68-0102 - Intermittent Pilot Retrofit Kit - Y8610F,H
Contents
1. PROPER FLAME ADJUSTMENT GROUND ROD ELECTRODE SCREW IGNITER SENSOR ASSEMBLY STUD TERMINAL IGNITION CABLE 11 073A erature limit controllers and relief rating in accordance with the appli et thermostat or controller above room tempera ture to call for heat Ensure pilot lights smoothly when gas reaches the pilot burner e Ensure main burner lights smoothly without flash back e Ensure main burner operates smoothly without floating lifting or flame rollout to the furnace vesti bule or heat buildup in the vestibule e f gas line has been disturbed complete the Gas Leak Test page 14 Turn thermostat or controller below room tempera ture Ensure the main burner and pilot flames go out 68 0102 2 System operation is divided into two stages 1 Trial for ignition 2 Main burner operation Refer to Fig 19 for the normal operating sequence START e THERMOSTAT CONTROLLER CALLS FOR HEAT STAGE 1 o TRIAL FOR SPARK GENERATOR POWERED IGNIITION First valve pilot operator opens Pilot burner lights Module senses OH flame current D STAGE 2 Spark genera OPERATION ia b Aves close burners are of END module energizes the I he first main valve opens which lot burner At the same time the ir in the module produces a high t The voltage generates a spark If the pilot 665 not light or th2. a a 0 Pa a aor ania Ba Ta eas Pa e e e y sa a a aS FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE IN THERMOCOUPLE JURY OR DEATH Follow these warnings exactly 1 Do not bend the pilot gas tubinc or at the pilot burner after com is tightened Gas leakage Fas control Ssion fitting e con ion 8743 may result 2 Always install a sedimant t jas sup FIG 7 REMOVE THERMOCOUPLE FROM PILOT ply line to prevent of the gas BURNER control INSTALL THE IGNITER SENSOR ASSEMBLY 3 Do not force t your hand t 1 Install the ground rod if needed Refer to Fig 8 Mount adapter to ground rod if needed gas control will Line up ground rod so clip will hug pilot burner and gas co should be re keep ground rod from rotating Refer to Fig 9 servio chnician Force empted repair ma ult in agire or explosien Insert ground rod in place of thermocouple on pilot burner Push ground rod all the way up Fasten as shown in Fig 8 2 Slide igniter sensor mounting bracket over ground rod top 3 Adjust electrode position so electrode tip and spark gas are in pilot flame Turn ground rod to move igniter sensor up and down 4 Check that the chosen position allows room to nect the ignition cable to the stud terminal 5 Tighten the setscrews on mounting bracke wrench provided I
3. Honeywell THE Y8610F H ARE COMPLETE KITS FOR CONVERTING CONVENTIONAL STANDING PILOT SYSTEMS TO INTER MITTENT PILOT SYSTEMS THEY ARE USED ON GAS FIRED ATMOSPHERIC FURNACES BOILERS AND HEATING APPLIANCES NOT FOR USE ON DIRECT VENT OR POWER BURNER EQUIPMENT MEETS ANSI Z21 71 STANDARD FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD INSTALLATIONS Y8610F kits are for use on natural gas only they continue trial for ignition until either the pilot lights or the system is shut down manually Y8610H kits are available for either natural or LP gas they provide timed trial for ignition and 100 percent pilot shutoff on loss of flame J Each kit includes 58610 or intermittent Pilot Module VR8440A or Mor VR8204A Dual Valve Combination Gas Control 392431 Igniter Sensor 394800 30 ignition Cable Wiring Harness 393690 14 Straight Flange Kit 3 4 inch VR8204A appli cations only Reducer adapters for gas control Adhesive mounting option for 58610 Installation hardware 1 Temperature Rating VR8204A 0 to 175 F 18 to 79 C VR8440A 40 to 175 F 40 to 79 C VR8440M 32 to 175 F 0 to 79 C MODULE J Uses rectification principle for ftaa sensing Provides 13kV peak capacitive at 25 pf load GAS CONTROL J Straight through 1097 pattem Some 778 1 2 in plugged side outlej O Capacities at 1
4. 3 Shut off all gas to the appliance a a manual gas valve is not in the 6 feet of the appliance in an ac shall be installed corrosion 5 Applicable o Inspect heat excha Sive corrosion 6 Appli water ween the space in which the other spaces of the building rn on any exhaust fans such room exhausts so they will EXHIBIT A OF ANSI STANDARD Z21 71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD INSTALLATION 22 operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers If omplet ing steps 7 through 12 it is believed suffit combus tion airis not available referto 1 3 4 0 Gas Code 2223 1 for guidance 8 Place in operation the applian Follow the lighting instructio appliance will operate conti Dected ostat se 2194 y r the new control is installed main burner gas is equipped with high and low flame cop rol or flame modulation check for lage at the draft hood relief opening of main burner operation Use a draft ette cigar or pipe Return doors windows exhaust fans fireplace bers and all other fuel burning appliances to their Previous conditions of use 13 Applicable only to warm air heating appliances Check both limit controller and fan controller for proper operation Limit controller operation can be checked by temporarily disconnecting the electrical supply to the blower motor and det
