Honeywell Hot Surface Control - cyb
Contents
1. MAKE SURE L1 AND L2 ARE NOT REVERSED A THIS WOULD PREVENT FLAME DETECTION FACTORY TEST TERMINAL DO NOT USE ALTERNATE LIMIT CONTROLLER LOCATION A LEADWIRE MODEL IS COLOR CODED AS SHOWN A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER FIG 3 S89D H AND S890D H IN AN ATMOSPHERIC BURNER HEATING SYSTEM DUAL VALVE COMBINATION S89C G J S890C G J HOT SURFACE GAS CONTROL IGNITION CONTROL HOT S E SURFACE D80D VENT IGNITER DAMPER SENSOR WIRING ee HARNESS VENT DAMPER PLUG BURNER LIMIT GROUND CONTROLLER THERMOSTAT OR CONTROLLER A POWER SUPPLY PROVIDE DISCONNECT MEANS A REMOVE PLUG ONLY IF USING VENT DAMPER FUSE BLOWS ON AND PROTECTION AS REQUIRED STARTUP WHEN PLUG IS REMOVED THEN MODULE WILL A ALTERNATE LIMIT CONTROLLER LOCATION OPERATE ONLY WHEN VENT DAMPER IS CONNECTED A FACTORY TEST TERMINAL DO NOT USE N LEADWIRE MODEL IS COLOR CODED AS SHOWN M2191 A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER FIG 4 589 G J AND S890C G J IN AN ATMOSPHERIC BURNER HEATING SYSTEM WITH THE 0800 VENT DAMPER 7 68 0070 1 THERMOSTAT DUAL VALVE OR COMBINATION 89C_G J S890C G J HOT CONTROLLER GAS CONTROL SURFACE IGNITION CONTROL HOT SURFACE IGNITER SENSOR GND BURNER VENT DAMPER PLUG BURNER LIMIT GROUND CONTROLLER CONTROLLER J w man maa mag L1 C R mm om vi HOT AN L2 air TRANSFORMER POWER SUPPLY2. 1 Hot surface ignition systems are used on a wide variety of central heating equipment and on heating appliances such as agricultural equipment industrial heating equip ment and pool heaters Some of these applications may make heavy demands on the controls either because of frequent cycling or because of moisture corrosive chemi cals dust or excessive heat in the environment In these situations special steps may be required to prevent nui sance shutdowns and premature control failure These applications require Honeywell Residential Division Engi neering review contact your Honeywell Sales Represen tative 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 an application with significantly greater cycling rates and closer to year round use we recommend monthly checkout because the controls may wear out more quickly WATER OR STEAM CLEANING Once a module or gas control has been wet it may operate unreliably and must be replaced If the appliance is likely to 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 bottom of the cabinet so they will not be subject to flooding or splashing during normal cleaning procedures If necessary shield the cont
3. BE RESET M ttOA FIG 12 589 5890 NORMAL OPERATING SEQUENCE 68 0070 1 IMPORTANT 1 The following service procedures are provided as a general guide Follow appliance manufac turer s service instructions if available 2 All meter readings must be taken within the trial for ignition period Once the ignition period ends the system must be reset by setting the thermo stat down for at least 45 sec before continuing 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 mal functions it must be replaced 5 Only trained experienced service technicians should service direct ignition systems Perform the checkout steps on page 11 as the first step in troubleshooting Then check the troubleshooting guide Fig 13 and the schematic diagram Fig 14 to pinpoint the cause of the problem Following troubleshooting perform the checkout pro cedure page 11 again to be sure system is operating normally IGNITION SYSTEM CHECKS STEP 1 Check igniter wire harness Make sure Ignition wire does not touch any metal surface Connections to the module and the igniter sensor are clean and tight C Ignition wire provides good electrical continuity STEP 2 Check ignition system grounding Nuisance shutdowns are often caused by a poor or erratic ground L A common ground is required
