommended in Table 3 (orequivalent), insulated female 1/4 in. quick connect andinsulated Rajah connector receptacle. Maximumrecommended length is 36 in. (914 mm).
Table 3. Recommended Ignition Cable for Field Assembly.
Voltage Temperature Rating
Cable Type Rating (rms) °C °F
UL Style 3217 10,000 150 302
UL Style 3257 10,000 250 484
Transformer:Add current ratings of module, pilot valve, main valve, ventdamper and any other components of the control system todetermine transformer-size requirement. Use a 30 VA orlarger transformer if a vent damper will be connected to theS8610U Vent Damper Connector.
Thermostat:Use open-close switch type, or independently-poweredelectronic, 24V thermostat capable of switching rated controlsystem load. Before using electronic thermostat poweredthrough the heating/cooling controls, consult thermostatmanufacturer to assure proper control system operation.
High Limit and Other Auxiliary Controls:As specified by the heating appliance manufacturer.
Ignition Modules Replaced
WARNINGCheck Table 4 before replacing an existing intermittentpilot module with the S8610U. If the existing module isnot listed, do not use the S8610U to replace it unlessyou are certain the specifications of the S8610Umatch those of the existing module.
Pilot Burner/ Flow Rate*Igniter-Sensor cfh m3/hr
Combined Q345 0.8 0.02
Q348 1.5 0.04
Q362 0.5 0.014
Q373 0.8 0.02
Q381 0.5 0.014
Separate Q179C 1.8 0.05
Q354 with Q345, Q348, Q362 or Q381.
*With natural gas at 7.0 in. wc (1.7 kPa).
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—2 4
The S8610U replaces existing flame rectification typeintermittent pilot ignition modules with the followingcharacteristics:• Single rod (local sense) or two rod (remote sense) flame
sensing.• Non-100 percent shutoff, 100 percent shutoff/lockout, or
100 percent shutoff/continuous retry.• Natural or LP gas.• Shutoff/lockout times of 30 seconds or longer.• Prepurge times of four seconds or shorter.• Pilot burners with flow rates of 1500 Btuh or less.• With or without vent dampers.
A complete list of the specific Honeywell and other modulesthat the SUPER TRADELINE® S8610U is designed toreplace is provided in Table 4.
The S8610U SUPER TRADELINE® package containscomplete, easy-to-use instructions, plus the accessoriesrequired to adapt the existing spark cable (Rajah, stud, nail,or other) to the spark terminal on the S8610U. It also provideslabels to help assure proper marking of the wires attached tothe existing module.
The S8610U SUPER TRADELINE® Universal Module is notdesigned to replace controls with the following characteristics:• Flame sensing other than by flame rectification (White
Rodgers Cycle-Pilot®, Robertshaw thermal sensing).• Flame rectification modules with shutoff/lockout times of
less than 30 seconds, prepurge times of more than fourseconds, or pilot burners larger than 1500 Btuh.
• Standing pilot appliances.
Honeywell provides additional control packages toaccomplish these replacements. See the HoneywellElectronic Ignition Service Manual, form 70-6604, or call yourHoneywell wholesaler.
PLANNING THE INSTALLATIONWARNINGFIRE OR EXPLOSION HAZARDCAN CAUSE PROPERTY DAMAGE, SEVEREINJURY OR DEATH.Follow these warnings exactly:1. Plan the installation as outlined below.2. Plan for frequent maintenance as described in
the Maintenance section.
When intermittent pilot systems are used on central heatingequipment in barns, greenhouses, and commercial propertiesand on heating appliances such as commercial cookers,agricultural equipment, industrial heating equipment and poolheaters, heavy demands are made on the controls. Specialsteps may be required to prevent nuisance shutdowns andcontrol failure due to frequent cycling, severe environmentalconditions related to moisture, corrosive chemicals, dust orexcessive heat. These applications require Honeywell Homeand Building Control Engineering review; contact yourHoneywell Sales Representative for assistance.
Review the following conditions that could apply to yourspecific installation and take the precautionary stepssuggested.
Frequent CyclingThese controls are designed for use on appliances thattypically cycle three to four times an hour only during theheating season only. In year-round applications with greatercycling rates, the control can wear out more quickly. Performa monthly checkout.
Water Or Steam CleaningIf a module or gas control gets wet, replace it. If the applianceis likely to be cleaned with water or steam, protect (cover) thecontrols and wiring from water or steam flow. Mount thecontrols high enough above the bottom of the cabinet so theydo not get wet during normal cleaning procedures. Use aNEMA 4 enclosure for the ignition module; see the ElectronicIgnition Service Manual, form 70-6604.
High Humidity or Dripping WaterDripping water can cause the module to fail. Never install anappliance where water can drip on the controls.In addition, high ambient humidity can cause the gas controlto corrode and fail.
If the appliance is in a humid atmosphere, make sure aircirculation around the controls is adequate to preventcondensation. Also, regularly check out the system. A NEMA4 enclosure is recommended for the ignition module; see theElectronic Ignition Service Manual, form 70-6604.
Corrosive ChemicalsCorrosive chemicals can attack the module and gas control,eventually causing a failure. If chemicals are used for routinecleaning, make sure they cannot reach the controls. Wherechemicals are suspended in air, as in some industrial oragricultural applications, use a NEMA 4 enclosure for theignition module; see the Electronic Ignition Service Manual,form 70-6604.
Dust or Grease AccumulationHeavy accumulations of dust or grease can cause controls tomalfunction. Where dust or grease can be a problem, providecovers for the module and the gas control to limitcontamination. A NEMA 4 enclosure is recommended for theignition module; see the Electronic Ignition Service Manual,form 70-6604.
HeatExcessively high temperatures can damage controls. Makesure the maximum ambient temperature at the control doesnot exceed the rating of the control. If the appliance operatesat very high temperatures, use insulation, shielding, and aircirculation, as necessary, to protect the controls. Properinsulation or shielding should be provided by the appliancemanufacturer; verify that proper air circulation is maintainedwhen the appliance is installed.
INSTALLATION1. Read these instructions carefully. Failure to follow them
could damage the components or cause a hazardouscondition.
2. Check the ratings given in the instructions and on thecomponents to make sure they are suitable for yourapplication.
3. Installer must be a trained, experienced servicetechnician.
4. After installation is complete, check out componentoperation as provided in these instructions.
WARNINGFIRE OR EXPLOSION HAZARD CAN CAUSEPROPERTY DAMAGE, SEVERE INJURY, ORDEATH.1. If it gets wet, the ignition module can malfunction,
leading to accumulation of explosive gas.• Never install where water can flood, drip or
condense on the module.• Never 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 the pilot or operate electric
switches, lights or appliances until you aresure the appliance area is free of gas.