5. 955 0 25 kPa pressure drop VR82 l ar wit qe 2 x 34 adapter BO ft hr 47 hr YG 440A M with x 3 4 f inlet x outlet 190 ft hr 5 4 mW 18440A M with 3 4 3 4 NPT inlet x outlet ROO ft hr 5 7 7 blocks gas flow into gas control in the OFF positi i Es Two main automatic valves one solenoid operated the other diaphragm operated IGNITER SENSOR Single electrode made of Kanthal provides both ignition and flame sensing 1 Rated for 1775 F 968 C at electrode tip 1250 F 677 C at ceramic insulator D T Form Number 68 0102 2 Rev 5 93 Honeywell inc 1993 INTERMITTENT PILOT RETROFIT Y8610F H IMPORTANT THE SPECIFICATIONS GIVEN IN THIS PUBLICATION DO NOT INCLUDE NORMAL MANUFACTURING TOLERANCES THEREFORE UNITS MAY NOT MATCH THE LISTED SPECIFICATIONS EXACTLY ALSO UNITS ARE TESTED AND CALIBRATED UNDER CLOSELY CONTROLLED CONDITIONS AND SOME MINOR DIFFERENCES IN PERFORMANCE CAN BE EXPECTED IF THOSE CONDITIONS ARE CHANGED TRADELINE MODELS TRADELINE models are selected and packaged for AMBIENT TEMPERATURE RATING ease of handling ease of stocking and maximum replace VR8204A 0 to 175 F 18 to 7 ment value TRADELINE model specifications are the same as those of standard models except as noted TRADELINE MODELS AVAILABLE Y8610F Intermittent Pilot Retrofit Kit Allmodels meet ANSI 221 71 Automatic Inte
6. fuse has blown the module won t work unless the vent damper is connected To connect the plug in vent damper 1 Remove and discard the vent damper plug from the module terminal strip 2 Using the wiring harness supplied insert the match ing pin plug into the receptacle on the module and the other end to the vent damper To connect the D80B Vent Damper follow the wiring diagrams supplied with the vent damper Connect S8610 Module 1 Connect the gas control and other remaining system components to the ignition module terminals as shown in the Figs 14 through 16 Fig 14 shows a basic circuit for a heating only atmospheric burner system Fig 15 shows a heating only atmospheric burner system with D80D Vent Damper Fig 16 shows a heating only system with a D80B Vent Damper 2 Adjust the thermostat heat anticipator to match sys tem current draw The current draw equals the total current required for the ignition module 0 2A plus the gas control and any other auxiliary equipment in the control circuit Pd Connect Ground Control System The igniter flame sensor and ignition module must share a common ground with the main burner PV GND VR8204A 2 COMBINATION 1 MV MV PV PV BU GAS CONTROL MV VR8440A M ndis a COMBINATION TR cas conTROL ott THITR wu j GROUND wa 24V OPEN DO NOT REMOVE VENT DAMPER PLUG 1 Fit one end of
7. The second main valve opens and gas flows to the main burner where it is ignited by the pilot burner On lockout models the flame current also holds the safety lockout timer in the reset normal operating condition When the call for heat ends both valve operators are de energized and both valves in the gas contro close IMPORTANT 1 Thefollowing service procedures are provided as a general guide Follow appliance manufacturers service instructions if available 2 On lockout and retry models meter readings between gas control and ignition module must be taken within the trial for ignition period Once the ignition module shuts off lockout models must be reset by setting the thermostat down for at least one minute before continuing On retry models wait for retry or reset at the thermostat 3 If any component does not function properly make sure 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 Perform the Checkout on page 14 as the first step in troubleshooting Then check the appropriate troubleshoot ing guide Fig 20 and the schematic diagram Figs 23 25 to pinpoint the cause of the problem If troubleshooting indicates an ignition problem see Ignition System Checks below to isolate and correct the problem Follo
8. nameplate or manufacturer s recom mended burner orifice pressure for the size orifice s used Ensure the main burner primary air supply is properly adjusted for complete com bustion refer to the appliance manufacturer s instructions 2 IF CHECKING GAS INPUT BY CLOCKING THE GAS METER Ensure that they only gas flow through the meter is that of the appliance being tested Ensure that other appliances are turned off and that their pilot burners are extinguished or deduct their gas consumptions from the meter reading Convert the flow rate to Btuh as described in the Gas Controls Handbook form number 70 6202 and compare to the Btuh input rating on the appliance nameplate 3 IF CHECKING GAS INPUT WITH A MANOME PRESSURE GAUGE Ensure the gas control knob is in the PILOT position before removing the outlet pressure tap plug to connect the manometer Turnthe gas control knob back to PILOT when removing the manometer and replacing outlet pressure tap plug Shut off the gas supply at the appliance serv ice valve or for LP gas at the gas tank before removing outlet the pressure tap plug and before disconnecting the manometer and re placing the outlet pressure tap plug Perform the Gas Leak Test at the inlet pres sure tap plug 1 The gas control output pressure should match the manifold pressure listed on the appliance nameplate 2 With the mai
9. the ground wire with a female 1 4 inch quick connect terminal and connect it to the male quick connect GND BURNER terminal on the ignition module 2 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 3 The burner serves as the common grounding area If there is not a good metal to metal contact between burner and ground run a lead from the burner to ground NOTE Earth ground is not required 24V TH W GND 24V OPT ODULE WITH TH W TERMINAL AND VENT DAMPER PLUG CONNECT THERMOSTAT TO TH W LEAVE M 553 FIG 14 Y8610 IN TYPICAL ATMOSPHERIC BURNER HEATING SYSTEM 11 68 0102 2 S8610F H GND 24V VR8204A MV MV PV PV BURNER GND 24V TH W COMBINATION GAS CONTROL MV WIF HARNE pw 0800 VENT DAMPER VR8440A M TV E COMBINATION TR GAS CONTROL HERMO d TH TR STAT mm MIT CONTROLLER L1 FOP A L2 PILOT BURNER GROUND 7 POWER SUPPLY RLOAD PROTECTION AS REQUIRED ALTERNATE LIMI fA Y8610 INCLUDES OR VR8440M COMBINATION GAS CONTROL GROUND LEG TO TRANSFORMER AMPER FUSE BLOWS ON STARTUP WHEN PLUG IS REMOVED G HARNESS 15 INSTALLED THEN MODULE WILL OPERATE ONLY WHEN VENT FIG 15 Y8610 IN A TYPICAL ATMOSPHERIC BURNER HEATIN