4. fan assisted combustion system or an LP gas system and that the vent damper plug must not be removed except to connect a D80D with the plug in cable S89D H S890D H with separate igniter and sensor can be substituted inthese hookups by simply connecting the sensor as shown in Fig 3 2 Refer to heating appliance manufacturer s instruc tions for wiring auxiliary controls 3 Adjust thermostat heat anticipator to match system current draw The current draw equals the total current required for the ignition module 0 2 A plus the gas control and any other auxiliary equipment in the control circuit Connect Gas Control Use No 18 gauge solid or stranded wire Use 3 16 in female quick connects for module connections Connectto gas control terminals as shown in wiring diagrams using terminals appropriate to the gas control Ground Control System The igniter flame sensor and ignition module must share acommon ground with the main burner Use thermo plastic insulated wire with a minimum rating of 105 C 221 F for the ground wire asbestos insulation is not ac ceptable If necessary use a shield to protect the wire from radiant heat generated by the burner Connect the ground wire as follows 1 Fit one end of the ground wire with a female 3 16 in 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
5. 2 sec max with a 2 5 flame signal FLAME CURRENT 0 8 pA DC min TERMINALS 1 4 in male quick connects for line voltage and sensor connections 3 16 in male quick connects for all low voltage connections Terminal options spec ify when ordering Molex plug for connection to D80D Vent Damper 10 in 250 mm min color coded leadwires for all line voltage connections MOUNTING Mounts in any position Fasten with No 6 32 machine or No 8 sheetmetal screws 1 in long DIMENSIONS See Fig 1 UNDERWRITERS LABORATORIES INC COMPONENT RECOGNIZED FILE NO MP268 Guide No MCCZ2 CANADIAN GAS ASSOCIATION CERTIFIED 1029 ABI 6218 AMERICAN GAS ASSOCIATION CERTIFIED 20 20B1 OTHER SYSTEM CONTROLS The S89 and 890 provide operating control of a direct ignition system using a hot surface igniter Additional components required to complete the system must be ordered separately They include DUAL VALVE COMBINATION GAS CONTROL Any di rect ignition gas control with 2 0 max main valve A MOLEX PLUG AND TH W TERMINAL ON VENT DAMPER MODELS ONLY AX SENSE TERMINAL ON D AND H MODELS ONLY LEADWIRE MODELS HAVE 4 LEADWIRES IN PLACE OF LINE VOLTAGE TERMINALS rating VR8205 VR845 VR854 VR8450 or VR8540 recommended HOT SURFACE IGNITER OR IGNITER SENSOR Nor ton Model 201 or 271 or equivalent NOTE If igniter other than Norton Model 201 or 271 is used the igniter must meet the following minimum specifi
6. 0 75 sec If lightoff is successful the burner operation phase begins BURNER OPERATION When flame is detected a flame rectification circuit is completed between the sensor and burner ground The flame sensing circuit in the module detects the flame current and holds the safety lockout timer in the reset normal operation condition When the callfor heat ends the module and gas contro are de energized The gas control closes stopping gas flow to the burner SAFETY SHUTDOWN The S89 and S890 provide 100 percent shutoff or safety lockout on ignition failure or loss of established flame C D and J models of the 89 and S890 lock out after one trial for ignition G and H models lock out after three trials for ignition One Trial for Ignition Modules If no flame is sensed by the end of the timed trial for ignition the gas control closes and the module locks out It mustbe manually reset by removing power or setting the thermostat below room temperature for at least 45 sec onds If the burner lights normally but goes out during the run cycle the gas control closes and the module initiates a warmup period followed by one trial for ignition If flame is not established the gas control closes and the module locks out requiring manual reset Three Trial for Ignition Modules If no flame is sensed by the end of the first timed trial for ignition the gas control closes and the module initiates a second 30 sec minimum purge cyc