3. Do not attempt to disassemble or clean themodule. Improper reassembly and cleaning cancause unreliable operation.
CAUTION1. Disconnect the power supply before beginning
the wiring to prevent electrical shock orequipment damage.
2. If a new gas control is to be installed, turn off thegas supply before starting the installation.Conduct a Gas Leak Test according to the gascontrol manufacturer instructions after the gascontrol is installed.
3. If the module must be mounted near moisture orwater, provide a suitable waterproof enclosure.
4. Using the wire labels provided, label all wiresbefore they are disconnected. Wiring errors cancause improper appliance operation anddangerous conditions such as bypassing safetyfeatures.
Perform Preinstallation Safety InspectionThe preinstallation checks described in ANSI StandardZ21.71 in Exhibit A must be done before the replacementmodule is installed. If a condition is detected that could resultin unsafe operation, the appliance should be shut off and theowner advised of the unsafe condition. Correct any potentiallyunsafe condition before proceeding with the installation.
Remove Old ModuleDisconnect power supply before doing any work on the unit.Disconnect and tag the wires from the old module using thewire labels provided. Remove the old module from itsmounting location.
Mount New Ignition ModuleWe recommend mounting the S8610U Module in the samelocation as the old module, if possible. Otherwise, select alocation close enough to the burner to allow a short (3 ft(0.9m) maximum) direct cable route to the igniter. Ambienttemperature at the module must be within the range listed inthe Specifications section.
Mount the module with the terminals pointing down to protectthem from dripping water and dust. The module can also bemounted with the terminals on either side. Do not mount withterminals pointing up. Refer to Fig. 2 for mountingrecommendations. When it is necessary to drill new mountingholes, use the S8610U as a template to mark the mountinghole pattern. Drill new holes as required. Fasten securely withfour no. 6-32 machine or no. 8 sheetmetal screws.
Wire the Module
CAUTION1. Check the wiring diagram furnished by the
appliance manufacturer, if available, andcompare with Tables 5 through 8. Carefully followany special instructions affecting the generalprocedures outlined below.
2. Disconnect the power supply before makingwiring connections to prevent electrical shock orequipment damage.
IMPORTANT1. A common ground is required on:
a. The pilot burner mounting bracket, andb. The GND (BURNER) terminal on the ignition
module. Failure to use the GND (BURNER)terminal can result in intermittent loss of sparkand/or loss of flame current sensitivity.
2. Make sure the transformer has adequate VA. Theignition module requires at least 0.2A at 24 Vac. Addthe current draws of all other devices in the controlcircuit, including the pilot and main valves in the gascontrol, and multiply by 24 to determine the total VArequirement of these components. Add this total to4.8 VA (for the ignition module). The result is theminimum transformer VA rating. Use a Class IItransformer when replacement is required.
3. When a vent damper is connected to the S8610Uvent damper connector, be sure the systemtransformer delivers at least 30 VA. The S8610U hasan internal fuse that is intended to prevent appliancelightoff if the vent damper is not in place or wiredproperly. Using a small transformer can interfere withthe proper operation of the fuse and bypass theintended safety feature.
� Connect the wires to the S8610U Ignition Module asshown in Tables 5 through 8. Make sure that adequatesystem ground is provided as indicated in the wiringtables.
� Verify the thermostat anticipator setting as explained inthe IMPORTANT above.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—27
Fig. 2. Module mounting recommendations.
TERMINALS FACING DOWN
TERMINALS FACING LEFT TERMINALS FACING RIGHT
MOUNT IN ONE OF THESE POSITIONS
DO NOT MOUNT WITH TERMINALS FACING UP
M2647
NOTE: The wiring diagrams in Fig. 5 through 8 show typicalhookups for the S8610U Ignition Module and shouldbe used for reference only.
Modify Ignition Cable, If NecessaryUse existing ignition cable if it is in good condition. If theexisting ignition cable does not have a 1/4 in. quick-connecton the module end, either use the Rajah adapter or strip thewire and replace with the 1/4 in. insulated quick-connectsupplied. If the cable must be replaced, order a Honeywellignition cable, see Table 2. It may be necessary to replace theconnector at the pilot burner end to match the pilot burnerspark termination.
NOTE: When using an S8610U to replace an S86, use theenclosed adapter to convert the S86 Ignition Cableto an S8610U Ignition Cable. Then, install theadapter and cable to the S8610U Ignition Module.
NOTE: The cable must not run in continuous contact with ametal surface or spark voltage is greatly reduced.Use ceramic or plastic standoff insulators asrequired.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—2 8
Tab
le 5
. Co
nver
sio
n f
rom
Ho
ney
wel
l S86
, S90
, S86
00 a
nd
S86
10 t
o S
8610
U10
03.
Rep
lace
men
tC
on
tro
lO
ld C
on
tro
l
Ter
min
al F
un
ctio
nS
8610
U10
03S
86A
,CS
86B
,DS
86E
,F,G
,H
S86
00A
,B,C
S86
10A
,B,C
S90
A,B
S86
00F
,H,M
S86
10F
,H,M
Pro
ced
ura
l No
tes
Mai
n va
lve
oper
ator
MV
MV
MV
MV
MV
MV
Mai
n va
lve
and
pilo
tco
mm
onM
V/P
VM
V/P
VM
V/P
VM
V/P
VM
V/P
VM
V/P
V
Pilo
t val
ve o
pera
tor
PV
PV
PV
PV
PV
PV
Bur
ner
grou
ndco
nnec
tion
GN
D(B
UR
NE
R)
GN
D
GN
D
GN
D(B
UR
NE
R)
GN
D(B
UR
NE
R)
GN
D(B
UR
NE
R)
Tra
nsfo
rmer
seco
ndar
y(u
nsw
itche
d le
g)
24V
GN
D25
V (
1)25
V (
GN
D)
25V
(1)
e24
V G
ND
24V
GN
D
Tra
nsfo
rmer
seco
ndar
y
(sw
itche
d le
g)
24V
*25
V (
2)25
V25
V (
2)e*
24V
*24
V*
*Im
po
rtan
t: If
the
old
mod
ule
had
a ve
nt d
ampe
rpl
ug b
ut a
ven
t dam
per
was
not
inst
alle
d, o
r if
itdi
d no
t hav
e a
vent
dam
per
plug
: lea
ve th
e ve
ntda
mpe
r pl
ug in
pos
ition
on
the
S86
10 a
ndco
nnec
t the
25V
(2)
or
24V
wire
from
the
old
mod
ule
to th
e T
H-W
term
inal
on
the
S86
10U
.D
o n
ot
use
th
e 24
V t
erm
inal
on
th
e S
8610
U.
25V
(2)
or
24V
use
d on
ly in
sys
tem
s w
here
plug
-in c
able
con
nect
s da
mpe
r to
mod
ule.