10. ES PLEASE WRITE OR PHONE PHONE DIRECTORY 2 RESIDENTIAL AND BUILDING CONTROLS CUSTOMER SERVICES HONEYWELL INC 1885 DOUGLAS DRIVE NORTH MINNEAPOLIS MINNESOTA 55422 612 542 7500 IN CANADA HONEYWELL CONTROLS LIMITED 740 ELLESMERE ROAD SCARBOROUGH ONTARIO M1P 2V9 INTERNATIONAL SALES AND SERVICE OFFICES IN ALL PRINCIPAL CITIES OF THE WORLD 58610 INTERMITTENT PILOT MODULE WITH WIRING HARNESS VR8204 OR VR8440 DUAL VALVE COMBINATION GAS CONTROL ASSEMBLY GROUND ROD IGNITER SENSOR ADAPTE DEL SPECIFICATIONS FLAME FAILURE RESPONSE TIME 0 8 seconds maxi mum at 1 0 uf flame current IGNITION TIMING S8610F Until pilot lights or system is shut down manually S8610H Until pilot lights or lockout occurs MOUNTING Mounts in any position except with terminals up Recommended mounting position is with terminals down to provide maximum protection from dripping S ALSO INCLUDED 392125 IGNITION CABLE 30 INCHES 760 mm 393690 14 STRAIGHT FLANGE KIT VR8204A ONLY REDUCER BUSHINGS FOR GAS CONTROL SCREWS WIRE NUTS 3 12 982A FIG 1 Y8610 RETROFIT KIT COMPONENTS water or dust accumulation Fasten with No 6 32 machine screws or No 8 sheet metal screws of appro priate length Refer to Fig 13 SAFETY LOCKOUT TIMING 58610 None Ignition trial continues until pilot lights or system is manually shut down 58610 70 seconds nominal 90 seconds maximum
11. FTD80D VENT DAMPER SCHEMATIC DIAGRAM REFER TO FIG 15 FOR WIRING DIAGRAM 21 68 0102 2 EXHIBIT A RECOMMENDED PROCEDURE FOR SAFETY INSPECTION OF AN EXISTING APPLIANCE INSTALLATION AS A PRELIMINARY STEP TO APPLYING AN AUTOMATIC INTERMITTENT PILOT SYSTEM The following procedure is intended as a guide to aid in determining that an appliance is properly installed and is in a safe condition for continuing use This procedure is predicated on central furnace and boiler installations equipped with an atmospheric gas burner s and not of the direct vent type It should be recognized that generalized test procedures cannot anticipate all situations Accordingly in some cases deviation from this procedure may be necessary to determine safe operation of the equipment a This procedure should be performed prior to any attempt at modification of the appliance or the installation b If itis determined there is a condition which could result in unsafe operation the appliance should be shut off and the owner advised of the unsafe condition The following steps should be followed in making the safety inspection 1 Conduct a Gas Leakage Test of the appliance piping and control system downstream of the shutoff valve in the supply line to the appliance 2 Visually inspect the venting system for prope and horizontal pitch and determine there is no blc or restrictions leakage or corrosion or other d cies which could cause an unsafe condition
12. G SYSTEM WITH A D80D VENT DAMPER 12 58610 VENT GND 24V TH W DAMPER MV MVV PV BURNER 24V OPT PLUG r I PV VR8204A cowananion GAS CONTROL MV VR8440A M COMBINATION GAS CONTROL THERMOSTAT OR PILOT CONTROLLER BURNER Y Y GROUND me CONTROLLER CONTROLLER MEANS AND OVERLOAD PROTECTION AS REQUIRED A ALTERNI CONTROLLI OCATION INCLUDES 4 5204A VR8440A OR VR8440M COMBINATION GAS CONTROL FCUIT MUST NOT IN GROUND LEG TO TRANSFORMER TH TH W TERMINAL AND VENT DAMPER PLUG CONNECT VENT DAMPER H W LEAVE 24V OPEN DO NOT REMOVE VENT DAMPER PLUG ER TO WIRE HARNESS IF USED en T 4 FIG 16 Y8610 IN TYPICAL FAN ASSISTED COMBUSTION BURNER HEATING SYSTEM 13 68 0102 2 out the gas control system At initial appliance installation As part of regular maintenance procedures Mainte nance intervals are determined by the application See PLANNING THE INSTALLATION page 6 for more information Asthe first Troubleshooting step Anytime work is done on the system a a a eT eT el e FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE IN JURY OR DEATH 1 If you smell gas or suspect a gas leak turn off gas at the manual service valve and evacuate the building Do not try to light a
13. HREAD LEN INCHES imum Depth Pipe Can Be Pipe d inserted into Size Gas Control 3 8 LEAVE 2 END THREADS MESS THREAD PIPE RIGHT LENGTH 313E FIG 11 USE MODERATE AMOUNT OF COMPOUND 4 Apply a moderate amount of good quality pipe com pound to pipe only leaving two end threads bare DONOT USE TEFLON TAPE In LP installations use compound resistant to LP gas Refer to Fig 11 5 Remove protective seals over the gas control inlet and outlet if necessary 6 Connect pipe to the gas control inlet and outlet Tighten the inlet and outlet connections using a wrench on the gas control projecting wrench boss Refer to Figs 3 or 4 CONNECT PILOT GAS TUBIN 1 Cut the pilot gas tubing routing to the pilot burner end as necessary for 5 tubing into pilot gas tapping until it olding tubing all the way in slide compres into place and engage threads Turn until finger g a wrench tighten one more turn Do not en onnect other end of pilot gas tubing to pilot burner actording to pilot burner manufacturer s instructions TIGHTEN NUT ONE TURN BEYOND FINGER TIGHT PILOT TUBING GAS CONTROL BODY FITTING BREAKS OFF AND CLINCHES TUBING AS NUT IS TIGHTENED FIG 12 ALWAYS USE A NEW COMPRESSION FITTING MOUNTING S8610 INTERMITTENT PILOT MODULE Select a location close to the pilot burner to allow the ignition cable to run to the igniter sensor The ambient te