7. 12 and SPECIFICATIONS page 2 STEP 3 Reset the Module C Turn the thermostat to its lowest setting O Wait one minute As you do Steps 4 and 5 watch for points where operation deviates from normal Refer to Troubleshooting Chart Fig 13 to correct problem STEP 4 Check Safety Lockout Operation C Turn gas supply off Set thermostat or controller above room temperature to call for heat L Watch for igniter warmup either immediately or follow ing prepurge See SPECIFICATIONS page 2 Time the length of time gas control stays open The time should not exceed the following 4 sec model 5 5 sec 6 sec model 7 5 sec 11 sec model 15 0 sec 15 sec model 22 0 sec C Three try for ignition modules only S89G H S890G H Watch for start of 30 sec min purge followed by 34 sec nom igniter warmup and second try for ignition After a third purge warmup and trial for ignition sequence these modules lock out 0 Open manual gas control knob and make sure no gas is flowing to burner 68 0070 1 C Set thermostat below room temperature and wait one minute before continuing STEP 5 Check Normal Operation I Setthermostat or controller above room temperature to call for heat 1 Make sure burner lights smoothly without flashback 1 Make sure burner operates smoothly without floating lifting or flame rollout to the furnace vestibule or heat buildup in the vestibule 3 If gas line has been disturb
8. 5890 IF VALVE CLOSES RECHECK TEMPERATURE CONTROLLER AND WIRING IF NOT REPLACE GAS CONTROL REPEAT PROCEDURE UNTIL TROUBLEFREE OPERATION IS OBTAINED M2198 FIG 13 S89 S890 TROUBLESHOOTING SEQUENCE 15 68 0070 1 LIMIT ON OFF SWITCH E A EEA A N AN lt 4 HOTSURFACE 24V t 4 IGNITER RELAY TRANSFORMER ma m ung pm GS Tor o SURFACE Loker 4 IGNITER 2 ALTERNATE a LIMIT OR CONTROLLER HE 4a Ima E PREPURGE DUAL SENSOR TIMING NE CIRCUIT CIRCUIT VALVE GAS CONTROL 2 AMP MAX INTERNAL WIRING ono A POWER SUPPLY PROVIDE DISCONNECT A SEN TERMINAL REPLACES CONNECTION MEANS AND OVERLOAD PROTECTION AS BETWEEN HSI TERMINAL AND SENSOR CIRCUIT _ _ _ EXTERNAL BURNER REQUIRED ON MODELS WITH SEPARATE IGNITER AND SENSOR WIRING I M2199 FIG 14 S89 S890 SIMPLIFIED SCHEMATIC 1885 Douglas Drive N Australia Canada Finland France Germany Japan Mexico Netherlands Honeywell Inc International Sales Offices in all principal cities of the world Manufacturing in Golden Valley MN 55422 4386 Spain Taiwan United Kingdom U S A Q PRINTED IN U S A QUALITY IS KEY
9. module and the gas control that will limit environmental contamination A NEMA 4 enclosure is recommended forthe ignition module see the Electronic Ignition Service Manual form 70 6604 HEAT The controls can be damaged by excessively high tem peratures Make sure the maximum ambient temperature at the control locations will not exceed the rating of the control the appliance normally operates at very high temperatures insulation shielding and air circulation may be necessary to protect the controls Proper insulation or shielding should be provided by the appliance manufac turer make sure adequate air circulation is maintained when the appliance is installed WHEN INSTALLING THIS IGNITION SYSTEM 1 Read these instructions carefully Failure to follow them could damage the components or cause ahazardous condition 2 Check the ratings given in the instructions and on the components to make sure they are suitable for your application 3 Installer must be atrained experienced service tech nician 4 After installation is complete check out component operation as provided in these instructions ARD CAN CAUSE SERIOUS INJURY OR DEATH 1 The ignition module can malfunction If it gets wet leading to accumulation of explosive gas Never install where water can flood drip or condense on module Never try to use a module that has been wet replace it 2 Liquefied petroleum LP gas is heavier than air an