If th
e ol
d m
odul
e ha
d a
vent
dam
per
with
a p
lug
con
ne
ctio
n
to
a
Mo
lex
con
ne
cto
r,
wir
e
the
term
inal
s as
indi
cate
d in
the
tabl
e.
TH
-WT
H-R
aT
H-R
aT
H-R
aT
H-W
(Thi
s te
rmin
alno
t inc
lude
don
S90
.)
TH
-W
TH
-Wb
TH
-WT
H-W
b
Fla
me
sens
orS
EN
SE
fd
dd
SE
NS
Ef
d
Igni
ter/
sens
orS
PA
RK
IGN
CO
ILc
IGN
CO
ILc
IGN
CO
ILc
S
PA
RK
SP
AR
Ka
If 25
V (
2) a
nd T
H-R
hav
e w
ires
conn
ecte
d, d
isco
nnec
t and
spl
ice
toge
ther
with
sol
derle
ss c
onne
ctor
.b
If T
H-R
and
TH
-W a
re ju
mpe
red
toge
ther
, con
nect
25V
(2)
lead
from
S86
to T
H-W
on
S86
10U
1003
.c
Use
Raj
ah to
qui
ck c
onne
ctor
ada
pter
(su
pplie
d) o
r cu
t Raj
ah c
onne
ctor
off
igni
tion
cabl
e at
mod
ule
end;
atta
ch in
sula
ted
quic
k co
nnec
t for
con
nect
ion
to S
8610
.d
Leav
e bl
ack
jum
per
conn
ecte
d.e
Ter
min
als
may
be
mar
ked
25V
on
som
e m
odel
s an
d 24
V o
n la
ter
mod
els.
The
se a
re fu
nctio
nally
equ
ival
ent.
fO
n du
al ig
nite
r an
d se
nsor
mod
els,
rem
ove
jum
per
quic
k co
nnec
t fro
m S
8610
U10
03 S
ense
term
inal
, cut
jum
per
wire
at c
ircui
t boa
rd, a
nd d
isca
rd.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—29
Tab
le 6
. Co
nver
sio
n f
rom
Ro
ber
tsh
aw S
P71
5 an
d S
P73
5 to
S86
10U
1003
(in
c lu
des
780
-XX
X a
nd
US
1715
U).
Rep
lace
men
tC
on
tro
lO
ld C
on
tro
l SP
715
and
SP
735
(in
clu
des
780
-XX
X a
nd
US
I 715
U)c
,d
Ter
min
al F
un
ctio
nH
on
eyw
ell
S86
10U
1003
7000
D V
alve
7100
D V
alve
7100
K V
alve
Pro
ced
ura
l No
tes
Mai
n va
lve
oper
ator
MV
MV
(to
: Val
ve T
H)
MV
(to
: Val
ve M
)M
V (
to: V
alve
TR
)—
Mai
n va
lve
and
pilo
t com
mon
M
V/P
VM
V/P
V (
to: V
alve
TR
)M
V/P
V (
to: V
alve
C)
P
V (
to: V
alve
C a
nd T
H)
—
Pilo
t val
ve o
pera
tor
PV
PV
(to
: Val
ve P
ILO
T)*
PV
(to
: Val
ve P
)P
V (
to: V
alve
PIC
K &
HO
LD)
*Thi
s is
the
term
inal
not
jum
pere
dto
TR
.
Bur
ner
grou
nd c
onne
ctio
nG
ND
(B
UR
NE
R)
GN
DG
ND
GN
D—
Tra
nsfo
rmer
sec
onda
ry
24V
GN
DT
RT
RT
R—
(uns
witc
hed
leg)
24V
No
conn
ectio
nN
o co
nnec
tion
No
conn
ectio
n—
E3a
E3a
E3a
Whe
n su
pplie
d, E
3 pr
ovid
esco
nnec
tion
to L
ocko
ut T
imer
.
Tra
nsfo
mer
sec
onda
ry
(sw
itche
d le
g)
TH
-WT
HT
HT
HIf
LO-1
5 is
par
t of t
he in
stal
latio
n,us
e th
e w
ire d
isco
nnec
ted
from
E1
tagg
ed T
herm
osta
t.
Fla
me
sens
orS
EN
SE
bS
EN
SE
eS
EN
SE
eS
EN
SE
e—
Pilo
t ign
iter
SP
AR
KIG
NIG
NIG
N—
1.U
se e
xist
ing
wiri
ng h
arne
ss to
mak
e co
nnec
tions
to S
8610
per
tabl
e. I
MP
OR
TA
NT
If in
stal
latio
n in
clud
es L
O-1
5 Lo
ckou
t Tim
er, d
isca
rd w
ires
to E
3 an
d T
H.
Dis
conn
ect a
nd r
etai
n w
ire to
LO
-15
term
inal
E1.
Tag
wire
,The
rmos
tat.
Dis
card
LO
-15.
2.O
n 70
00D
ser
ies
valv
e, r
etai
n (o
r in
stal
l) w
hite
jum
per
betw
een
valv
e T
R a
nd p
ilot s
olen
oid.
aIf
LO-1
5 Lo
ckou
t tim
er is
not
inst
alle
d, E
3 co
nnec
tor
prov
ided
on
SP
715
is n
ot u
sed.
bIm
po
rtan
tIf
the
US
I 715
U w
ith c
ombi
natio
n ig
nite
r se
nsor
is n
ot u
sed,
rem
ove
blac
k ju
mpe
r qu
ick
conn
ect f
rom
Sen
se te
rmin
al o
f S86
10U
1003
. Cut
jum
per
wire
at
circ
uit b
oard
and
dis
card
.
cF
or r
epla
cem
ent o
f Rob
erts
haw
Fla
me
Sw
itch
syst
ems
(SP
710,
720
, 730
, 750
, 780
-700
, 780
-701
, 780
-710
, 780
-711
, 780
-712
and
780
-713
), s
ee H
oney
wel
l Ign
ition
Con
trol
Han
dboo
k.d
780-
715
and
US
I 715
U a
re e
quiv
alen
t to
SP
715;
780
-735
and
780
-737
are
equ
ival
ent t
o S
P73
5. F
or o
ther
780
-XX
X m
odel
s, s
ee n
otec
.e
OP
T. S
EN
SO
R o
n U
SI 7
15U
. No
exte
rnal
con
nect
ion
if co
mbi
natio
n ig
nite
r se
nsor
is u
sed.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—2 10
Tab
le 7
. Co
nver
sio
n f
rom
Pen
n-J
oh
nso
n C
SA
(A
ll), G
60, G
66, G
67, G
600,
G67
0 o
r G
770
to S
8610
U10
03.