14. MPOBRANT trols with protective seals lo appings Do not remove the onnect piping seals unti reac L AD ERS TO GAS CONTROL if used 3690 14 Straight Flange 3 4 inch VR8204 only Remove seal over gas control inlet or outlet 2 Ensure that the O ring is fitted in the flange groove If e O ring is not attached or missing do not use the flange 3 With the O ring facing the gas control align the gas control threaded holes with the flange clearance holes 4 Insert and tighten the screws provided with the flange Tighten the screws to 25 inch pounds of torque to provide a gas tight seal ADD ADAPTER INSERT GROUND ROD IN PILOT Bushings 1 Remove seal over gas control inlet or outlet 2 Apply moderate amount of good quality pipe com pound to bushing leaving two end threads bare On LP installation use compound resistant to LP gas Do not use Teflon Tape 3 Insertbushing in gas control and thread pipe carefully into bushing until tight INSERT GROUND ROD BE SURE T PILOT BURNE 8 MOUNT QESOUND ROD ON PILOT BURNER ELECT E GAP TRODE EL CTRODE BEW 2 GROUND ROD LA OTT 1 J Q D 5529 NNj NM LN SEN ETT STUD TERMINAL INSTALL GAS CONTROL PIPING All pipe must comply with local codes and ordinances or with the National Fuel Code ANSI Z223 1 NFPA No 54 whichever applies Tubing installation must compl
15. Provides 100 percent gas shutoff if pilot does not light SPARK GENERATOR OUTPUT 13 peak at 25 pf load 16kV peak open circuit TERMINALS 1 4 inch male quick connects S8610F 1016 has Molex plugfor connection to Honeywell D80D Vent Damper or Penn Baso G60 or G66 Vent Damper Once the S8610F has powered a vent damper the module will work only if the vent damper is connected 68 0102 2 3 3 16 181 8 8 186 15 316 100 2 51 1 5 6 P 23 17 A ONLY ON MODELS WITH VENT DAMPER PLUG M1123 PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW PILOT ADJUSTMENT UNDER CAP SCREW 1 4 in QUICK CONNECT ERMINALS 3 5 8 91 SWIN RADIUS 41 a 104 12 983 FIG 3 VR8204A MOUNTING DIMENSIONS IN INCHES AND MILLIMETERS ke 516789 GROUND TERMINAL PILOT ADJUSTMENT SCREW UNDER 3 61 CAP SCREW we uaa IN OPTIONAL INLET PRESSURE TAP 1 8 in NPT 1 avg 110 SWING RADIUS 319 16 100 N NI Jl J 311 EE 5 1611 25167 FIG 4 VR8440A DUAL VALVE COMBINATION GAS SPECIFICATIONS MODELS VR8204A Dual Valv VR8440A Dual Val VR8440M Dual Val AMBIENT TEMPERAT VR8204A 0 7 132 12 150 702 340 150 1 2 3 4 3 4x3 4 200 200 Btuh ft 0 64 specific gravity natural gas z WC pressure drop 37 3 MJ m 0 64 specific gravity natur
16. W DAMPER PLUG OPT r73 GND MV MV PV PV BURNER 24V ER BLACK owe A ADJUST IGNITER SENSOR UNTIL FLAME CURRENT EQUALS AT LEAST 1 0 uA AND STEADY M 560 FIG 21 ADJUSTING FLAME CURRENT 19 68 0102 2 L1 LIMIT on off 12 CONTROLLER SWITCH A i ee m m m cU M um e m THERMOSTAT OR i i CONTROLLER A vanas 24 nm M AA ce N POWER SUPPLY P ALTERNATE LIMIT C A 3K RELAY PERC WIRED ys TO ONLY ON NON SHUTOFF MODELS PV AND MV TO 24V GND MAIN INTERNAL WIRING VALVE EXTERNAL WIRING 4 PILOT 2 VALVE 11658 SCHEMATIC DIAGRAM REFER TO FIG 14 FOR WIRING DIAGRAM 20 L1 L2 Pu ON OFF LIMIT SWITCH CONTROLLER I p THERMOSTAT 1 F i le am am um 7 pemn I GNO gt 9 1 BUR IGNITER NER CIRGUI SENSOR T BURNER GROUND DAMPER YELLOW MAIN PLUG VALVE PILOT VALVE A POWER SUPPLY PROVIDE DIS ALTERNATE LIMIT CONZBOLLER A 3 0 NONRI PACEARUE FUSE FU AEN VENT DAMPER IS PLUGGED IN N RELAY PERCE MODELS ONLY ON NON SHUTOFF MODELS PV AND MV WIRED AS FOLLOWS TO 24V TO 24V GND MAIN VALVE INTERNAL WIRING Mee NS EXTERNAL WIRING PILOT VALVE N 4 1170 23 86107 WIT
17. addi tion replace any module i wet or looks like it has ever been wet Prote enclosures as outlined e recommended and tag the wires before efer to Fig 6 for the most common types TO THERMOSTAT COMMON TRANSFORMER TO THERMOSTAT COMMON TO TRANSFORMER THERMOSTAT FIG 6 WIRING CONNECTIONS ON STANDING PILOT GAS CONTROLS REMOVE STANDING PILOT GAS CONTROL 1 If the gas control has common terminal s remove the wires connected to the common terminal s and splice together with one of the wire nuts provided 2 Tag and remove the remaining wires CAUTION Do not bend the pilot gas tubing at the gas control or atthe pilot burner Gas leakage atthe connection will result 3 Disconnect the pilot tubing at the gas control Cut off and discard the compression fitting Do not disturb the compression fitting or pilot tubing at the pilot burner 4 Disconnect the thermocouple lead at the gas control 5 Disconnect the gas piping at the gas control 6 Discard the gas control REMOVE THERMOCOUPLE Unscrew or snap the thermocouple out of the pilot burner and discard Refer to Fig 7 NOTE It may be necessary to pull main burner out for access to the pilot burner Do not move or relocate the pilot burner Do not bend tubing near the pilot burner 68 0102 2 INSTALL THE GAS CONTROL PILOT BURNER ta ame ner cere
18. ady or nuisance shutdowns may occur Use a Hon eywell W136 to adjust the pilot flame current APPEARANCE CAUSE SMALL BLUE FLAME CHECK FOR LACK OF GAS FROM CLOGGED ORIFICE FILTER CLOGGED PILOT FILTER LOW GAS SUPPLY PRESSURE PILOT ADJUSTMENT AT MINIMUM 1 Disconnect the furnace power at the service en trance 2 Disconnect the control module green ground wire LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM DIRTY ORIFICE DIRTY LINT SCREEN iF USED DIRTY PRIMARY AIR OPENING IF THERE 15 ONE PILOT ADJUSTMENT AT MINIMUM 3 Connect the microammeter negative lead to the control module GND BURNER terminal and the positive lead to the green ground wire Refegto Fig 21 WAVING BLUE FLAME CHECK FOR A EXCESSIVE DRAFT AT PILOT LOCATION RECIRCULATING PRODUCTS OF COMBUSTION i CHECK FOR HIGH GAS PRESSURE NOISY LIFTING BLOWING FLAME igniter sensor position that gives mmeter reading tighten the set screws to loc igniter sensor in place This reading ust be at least 1 0 pA and steady HARD SHARP FLAME THIS FLAME IS CHARACTERISTIC OF MANUFACTURED GAS CHECK FOR D Lar off power remove microammeter and recon HIGH GAS PRESSURE ne and green leads TOO SMAL 11 Perform Checkout procedures FIG 20 EXAMPLES OF UN FLAMES N TH