Rep
lace
men
t
Co
ntr
ol
Old
Co
ntr
ol
Ho
ney
wel
l
CS
A45
A-6
00R
d, G
60, G
65, G
66, G
67, G
600
or
G67
0 In
stal
lati
on
wit
h L
ock
ou
t M
od
ule
s as
follo
ws:
*
Ter
min
al F
un
ctio
nS
861U
1003
No
ne
(Y79
)Y
79A
mo
du
led
Y79
B m
od
ule
cG
770
Pro
ced
ura
l No
tes
Mai
n va
lve
oper
ator
MV
33
Y79
B M
VM
V (
3)
Mai
n va
lve
and
pilo
t com
mon
MV
/PV
GR
GR
GR
GR
OU
ND
(5)
Pilo
t val
ve o
pera
tor
PV
11
Y79
B P
VP
V (
1)
Bur
ner
grou
nd c
onne
ctio
nG
ND
(BU
RN
ER
)G
RG
RG
RG
RO
UN
D
Tra
nsfo
rmer
sec
onda
ry(u
nsw
itche
d le
g)24
V G
ND
GR
GR
GR
GR
OU
ND
Tra
nsfo
rmer
sec
onda
ry(s
witc
hed
leg)
TH
-W*
2aY
79 T
HS
b2
TH
-S (
2)
24V
*N
o co
nnec
tion*
No
conn
ectio
n*N
o co
nnec
tion*
No
conn
ectio
n*
Fla
me
sens
orS
EN
SE
*4e
4e4e
SE
NS
E (
4)e
Pilo
t ign
iter
SP
AR
KIG
N C
OIL
IGN
CO
ILIG
N C
OIL
IGN
CO
ILIt
mig
ht b
e ne
cess
ary
to c
ut o
ff R
ajah
conn
ecto
r an
d/or
atta
ch in
sula
ted
quic
kco
nnec
t.a
Dis
card
wire
bet
wee
n tr
ansf
orm
er a
nd te
rmin
al 5
(G
60)
or 6
(G
600)
; oth
erw
ise,
use
exi
stin
g ha
rnes
s fo
r w
iring
.b
Dis
card
wire
s be
twee
n Y
79A
and
mod
ule
as fo
llow
s: R
ed to
3, B
lack
to 2
, Whi
te to
GR
. Dis
card
wire
bet
wee
n tr
ansf
orm
er a
nd 6
.c
Dis
card
wire
s be
twee
n Y
79B
and
mod
ule
as fo
llow
s: W
hite
to 3
, Bla
ck to
1, B
row
n to
GR
. Dis
card
wire
bet
wee
n tr
ansf
orm
er a
nd 6
.d
CS
A c
ode
num
bers
(fo
r ex
ampl
e, C
SA
45A
-600
R)
are
equi
vale
nt to
G60
0 an
d us
e th
e sa
me
wiri
ng in
form
atio
n ta
bles
.e
Imp
ort
ant
Rem
ove
blac
k ju
mpe
r qu
ick
conn
ect f
rom
Sen
se te
rmin
al o
f S86
10U
1003
; cut
jum
per
wire
at c
ircui
t boa
rd a
nd d
isca
rd.
*IF
INS
TA
LLA
TIO
N D
OE
S N
OT
INC
LUD
E V
EN
T D
AM
PE
R W
ITH
PLU
G C
ON
NE
CT
ION
TO
MO
DU
LE:
1.Le
ave
vent
dam
per
plug
on
S86
10U
Mod
ule
in p
ositi
on.
2.U
se T
H-W
term
inal
.*I
F IN
ST
ALL
AT
ION
INC
LUD
ES
VE
NT
DA
MP
ER
WIT
H P
LUG
CO
NN
EC
TIO
N T
O M
OD
ULE
:1.
Rep
lace
S86
10U
Mod
ule
vent
dam
per
plug
with
dam
per
Mol
ex c
onne
ctor
.2.
Wire
ther
mos
tat W
wire
to T
H-W
.3.
Run
wire
from
sw
itche
d le
g of
tran
sfor
mer
sec
onda
ry to
bot
h th
erm
osta
t R a
nd S
8610
Mod
ule
24V
term
inal
s.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—211
Tab
le 8
. Co
nver
sio
n f
rom
CA
MS
TAT,
FE
NW
AL
or
HS
C t
o S
8610
U10
03.
Rep
lace
men
tC
on
tro
lO
ld C
on
tro
l
Ter
min
al F
un
ctio
nH
on
eyw
ell
S86
10U
1003
CA
MS
TA
T
IPI-
24-0
0aF
EN
WA
L05
-20X
bH
SC
100
3-3
and
10
03-3
00a
Pro
ced
ura
l No
tes
Mai
n va
lve
oper
ator
MV
MV
MA
IN V
ALV
EM
V—
Mai
n va
lve
and
pilo
t com
mon
MV
/PV
GN
DG
RO
UN
DG
ND
/CO
MF
enw
al o
nly:
run
sep
arat
e le
ad to
S86
10 v
alve
com
mon
term
inal
.
Pilo
t val
ve o
pera
tor
PV
PV
PIL
OT
VA
LVE
PV
—
Bur
ner
grou
nd c
onne
ctio
nG
ND
(B
UR
NE
R)
GN
D—
—T
o as
sure
goo
d gr
ound
, run
sep
arat
e w
ire fr
ompi
lot b
urne
r to
S86
10 G
ND
(B
UR
NE
R).
Tra
nsfo
rmer
sec
onda
ry(u
nsw
itche
d le
g)24
V G
ND
T2
GR
OU
ND
GN
D/C
OM
—
24V
No
conn
ectio
nN
o co
nnec
tion
No
conn
ectio
n—
Tra
nsfo
rmer
sec
onda
ry
(sw
itche
d le
g)T
H-W
T
1P
OW
ER
24 V
AC
—
Fla
me
sens
orS
EN
SE
Sc
—S
EN
SO
Rc
—
Pilo
t ign
iter
SP
AR
KIG
NH
.V.
IGN
CO
ILS
trip
mod
ule
end
of ig
nitio
n ca
ble
as n
eces
sary
and
atta
ch in
sula
ted
quic
k co
nnec
t for
con
nect
ion
to S
8610
.a
Use
exi
stin
g w
iring
har
ness
to m
ake
conn
ectio
ns to
S86
10.
bT
ag a
ll w
ires
at m
odul
e co
nnec
tor
with
term
inal
des
igna
tions
. Cut
wire
s at
con
nect
or, a
ttach
qui
ck c
onne
cts
and
conn
ect t
o S
8610
; per
tabl
e.
cIm
po
rtan
tR
emov
e bl
ack
jum
per
quic
k co
nnec
t fro
m S
ense
term
inal
of S
8610
U10
03; c
ut ju
mpe
r w
ire a
t circ
uit b
oard
and
dis
card
.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—2 12
Fig. 3. S8610U in heating system with atmospheric burner.
L1 (HOT)
L2
1
4
8
1
2
3
4
5
6
7
8
2
7
5
63
M2641D
S8610U
MV MV/PV PVGND(BURNER)
24VGND 24V TH-W
VENTDAMPERPLUG SENSE SPARK
WIRINGHARNESS
THERMOSTAT
D892 VENTDAMPER
LIMITCONTROLLER
GROUND
SENSOR
IGNITER
MAINVALVECOMPILOT
1STOPERATOR
2NDOPERATOR
DUAL VALVE COMBINATIONGAS CONTROL
PILOT GASSUPPLY
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
MAXIMUM CABLE LENGTH 3 ft (0.9m).
CONTROLS IN 24V CIRCUIT MUST NOT BE GROUND LEG TO TRANSFORMER.
REMOVE PLUG ONLY IF USING VENT DAMPER. FUSE BLOWS ON STARTUP WHEN PLUG ISREMOVED AND VENT DAMPER WIRING HARNESS IS INSTALLED; THEN MODULE OPERATES ONLY WHEN VENT DAMPER IS CONNECTED.
REMOVE JUMPER AND CONNECT SENSE TERMINAL ON TWO ROD APPLICATION ONLY.
IF THE VENT DAMPER IS CONNECTED, WIRE 24V TERMINAL, AS SHOWN. CONNECT VENTDAMPER CABLE IN PLACE OF PLUG SHIPPED WITH THE S8610U. IF NO VENT DAMPER IS CONNECTED, DO NOT WIRE 24V TERMINAL.
30 VA MINIMUM WHEN VENT DAMPER IS CONNECTED TO DAMPER PLUG.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—213
Fig. 4. S8610U in heating system with power-assisted combustion.
L1 (HOT)
L2
L2
1
L1 (HOT)
1
4
1
2
3
4
5
6
2
5
6 3
M2642B
S8610U
MV MV/PV PVGND(BURNER)
24VGND 24V TH-W
VENTDAMPERPLUG SENSE SPARK
THERMOSTAT
LIMITCONTROLLER
PILOT BURNERGROUND
SENSOR
IGNITER
MAINVALVECOMPILOT
1STOPERATOR
2NDOPERATOR
DUAL VALVE COMBINATIONGAS CONTROL
PILOT GASSUPPLY
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
MAXIMUM CABLE LENGTH 3 ft (0.9m).
CONTROLS IN 24V CIRCUIT MUST NOT BE GROUND LEG TO TRANSFORMER.
LEAVE VENT DAMPER PLUG CONNECTED.
REMOVE JUMPER AND CONNECT SENSE TERMINAL ON TWO ROD APPLICATION ONLY.
CONTROLLER
COMBUSTIONAIR BLOWERMOTOR
COMBUSTIONAIR BLOWERRELAY
AIRPROVINGSWITCH
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—2 14
Fig. 5. S8610U in a typical ST9120 application.
1
1
S8610U
MV MV/PV PVGND(BURNER)
24VGND 24V TH-W
VENTDAMPERPLUG SENSE SPARK
L2 (N)
L1 (N)
TO 120 OR240 VACPOWER SUPPLY
120 OR240 VAC
TRANSFORMER
24 VAC
COMBUSTIONBLOWER
STARTINGCAP
CIRCULATINGFAN
COMPRESSORAND OUTDOORFAN NETWORK
UNUSEDMOTOR LEDS
M1
M3
M2 H
1 2 3 4 5
1 2 3 4 CR
L2
L1
C
C C
X X YHEAT
COOL
ST9120ELECTRONICFAN TIMER
ROLLOUTFUSE
LIMIT
PILOT GASSUPPLY
PILOT BURNERGROUND
Q345, Q348, Q362, Q381PILOT BURNER/IGNITER-SENSOR
PV
MV/PV
MVC
COMBINATIONGAS CONTROL
COM.
PRESSURESWITCH
N.O.
AUXILIARYLIMIT
5-WIRECABLE
COMPRESSORCONTACTOR
= STANDARD TERMINAL = OPTIONAL TERMINAL
REMOVE JUMPER AND CONNECT SENSE TERMINALON TWO ROD APPLICATION ONLY.
M2644B
THERMOSTAT
G
GW
W C
Y
Y
R
R
LOMLMHHI
FUSE
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—215
STARTUP AND CHECKOUTCheck out the gas control system:• At initial appliance installation.• As part of regular maintenance procedures.• At maintenance intervals determined by the application.• As the first step in troubleshooting.• Any time work is done on the system.
Maintenance frequency must be determined individually foreach application. See Maintenance section.
WARNINGFIRE OR EXPLOSION HAZARDCAN CAUSE PROPERTY DAMAGE, SEVEREINJURY, OR DEATH.1. If you smell gas or suspect a gas leak, turn off the
gas at the manual service valve and evacuate thebuilding. Do not try to light any appliance; do nottouch any electrical switch or telephone in thebuilding until you are sure no spilled gas remains.
2. Gas leak test must be done as described in steps1 and 6 below on initial installation and anytimework 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 the power to the appliance.c. Open the manual shutoff valves in the gas line to the
appliance.d. Test for gas leak before gas control if piping has been
disturbed.
Gas Leak Test:Paint the gas control gasket edges and all pipe connectionsdownstream of the gas control, including pilot tubingconnections, with a rich soap and water solution. Bubblesindicate gas leaks. Tighten the joints and screws or replacethe component to stop the gas leak. Recheck with soap andwater solution.
Step 2: Verify control system ground.The igniter, flame sensor, and ignition module must share acommon ground with the main burner. Use thermoplasticinsulated wire with a minimum rating of 105°C (221°F) for theground wire; asbestos insulation is not acceptable. If thetemperature at the wire could exceed 105°C (221°F), use ashield to protect the wire from radiant heat generated by theburner. Connect the ground wire as follows: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 theigniter bracket mounting screw. If necessary, use a shieldto protect the ground wire from radiant heat.
c. The burner serves as the common grounding area. Ifthere is not good metal-to-metal contact between theburner and ground, run a lead from the burner to ground.
NOTE: Earth ground is not required.
Step 3: Review normal operating sequence and modulespecifications.a. See Operation and Specifications sections.
Step 4: Reset the module.a. Turn the thermostat to its lowest setting.b. Wait one minute.
As you do Steps 5 and 6, watch for points where operationdeviates from normal. Refer to Troubleshooting Guide, Fig. 8,to correct the problem.
Step 5: Check safety shutoff operation.a. Turn off the gas supply.b. Set thermostat or controller above the room temperature
to call for heat.c. Watch for spark at pilot burner.d. Time spark from start to shutoff. Spark should shut off
after 90 seconds maximum. Ignition sequence repeatsafter five minutes minimum.
e. Open the manual gas control knob and make sure nogas is flowing to the pilot or main burner.
f. Set the thermostat below the room temperature and waitone minute before continuing.