19. al gas at 0 25 kPa pressure drop PWith a 1 2 x 3 4 inch straight flange included DIMENSIONS VR8204A Refer to Fig 3 VR8440A M Refer to Fig 4 MOUNTING Can be mounted from 0 to 90 degrees in any direction from the gas control upright position Two No 10 32 UNF tapped mounting holes in the base for bracket mounting VR8440A M only PRESSURE RATING 1 2 psig 3 45 kPa inlet pressure VR8440A 3 2 i PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW VR8440 MANUAL GAS VALVE KNOB OFF POSITION RADIUS PRESSURE TAP 1 8 in NPT 10 32 X 1 4 in MOUNTING HOLES 2 7 6187 11 468C NSIOWS IN INCHES AND MILLIMETERS TERMINALS VR8204A 1 4 inch male quick connect terminals VR8440A M Combination screw terminals and 1 4 inch male quick connect terminals IGNITER SENSOR SPECIFICATIONS MODEL 392431 igniter Sensor Includes igniter sensor assembly ground rod and adapter Refer to Fig 1 DIMENSIONS Refer to Fig 5 ELECTRODE FLAME ROD MATERIAL Kanthal MAXIMUM TEMPERATURE RATINGS Ground rod tip 1775 F 968 C Ceramic insulator 1250 F 677 C MOUNTING Replaces the thermocouple on the existing pilot burner 11 0798 FIG 5 392431 IGNITER SENSOR MOUNTING DI MENSION IN INCHES AND MILLIMETERS 68 0102 2 Intermittent pilot systems are used on a variety of central heating equipment and on heatin
20. andard Z21 710npage 24 mustbe performed before installing the Y8610 If an unsafe condition is detected the applig condition Any potentially unsafe condition must be amp rected before proceeding with the Installation Regular preventive maintenance i application but especially so in comm cultural and industrial applications be inmany applications ing the equipmen gas control in on furnace for whic tended 0 000 cycles A NEMA 4 enclosure can ironmental contaminants Service Manual form 70 FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE IN JURY OR DEATH Do not attempt to disassemble or clean the module Improper reassembly and cleaning may cause un reliable operation Maintenance frequency must be determined individu ally for each application Some considerations are e Cycling frequency Appliances that cycle more than 20 000 times annually should be checked monthly e Intermittent use Appliances that are used season ally should be checked before shutdown and again before the next use Consequence of unexpected shutdown Where the cost of an unexpected shutdown is high the system should be checked more often Dusty wet or corrosive environment Since these environments can cause the controls to deteriorate more rapidly the system should be checked more often Any control should be replaced if it does not perform properly on Checkout or Troubleshooting In
21. ctro Service Manual form 70 6604 HIGH HUMIDITY DRIPPING WATSEE Over time dripping water or hig 5 create unwanted electrical paths the module circt board causing the module to Never appli ance where water can drip on then lly Failure to follow or cause a hazardous gt prod 3 Ensure the installer is a trained experienced service technician 4 After completing installation use these instructions to check product operation In addition high ambient humidity can cause the gas control to corrode and finally to fail Where the appliance may be installed in a humid atmosphere make sure air circulation around the module and gas control is adequate to prevent condensation It s also important to regularly check out the system A NEMA 4 enclosure may be needed see the Electronic Ignition Service Manual form 70 6604 CORROSIVE CHEMICALS Corrosive chemicals can als gas control and eventually cause cals may be used routinel cleaning solution cannot r cals are likely to be sus and agricultural appli h can be damaged by excessively high ake sure the maximum ambient tempera ntrol locations will not exceed the rating of the rol If the appliance normally operates at very high beratures insulation shielding and air circulation may ecessary to protect the controls Proper insulation or ielding should be provided by the appliance manufac turer make sure a
22. dequate air circulation is maintained when the appliance is installed IMPORTANT 1 Installer must comply with local codes and ordi nances of the National Fuel Code ANSI Z223 1 NFPA No 54 and National Electrical Code ANSI NFPA No 70 2 Installer must fill in and attach label to appliance being converted 3 Use Y8610 retrofit kitonly with atmospheric burn ers Do not use on direct vent appliances or power burners 4 Do not use the Y8610 retrofit kit with mercury pilots or 250 to 750 mV pilot systems FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE IN JURY OR DEATH Follow these warnings exactly 1 Disconnect the power supply before wiring to prevent electrical shock or equipment damage 2 To avoid dangerous accumulation of fuel gas turn off gas supply at the appliance service valve before starting Installation and perform Gas Leak Test following the installation Never install where water can flood drip or condense on module or gas control Never use a module or gas control that has been wet If wet controls can malfunction and lead to an accumu lation of explosive gas Donotlight or operate electric switches lights or appliances until you are sure the appliance area is free of gas Liquefied petroleum LP gas is heavier than air and will not vent upward natu rally PERFORM THE PREINSTALLATION SAFETY INSPECTION The preinstallation checks described in ANSI St