Step 6: Check normal operation.a. Set the thermostat or controller above the room
temperature to call for heat.b. Make sure the pilot lights smoothly when the gas
reaches the pilot burner.c. Make sure the main burner lights smoothly without
flashback.d. Make sure the burner operates smoothly without floating,
lifting, or flame rollout to the furnace vestibule or heatbuildup in the vestibule.
e. If the gas line was disturbed, complete the gas leak test.
Gas Leak Test:Paint the gas control gasket edges and all the pipeconnections downstream of the gas control, including pilottubing connections, with a rich soap and water solution.Bubbles indicate gas leaks. Tighten the joints and screws orreplace the component to stop the gas leak. Recheck withsoap and water solution.
f. Turn the thermostat or controller below the roomtemperature. Make sure the main burner and pilot flamesgo out.
MAINTENANCE
WARNINGFIRE OR EXPLOSION HAZARD CAN CAUSEPROPERTY DAMAGE, SEVERE INJURY, ORDEATH.Do not attempt to take the module apart or to clean it.Improper assembly and cleaning can cause unreliableoperation.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—2 16
Regular preventive maintenance is important in commercialcooking, agricultural and industrial industries applications thatplace a heavy load on system controls, because:• In many such applications, particularly commercial
cooking, the equipment operates 100,000 to 200,000cycles per year. Such heavy cycling can wear out the gascontrol in one to two years.
• Exposure to water, dirt, chemicals and heat can damagethe gas control and shut down the control system. ANEMA 4 enclosure can reduce exposure to environmentalcontaminants. See Electronic Ignition Service Manual,form 70-6604.
The maintenance program should include regular systemcheckout as outlined in the Startup and Checkout section,and control system checkout as described in appliancemanufacturer literature.
Maintenance frequency must be determined individually foreach application. Some considerations are:• Cycling frequency. Appliances that can cycle 20,000 times
annually should be checked monthly.• Intermittent use. Appliances that are used seasonally
should be checked before shutdown and again before thenext use.
• Consequence of unexpected shutdown. Where the cost ofan unexpected shutdown would be high, the systemshould be checked more often.
• Dusty, wet, or corrosive environment. Because theseenvironments can cause the gas control to deterioratemore rapidly, the system should be checked more often.
Any control should be replaced if it does not perform properlyon checkout or troubleshooting. In addition, replace anymodule if it is wet or looks like it has ever been wet.Protective enclosures as described in the Planning theInstallation section are recommended, regardless of checkoutfrequency.
OPERATIONModule operation can be conveniently divided into twophases for the S8610:• Trial for ignition.• Main burner operation.
Fig. 6 summarizes the normal operating sequence of themodule.
Fig. 6. S8610U normal operating sequence.
THERMOSTAT (CONTROLLER)SATISFIEDValves close, pilot and mainburners are off.
MAIN BURNER OPERATIONModule monitors pilot flame current.
FLAME CURRENT SENSED• Spark generator off.• Second valve operator (main) opens.
POWER INTERRUPTIONSystem shuts off, restarts when poweris restored.
PILOT FLAME FAILUREMain valve closes.Module starts trial for ignition.
M2640A
PILOT BURNER OPERATION
ORPilot burner lights.Module sensesflame current.
After 90 seconds maximum, system shuts off; trial forignition restarts after minimum of 5 minutes (6 minutesnominal). Ignition, shutoff, wait sequence repeats until pilot lights or call for heat ends.
SPARK GENERATOR POWERED
First valve (pilot) operator opens
THERMOSTAT (CONTROLLER)CALL FOR HEAT
START
STAGE 1TRIAL FORIGNITION
STAGE 2MAIN BURNER
OPERATION
END
�
�
�
�
�
�
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—217
TROUBLESHOOTINGIMPORTANT
1. The following service procedures are provided as ageneral guide. Follow appliance manufacturerservice instructions if available.
2. Meter readings between gas control and ignitionmodule must be taken within the trial for ignitionperiod. Once the ignition module shuts off, wait forretry or reset at the thermostat.
3. If any component does not function properly, makesure it is correctly installed and wired beforereplacing it.
4. The ignition module cannot be repaired. If itmalfunctions, replace it.
5. Only trained, experienced service technicians shouldservice intermittent pilot systems.
6. After servicing, verify proper system operation.
Perform the checkout steps in the Startup and Checkoutsection as the first step in troubleshooting. Then check theappropriate troubleshooting guide (Fig. 8) and the schematicdiagram (Fig. 9) to determine the cause of the problem. Iftroubleshooting indicates an ignition problem, see IgnitionSystem Checks section to isolate and correct the problem.
After troubleshooting, perform the checkout procedures againto be sure the system is operating normally.
Ignition System ChecksStep 1: Check ignition cable.Make sure:a. Ignition cable does not run in contact with any metal
surfaces.b. Ignition cable is no more than 36 in. (0.9m) long.c. Connections to the ignition module and to the igniter or
igniter-sensor are clean and tight.d. Ignition cable provides good electrical continuity.
Step 2: Check ignition system grounding. Nuisance shutdowns areoften caused by a poor or erratic ground.a. A common ground, usually supplied by the pilot burner
bracket, is required for the module and the pilot burner/igniter-sensor.• Check for good metal-to-metal contact between the
pilot burner bracket and the main burner.• Check the ground lead from the GND (BURNER)
terminal on the module to the pilot burner. Make sureconnections are clean and tight. If the wire isdamaged or deteriorated, replace it with No. 14through 18 gauge, moisture-resistant, thermoplasticinsulated wire with 105°C (221°F) minimum rating.— Check the ceramic flame rod insulator for cracks
or evidence of exposure to extreme heat, whichcan permit leakage to ground. Replace pilotburner/igniter-sensor and provide a shield, ifnecessary.
— If flame rod or bracket are bent out of position,restore to the correct position.
Step 3: Check spark ignition circuit. You will need a short jumper wiremade from ignition cable or other heavily insulated wire.a. Close the manual gas valve.b. Disconnect the ignition cable at the SPARK terminal on
the module.
WARNINGELECTROCUTION HAZARD, CAN CAUSESERIOUS INJURY OR DEATH.When performing the following steps, do not touchstripped end of jumper or SPARK terminal. Theignition circuit generates over 10,000 volts andelectrical shock can result.
c. Energize the module and immediately touch one end ofthe jumper firmly to the GND terminal on the module.Move the free end of the jumper slowly toward theSPARK terminal until a spark is established.
d. Pull the jumper slowly away from the terminal and notethe length of the gap; when sparking stops, refer to thetable as follows:
Arc Length Action
No arc or arc lessthan 1/8 in. (3 mm).
Check external fuse, if provided.Verify power at module inputterminal. Replace module if fuseand power are okay.
Arc 1/8 in. (3 mm) orlonger.
Voltage output is okay.