23. e Tminal and note arkip Check table i Energize the module the jumper firmly to the the free end of the terminal until a ki 2 j Pull the slowly the length gap when below N b ACTION Check external fuse if provided Verify power at module input terminal Replace module if fuse and power ok Voltage output is okay Check pilot and main burner lightoff pen the manual gas valve Set the thermostat to call for heat Watch the pilot burner during the ignition sequence If the ignition spark continues after the pilot is lit e pilotlights and the spark stops but main burner does not light or e S8610H only the pilot lights the spark stops and main burner lights but the system locks out Ensure adequate flame current as follows Turn off furnace at circuit breaker or fuse box Clean the flame rod with emery cloth Makesureelectrical connections are clean and tight Replace damaged wire with moisture resistant No 18 wire rated for continuous duty up to 105 C 221 F e Check for cracked ceramic insulator which can cause short to ground and replace igniter sensor if necessary At the gas control disconnect main valve wire from the TH or 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 fla
24. e pilot flame current is not atleast 1 0 and steady the module will not energize the second main valve and the main burner will not light S8610F will continue to spark as long as the thermostat calls for heat or until the pilot lights Safety Lockout S8610H These modules provide 100 percent shutoff safety lockout A timer in these models starts timing the moment the trial for ignition starts Ignition spark continues only until the timed trial for ignition period ends Then the module 5 MAIN OPERATION Module md pilot flame t x CONTROLLER 16 4 Ignition s valve is W DN POWER INTERRUPTION System shuts off restarts when power is restored PILOT FLAME FAILURE Main valve closes Module starts trial for ignition M 557 58610 NORMAL OPERATING SEQUENCE goes into safety lockout Lockout de energizes the first main valve operator and closes the first main pilot valve in the gas control stopping pilot gas flow The control system mustbe reset by setting the thermostat below room temperature for one minute or by turning off power to the module for one minute MAIN BURNER OPERATION When the pilot flame is established a flame rectification circuit is completed between the sensor and burner ground The flame sensing circuit in the module detects the flame current shuts off the spark generator and energizes the second main valve operator
25. ermining that the limit control acts to shut off the main burner gas 14 Applicable only to boilers a Determine that the circulating water pumps are in operating condition b Test low water cutoffs automatic feed con trols pressure and temperature limit controls and relief valves in accordance with the manufacturer s recommendations and in structions to determine they are in operating condition EXHIBIT B PROCEDURE FOR INSTALLING AUTOMATIC INTERMITTENT PILOT SYSTEMS Prior to beginning this procedure a preliminary examination of the appliance and the automatic inter mittent pilot system should be made to determine that the automatic intermittent pilot system can be properly applied to the appliance This procedure is intended as a guide to aid in safely installing a listed automatic intermittent pilot system on an existing listed appliance equipped with an atmos pheric gas burner s and not of the direct vent type This procedure is based on the assumption that the history of the specific installation has been one of safe and satisfactory operation This procedure is predicated on central furnace and boiler installations and it should be recognized that generalized procedures cannot anticipate all situations Accordingly in some cases deviation from this proce dure may be necessary to determine safe operation of the equipment Thefollowing steps should be followed in makingthe modifications 1 Perform a sa
26. fety inspection of the existing appli ance installation See Exhibit A for a recommended procedure for such a safety inspection 2 Shut off all gas and electricity to the appliance To shut off gas use the shutoff valve in the supply line to the appliance If a manual gas valve is not in the g supply line within 6 feet of the appliance in an acessible location one shall be installed Do not use the instructions 4 Turn on all gas and electricity to the 5 Determine that the appli adequate capacity by followi low draw as computed e the total VA volt curre to deters volt ampere required is greater ating of the transformer the trans EXHIBIT B OF ANSI STANDARD Z21 71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD INSTALLATION 23 6 Check the heat antiicipator in the comfort thermo stat to determine if it is properly adjusted to the current draw of the control system Follow the thermostat manufacturer s instructions 7 certain wiring connections are tight and wires are positioned and secured so they will not be able to contact high temperature locations 8 Conduct a Gas Leakage Test of the appliance piping and control system downs of the shutoff adjust the pres p as many times as is necessary to at the automatic intermittent pilot ating properly e pilot safety device 1 to determine if it is properly and 2 for turndown characteristics accoMAng t
27. g 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 envi ronment In these applications special steps may be required to prevent nuisance shutdowns and premature control failure These applications require Honeywell Resi dential and Building Controls Engineering review contact your Honeywell Sales Representative for assistance FREQUENT CYCLING These controls are designed for use on space heating appliances that typically cycle 3 to 4 times an hour during the heating season and not at all during the cooling season In applications with significantly greater cycling rates andlongerheating seasons we recommend monthly checkout because the controls may wear out more quickly WATER OR STEAM CLEANING Once a module or gas control has been wet it may operate unreliably and must be replaced If the appliance will be cleaned with water or steam the controls and associated wiring should be covered so water or steam flow cannot reach them The controls should be high enough above the cabinet bottom so flooding or splashing water will not reach them during normal cleaning proce dures If necessary shield the controls to prote from splashing water A NEMA 4 enclosure is mended for the ignition module see the Ele