STEP 4: Check pilot and main burner lightoff.a. Set the thermostat to call for heat.b. Watch the pilot burner during the ignition sequence to be
sure:• Ignition spark continues after the pilot is lit.• The pilot lights and the spark stops, but the main
burner does not light.• The pilot lights, the spark stops and the main burner
lights, but the system shuts down.c. If so, verify adequate flame current as follows:
• Turn off the furnace at the circuit breaker or fuse box.• Clean the flame rod with an emery cloth.• Make sure the electrical connections are clean and
tight. Replace the damaged wire with moisture-resistant No. 18 wire rated for continuous duty up to105°C (221° F).
• Check for a cracked ceramic insulator, which cancause short to ground, and replace igniter-sensor orsensor, if necessary.
• At the gas control, disconnect the main valve wirefrom the TH or MV terminal.
• Turn on the power and set the thermostat to call forheat. The pilot should light but the main burnerremains off because the main valve actuator isdisconnected.
• Check the pilot flame. Make sure it is blue, steady,and envelops 3/8 to 1/2 in. (10 to 13 mm) of the flamerod. See Fig. 7 for possible flame problems and thecauses.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—2 18
• If necessary, adjust the pilot flame by turning the pilotadjustment screw on the gas control clockwise todecrease or counterclockwise to increase the pilotflame. Following adjustment, always replace the pilotadjustment cover screw and tighten firmly to assureproper gas control operation.
• Set the thermostat below the room temperature to endthe call for heat.
d. Recheck ignition sequence as follows:• Reconnect the main valve wire.• Set the thermostat to call for heat.• Watch the ignition sequence at the burner.• If spark still does not stop after pilot lights, replace the
ignition module.• If the main burner does not light or if the main burner
lights but system locks out, check module, groundwire, and gas control, as described in theTroubleshooting Guide, Fig. 8.
LAZY YELLOW FLAME
WAVING BLUE FLAME
NOISY LIFTING BLOWING FLAME
HARD SHARP FLAME
SMALL BLUE FLAME CHECK FOR LACK OF GAS FROM:
• CLOGGED ORIFICE FILTER
• CLOGGED PILOT FILTER
• LOW GAS SUPPLY PRESSURE
• PILOT ADJUSTMENT AT MINIMUM
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
CHECK FOR:
• EXCESSIVE DRAFT AT PILOT LOCATION
• RECIRCULATING PRODUCTS OF COMBUSTION
CHECK FOR:
• HIGH GAS PRESSURE
THIS FLAME IS CHARACTERISTIC OF MANUFACTURED GAS
CHECK FOR:
• HIGH GAS PRESSURE
• ORIFICE TOO SMALL
M2233A
APPEARANCE CAUSE
Fig. 7. Examples of unsatisfactory pilot flames.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—219
NOTE: Before troubleshooting, familiarize yourself with the startup and checkout procedure.
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 verify that vent damper (if used) is open and end switch is made.
On models with vent damper plug, make sure vent damper was not installed, then removed. Replace vent damper, if necessary.On other models, replace module.
Pull ignition lead and check spark at module.
Check ignition cable, ground wiring, ceramic insulator and gap, and correct.Check boot of the ignition cable for signs of melting or buckling. Replace cable and take protective action to shield cable and boot from excessive temperatures.
Check that all manual gas valves are open, supply tubing and pressures are good, and pilot burner orifice is not blocked.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
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.
Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.Check electrical connections between module and gas control. If okay, replace gas control or gas control operator.
Check continuity of ignition cable and ground wire.NOTE: If ground is poor or erratic, shutdowns can occur occasionally even though operation is normal at the time of checkout.Check temperature at igniter-sensor insulator. High temperatures can cause a short.Check that pilot flame covers flame rod and is steady and blue.If checks are okay, replace module.
Check for proper thermostat (controller) operation.Remove MV lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas control.
TURN OFF GAS SUPPLY.TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT.
POWER TO MODULE.(24V NOMINAL)
SPARK ACROSSIGNITER/SENSOR GAP?
TURN ON GAS SUPPLY.
PILOT BURNER LIGHTS?
SPARK STOPS WHEN PILOT IS LIT?
MAIN BURNER LIGHTS?
SYSTEM RUNS UNTIL CALL FOR HEAT ENDS?
CALL FOR HEAT ENDS.
SYSTEM SHUTS OFF?
TROUBLESHOOTING ENDS.
NO
NO
NO
NO
NO
NO
NO
NO
START
YES
YES
YES
YES
YES
YES
YES
YES
••
•
•
•
••
•••••••
••
•
•••
••
Repeat procedure until troublefree operation is obtained.M2643B
Spark okay?
CHECK AT TH-W TERMINAL, AND ALSO AT 24V TERMINALIF A VENT DAMPER IS CONNECTED TO THE DAMPER CONNECTOR.
Fig. 8. S8610U Troubleshooting Guide.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—2 20
Fig. 9. Schematic for S8610U.
FLAMEDETECTORCIRCUIT
SPARKDRIVECIRCUIT
RELAYDRIVERS
TIMINGCIRCUITS
LOWVOLTAGEPOWERSUPPLY
1 5 3 6 2 4
1 5 3 6 2 4
VENTDAMPERPLUG
YELLOW
FUSE
1K1 1K2 3K2
2K2 3K1
1K
2K
3K
24V(GND)
SENSE
SPARKGND(BUR-NER)
SENSOR
IGNITER
ARCGAP
ON-OFFSWITCH
LIMITCONTROLLER
24VTRANSFORMER
THERMOSTAT
TH-W
24V
MV/PV
MV
PV
MAINVALVE
PILOTVALVE
HYBRID CIRCUITS
2K1
BURNERGROUND
L1(HOT) L2
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
3 AMP NONREPLACEABLE FUSE. FUSE BLOWS WHEN VENT DAMPER IS PLUGGED IN AND POWER IS APPLIED.
SEPARATE SENSOR IS USED ON TWO-ROD SYSTEMS ONLY. DISCONNECT BLACK JUMPER WIRE FROM SENSE TERMINAL, CUT AT CIRCUIT BOARD AND DISCARD.
SINGLE ROD SYSTEM HAS IGNITER–SENSOR.
1
2
3
4
5
INTERNAL WIRINGEXTERNAL WIRING
1
3
2
2
5
4
M2646B
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—221
ANSI STANDARDS
Exhibit ARecommended 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 indetermining that an appliance is properly installed and is in asafe condition for continuing use.
This procedure is predicated on central furnace and boilerinstallations equipped with an atmospheric gas burner(s) andnot of the direct vent type. It should be recognized thatgeneralized test procedures cannot anticipate all situations.Accordingly, in some cases, deviation from this proceduremay be necessary to determine safe operation of theequipment.a. This procedure should be performed prior to any attempt
at modification of the appliance or the installation.b. If it is determined there is a condition which could result
in unsafe operation, the appliance should be shut off andthe owner advised of the unsafe condition.