28. me Make sure it is blue steady and envelops 3 8 to 1 2 in 10 to 13 mm of the flame rod See Fig 20 for possible flame problems and their causes f 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 AHC LEN 68 0102 2 j Recheck ignition sequence as follows if main burner doesn t light or if main burner lights but Reconnect main valve wire system locks out check module ground wire and Set thermostat to for heat gas control as described in the troubleshooting Watch ignition sequence at burner chart Fig 19 If spark still doesn t stop after pilot lights replace ignition module START NOTE Before troubleshooting familiarize yourself with the startup and checkout procedure TURN GAS SUPPLY OFF TURN THERMOSTAT CONTROLLER TO CALL FOR HEAT POWER TO MODULE 24V NOMINAL YES SPARK ACROSS IGNITER SENSOR GAP YES On models with vent damper plug has not been installed then remo if necessary On other models replace Pull ignition lead and check spark at module Check boot of the ignition cable for signs of melting o
29. mperature and other conditions should match those listed in Specifications We recommend mounting the module with the termi nals down so the terminals are protected from dripping water and dust It can also be mounted with the terminals on either side Do not mount the module with the terminals pointing up Refer to Fig 13 for mounting recommenda tions Fasten securely with four No 6 32 machine screws or No 8 sheetmetal screws of appropriate length 68 0102 2 MOUNT THE S8610 IN ANY OF THESE POSITIONS DO MOUNT THE 8610 lt WIRING THE 5 5 9 CA TION ore making wiring rical shock or equip of the ignition cable to the male quick conne AK terminal on the 8610 Module 2 Connect the other ignition cable end to the 392431 igniter Sensor Connect the Vent Damper The D80D Vent Damper can be used with all ignition modules although the Molex plug provided on some modules simplifies wiring connections when used with the D80D Plug in Vent Damper Once a module with a vent damper plug has powered a vent damper circuit it cannot be used in a gas system without a vent damper A replace able fuse in the module blows on initial power up Once this TERMINALS FACING DOWN LU KL Ja gt MOUNTING RECOMMENDATIONS 10 TERMINGSS FACING RIGHT ata a s Da a a a Sa S S a dna TERMINALST x v G UP
30. n burner operating checkthe gas control flow rate using the meter clocking method or check the gas pressure using a manometer connected to the gas control outlet pressure tap Refer to Figs 3 or 4 3 If necessary adjust the pressure regulator to match the appliance rating Gas control outlet pressure is normally set at 3 5 inches wc 0 9 kPa nominal for natural gas It can be adjusted from 3 to 5 inches wc 0 74 to 1 2 kPa Gas control outlet pressure is normally set at 10 inches wc 2 5 kPa nominal for LP gas It can be adjusted from 8 to 12 inches wc 2 to 3 kPa a Remove the pressure regulator adjustment cap and Screw b Using a screwdriver turn the inner adjustment screw clockwise m to increase or counterclockwise to decrease the main burner gas pressure c Always replace the cap screw and tighten firmly to ensure proper operation 4 f the desired outlet gas pressure or gas flow rate cannot be achieved by adjusting the gas control checkthe gas control inlet pressure using a manometer at the inlet pressure tap If the inlet pressure is in the normal range replace the gas control Otherwise take the necessary steps to provide proper gas pressure to the gas control STEP 6 Adjust Pilot Flame The pilot flame should envelop 3 8 to millimeters of the ground rod and tip oj Refer to Fig 17 To adjust the pilot f 1 Remove the pilot adjustment Figs 3 or 4 JIGNITER SENSOR TIP IN PILOT FLAME
31. ny appliance and do not touch any electrical switch or telephone in the building until no spilled gas remains 2 Perform the Gas Leak Test after initial Installa tion and any time work is done to the gas piping STEP 1 Perform a Visual Inspection With the power off ensure all wiring conneg clean and tight Turn off all power to appliances and igni Open manual shutoff valves in the ge appliance Perform Gas Leak Test ine to the ect pstream ofthe gas control ter sol tion Bubbles indicate a gas ected tighten the pipe connection e lighting main burner to prevent injury idden gas leaks which could cause flashback in ie appliance vestibule Light the main burner 4 With the main burner in operation paint all pipe joints including adapters and gas control inlet and outlet with rich soap and water solution 5 if another gas leak is detected tighten adapter Screws joints and pipe connections 6 Replace the part if gas leak can not be stopped STEP 2 Review Normal Operating Sequence and Module Specifications 14 e See OPERATION page 16 and SPECIFICA TIONS page 2 STEP 3 Reset the Module Turn the thermostat to its lowest setting Wait one minute As you perform Steps 4 through 9 wat operation deviates from normal Ref Chart to correct problem points where roubleshooting CAUTION exceed the input rating stamped on the ance
32. o the manufacturer s installation instruc tions No adjustments should be made other than those ecommended by the system manufacturer 13 Sequence the appliance through at least three operating cycles 14 Applicable only to furnaces Check both the limit controller and the fan controller for proper operation Limit control operation can be checked by blocking the circulating air inlet or temporarily disconnecting the electrical supply to the blower motor and determining that the limit controller acts to shut off the main burner gas 15 Applicable only to boilers a Determine that the circulating water pumps are in operating condition b Test low water cutoffs automatic feed water controls pressure and temperature limit con trollers and relief valves in accordance with the manufacturer s recommendation to deter mine they are in operating condition 16 Add the labels see 1 6 1 n and on the appli ance 68 0102 2
33. r b boot from excessive temperatures TURN GAS SUPPLY ON Check that all manual gas valves are open supply tubing anc PILOT BURNER LIGHTS is not blocked Check electrical connections between YES Check for 24 Vac across PV MV PV te replace module Gm 4 b d NOTE S8610H gc to lockout rese SPARK STOPS WHEN Check continuity of cable and grounc PILOT IS LIT Clean flame rod YES steady and blue terminals If no voltage replace module MAIN BURNER LIGHTS yo gt ections between module and gas control If okay replace gas control or gas control YES PN q _ on Esca gy S8610H goes into lockout reset system D 7 Check continuity of ignition cable and ground wire Y 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 if checks are okay replace module CALL FOR HEAT ENDS f Check for proper thermostat controller operation SYSTEM SHUTS OFF Remove MV lead at module if valve closes recheck temperature controller and wiring not replace gas control YES TROUBLESHOOTING P ENDS Repeat procedure until troublefree operation is obtained TTA FIG 19 58610 TROUBLESHOOTING GUIDE 18 Adjust Pilot Flame Current The pilot flame current must measure at least 1A and ste
34. rmittent Pilot Ignition Systems for Field Installation e Fornatural gas applications only Ignition trial continues until either the pilot lights or the system manually shuts down S8610F Intermittent Pilot Module Available with or without vent damper plug specify when ordering VR8204A or VR8440A or M Dual Valve Combination Gas Control specify when ordering Refer to Fig 1 for other components Y8610H Intermittent Pilot Retrofit Kit Allmodels meet ANSI 221 71 Automatic Intermittent Pilot Ignition Systems for Field Installation Car notiural i e For natural or LP gas applications 90 second maximum ignition trial 100 pg shutoff on loss of flame e 58610 Intermittent Pilot Module VR8204A or VR8440A or M Dual Valve Gas Control specify when ordering Refer to Fig 1 for other com 5 Between the module and gas control 30 inch 762 wiring harness with 1 4 inch quick connect terminals Between the module and the igniter sensor 30 inches 762 mm ignition cable with stud terminal and 1 4 inch quick connect terminal JRCHASING REPLACEMENT AND MODERNIZATION PRODUCTS R OR YOUR DISTRIBUTOR REFER TO THE TRADELINE CATALOG LETE ORDERING NUMBER OR SPECIFY FOR ORDERI FROM YOUE OR PRICE 4 Gas control inlet and outlet size 5 Vent damper plug on module if desired YOU HAVE AL RODUCTS OR TIONAL QUESTIONS NEED FURTHER INFORMATION OR WANT TO COMMENT ON OUR RVIC
35. wing troubleshooting perform the chec cedure page 14 again to be sure system is op normally IGNITION SYSTEM CHECKS STEP 1 Check ignition cable Make sure Ignition cable does not run in co surfaces LJ Connections to the ig igniter sensor are clea L Ignition cable provid by the pilot burner odule and the pilot burner 0 metal contact between the 6 the main burner f lead from the GND BURNER the module to the pilot burner Make sure s are clean and tight If the wire is dam deteriorated replace it with No 14 18 oisture resistant thermoplastic insulated h 105 C 221 F minimum rating eck the ceramic flame rod insulator for cracks or evidence of exposure to extreme heat which can permit leakage to ground Heplace pilot burner igniter sensor and provide shield if necessary f flame rod or bracket are 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 1 Close the manual gas valve Disconnect the ignition cable at the SPARK terminal on the module 17 When performing the following steps do not touch stripped end of jumper or SPARK terminal The ignition circuit generates over 10 000 volts and electrical shock can result rimmediately touch one end of termi on the module Move nper y toward the SPARK shed V from thaf
36. y with approved standards and practices 1 Use new properly reamed pipe free from chips f tubing is used ensure that ends are square deburred and clean All tubing bends must be smooth and without deformation 2 Run new pipe or tubing to the gas control If tubing is used obtain a tube to pipe coupling to connect tubing to BRACKET PILOT BURNER IGNITER SENSOR GROUND ROO CLIP id gas control TUBING 11 0728 3 Install a sediment trap in the gas supply line Refer to FIG 9 FASTEN IGNITER SENSOR TO GROUND Fig 10 ROD PIPED GAS SUPPLY DR HORIZONTAL 3 76 mm MINIMUM 3 in 76 mm MINIMUM 3 in 76 mm MINIMUM AN ALL BENDS IN METALLIC TUBING SHOULD BE SMOOTH A CAUTION SHUT OFF THE MAIN GAS SUPPLY BEFORE REMOVING END CAP TO PREVENT GAS FROM FILLING THE WORK AREA TEST FOR GAS LEAK AGE WHEN INSTALLATION IS COMPLETE MOUNT GAS CONTROL 1 The gas control can be mounted grees in any direction from the upright control knob including vertically 2 Mount the gas control so gas flow is as the arrow on the gas controldsettom 3 Thread the pipe as li 1 ed in Table 1 trol second NOTE Do not thread morg If pipe is inserted too 7 gas main valve or safety vam ay distort TABLE 1 T
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