The following steps should be followed in making the safetyinspection:
� Conduct a Gas Leakage Test of the appliance pipingand control system downstream of the shutoff valve inthe supply line to the appliance.
� Visually inspect the venting system for proper size andhorizontal pitch and determine there is no blockage orrestrictions, leakage or corrosion or other deficienciesthat could cause an unsafe condition.
� Shut off all gas to the appliance and shut off any otherfuel-burning appliance within the same room. Use theshutoff valve in the shutoff valve in the supply line toeach appliance.
� Inspect burners and crossovers for blockage andcorrosion.
� Applicable only to warm air heating appliances. Inspectheat exchangers for cracks, openings or excessivecorrosion.
� Applicable only to boilers. Inspect for evidence of wateror combustion product leaks.
� Insofar as is practical, close all building doors andwindows and all doors between the space in which theappliance is located and other spaces of the building.Turn on clothes dryers. Turn on any exhaust fans, suchas range hoods and bathroom exhausts, so they willoperate at maximum speed. Do not operate a summerexhaust fan. Close fireplace dampers. If, aftercompleting steps 7 through 12, it is believed sufficientcombustion air is not available, refer to 1.3.4 of theNational Fuel Gas Code (Z223.1) for guidance.
� Place in operation the appliance being inspected.Follow the lighting instructions. Adjust thermostat soappliance will operate continuously.
a. Determine that the pilot is burning properly andthat main burner ignition is satisfactory byinterrupting and re-establishing the electricalsupply to the appliance in any convenient manner.
Determine manifold pressure in order to match inputafter the new control is installed.
� a. Visually determine that main burner gas is burningproperly; i.e., no floating, lifting or flashback. Adjustthe primary air shutter(s) as required.
b. If appliance is equipped with high and low flamecontrol or flame modulation, check for proper mainburner operation at low flame.
� Test for spillage at the draft hood relief opening afterfive minutes of main burner operation. Use a draftgauge, the flame of a match or candle, or smoke from acigarette, cigar or pipe.
Return doors, windows, exhaust fans, fireplacedampers and all other fuel-burning appliances to theirprevious conditions of use.
� Applicable only to warm air heating appliances. Checkboth limit controller and fan controller for properoperation. Limit controller operation can be checked bytemporarily disconnecting the electrical supply to theblower motor and determining that the limit control actsto shut off the main burner gas.
� Applicable only to boilers:a. Determine that the circulating water pumps are in
operating condition.b. Test low water cutoffs, automatic feed controls,
pressure and temperature limit controls and reliefvalves in accordance with the manufacturer’s re-commendations and instructions to determine theyare in operating condition.
Exhibit A Of ANSI Standard Z21.71 for Automatic Intermittent Pilot Ignition Systems for Field Installation.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—2 22
Exhibit BProcedure for Installing Automatic Intermittent Pilot Systems
Prior to beginning this procedure, a preliminary examinationof the appliance and the automatic intermittent pilot systemshould be made to determine that the automatic intermittentpilot system can be properly applied to the appliance.
This procedure is intended as a guide to aid in safelyinstalling a listed automatic intermittent pilot system on anexisting listed appliance equipped with an atmospheric gasburner(s) and not of the direct vent type.
This procedure is based on the assumption that the history ofthe specific installation has been one of safe and satisfactoryoperation.
This procedure is predicated on central furnace and boilerinstallations, and it should be recognized that generalizedprocedures cannot anticipate all situations. Accordingly, insome cases, deviation from this procedure may be necessaryto determine safe operation of the equipment.
The following steps should be followed in making themodifications:
� Perform a safety inspection of the existing applianceinstallation. See Exhibit A for a recommendedprocedure for such a safety inspection.
� Shut off all gas and electricity to the appliance. To shutoff gas, use the shutoff valve in the supply line to theappliance. Do not use the shut-off valve which isprovided as part of a combination control.
� Install the automatic intermittent pilot system in strictaccordance with the manufacturer’s installationinstructions.
� Turn on all gas and electricity to the appliance.� Determine that the appliance transformer has adequate
capacity by following the steps outlined below:a. Compute the approximate current draw by adding
the current draw of the automatic intermit-tentpilot system to (1) the current draw of theassociated valving, and (2) the current draw ofany relays or other devices operated by thetransformer.
b. Multiply the total current draw as computedabove by 24V to determine the total volt-ampere(VA) required.
c. The total VA required should be equal to or lessthan the VA rating of the transformer.
d. If the total VA required is greater than the VArating of the transformer, the transformer must bereplaced with a Class 2 transformer of adequaterating.
� Check the heat anticipator in the comfort thermostat todetermine if it is properly adjusted to the current draw ofthe control system. Follow the thermostatmanufacturer’s instructions.
� Make certain wiring connections are tight and wires arepositioned and secured so they will not be able tocontact high temperature locations.
� Conduct a Gas Leakage Test of the appliance pipingand control system downstream of the shutoff valve inthe supply line to the appliance.
a. Adjust the thermostat to its highest temperaturesetting, and test manifold pressure and adjust thepressure regulator to match original input asrequired (refer to Exhibit A, step 9b).
b. Visually determine that main burner is burningproperly; i.e., no floating, lifting or flashback. Adjustthe primary air shutter(s) as required.
If the appliance is equipped with high and low flamecontrol or flame modulation, check for proper mainburner operation at both high and low flame.
� Determine that the pilot is igniting and burning properlyand that main burner ignition is satisfactory byinterrupting and reestablishing the electrical supply tothe appliance in any convenient manner. Make thisdetermination with the appliance burner both cold andhot. Perform this step as many times as is necessary tosatisfy yourself that the automatic intermittent pilotsystem is operating properly.
� Test the pilot safety device (1) to determine if it isoperating properly, and (2) for turndown characteristicsaccording to the manufacturer’s installation instructions.No adjustments should be made other than thoserecommended by the system manufacturer.
Sequence the appliance through at least threeoperating cycles.
� Applicable only to furnaces. Check both the limitcontroller and the fan controller for proper operation.Limit control operation can be checked by blocking thecirculating air inlet or temporarily disconnecting theelectrical supply to the blower motor and determiningthat the limit controller acts to shut off the main burnergas.
� Applicable only to boilers:a. Determine that the circulating water pumps are in
operating condition.b. Test low water cutoffs, automatic feed water
controls, pressure and temperature limitcontrollers and relief valves in accordance withthe manufacturer’s recommendation to determinethey are in operating condition.
� Add the labels (see 1.6.1-n and -o) on the appliance.
EXHIBIT B OF ANSI STANDARD Z21.71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FORFIELD INSTALLATION.
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—223
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
68-0135—2 24
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