10. 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 good metal to metal contact between the burner and ground run a lead from the burner to ground 89C G J S890C G J HOT SURFACE IGNITION CONTROL z HOT EACK SURFACE BLUE IGNITER l SENSOR M GND BURNER VENT DAMPER PLUGA L BURNER GROUND THERMOSTAT OR CONTROLLER POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED MAKE SURE L1 AND L2 ARE NOT REVERSED THIS WOULD PREVENT FLAME DETECTION N ALTERNATE LIMIT CONTROLLER LOCATION LIMIT CONTROLLER CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TRANSFORMER FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG JUMPER TH W AND 24V TERMINALS DO NOT REMOVE VENT DAMPER PLUG A FACTORY TEST TERMINAL DO NOT USE N LEADWIRE MODEL IS COLOR CODED AS SHOWN FIG 2 S89C G J AND S890C G J IN AN ATMOSPHERIC BURNER HEATING SYSTEM DUAL VALVE COMBINATION 89D H S890D H HOT SURFACE GAS CONTROL IGNITION CONTROL HOT SURFACE IGNITER GND BURNER VENT DAMPER PLUG FLAME SENSOR BURNER LIMIT GROUND CONTROLLER E THERMOSTAT OR CONTROLLER POWER SUPPLY PROVIDE DISCONNECT MEANS A FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG AND OVERLOAD PROTECTION AS REQUIRED JUMPER TH W AND 24V TERMINALS DO NOT REMOVE VENT DAMPER PLUG
11. prepurge the 890 energizes the igniter to start the igniter warmup IGNITER WARMUP Following prepurge timing S890 or call for heat from the thermostat S89 the module energizes the hot sur face igniter for a 34 sec nominal warmup period during which the gas control is closed TRIAL FOR IGNITION Following the warmup period the gas control opens for a timed trial for ignition allowing gas flow to the main burner Nearthe end of thetrialfor ignition period the igniter shuts off to allowthe rectification sensorto sense presence 12 CHECK BURNER FLAME CONDITION 6 CHECK FOR HIGH GAS PRESSURE EXCESS PRIMARY AIR OR DRAFT BURNER CHECK FOR POOR DRAFT EXCESS DRAFT HIGH VELOCITY OR SECONDARY AIR INSTALL SHIELD IF NECESSARY ZA WAVING FLAME NN GN P i SMALL BLUE FLAME CHECK FOR CLOGGED PORTS OR ORIFICE FILTER WRONG SIZE ORIFICE LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM DIRTY PRIMARY AiR OPENING LARGE PORTS OR ORIFICES GOOD RECTIFYING FLAME 3 4 TO TIN 19 TO 25 mm 11 5588 of flame On modules with specified Ignition Activation Period IAP timing the igniter is on for 2 or 4 sec maxi mum depending on model On other modules the igniter shuts off about 1 sec prior to lockout On all modules the flame sense time which is the time that the gas control is still open between igniter shutoff and lockout is at least
12. ASSISTED COMBUSTION HEATING CENTRAL COOLING SYSTEM A OPTIONAL LIMIT CONTROLLER LOCATION 9 68 0070 1 L8148J DUAL VALVE COMBINATION GAS CONTROL i V CIRCULATOR MOTOR S89C J S890C J HOT SURFACE IGNITION CONTROL 1K1 GND BURNER VENT DAMPER PLUG N A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED MAKE SURE L1 AND L2 ARE NOT REVERSED THIS WOULD PREVENT FLAME DETECTION A CONNECT COLORS OF WIRE AS SHOWN 2 A FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG JUMPER TH W AND 24V TERMINAL DO NOT REMOVE VENT DAMPER PLUG FACTORY TEST TERMINAL DO NOT USE AX LEADWIRE MODEL IS COLOR CODED AS SHOWN LEAVE TP Z AND Z W JUMPERS IN PLACE HOT SURFACE IGNITER SENSOR M2196 FIG 9 S89C J AND S890C J IN A HYDRONIC HEATING SYSTEM WITH ATMOSPHERIC BURNER DUAL VALVE COMBINATION GAS CONTROL L BURNER 7 GROUND S89C G J S890C G J HOT SURFACE IGNITION CONTROL HOT SURFACE IGNITER SENSOR CONTROLLER POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED MAKE SURE L1 AND L2 ARE NOT REVERSED THIS WOULD PREVENT FLAME DETECTION ECO SWITCH SHUTS DOWN SYSTEM IF TANK TEMPERATURE EXCEEDS 210 F 99 C CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER A FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG JUMPER TH W AND 24V TERMINALS DO NOT REMOVE VENT DAMPER PLUG A FACTORY TEST TERMINAL DO NO
13. GLAS DRIVE MPL5 MN 55422 S89G HOT SURFACE IGNITION THREE TRIALS FOR IGNITION d MORE 20 BJ RTER LE EKA EYAL ENT E 26 TEM COCKS BIT IEMOVE PONER FOR 4 SEK AMO RESET Expiosion hazard Can cause serious injury or death Replace with unit This device can naving Same safety maitunction d it gets wet lockout time See Never try to use a stamp on end of unit device that has been 97 4177 ev wet replace IMPORTANT THE SPECIFICATIONS GIVEN IN THIS PUBLICATION DO NOT INCLUDE NORMAL MANUFACTURING TOL ERANCES THEREFORE THIS UNIT MAY NOT MATCH THE LISTED SPECIFICATIONS EXACTLY ALSO THIS PRODUCT IS TESTED AND CALIBRATED UNDER CLOSELY CONTROLLED CONDITIONS AND SOME MINOR DIFFERENCES IN PERFORMANCE CAN BE EXPECTED IF THOSE CONDITIONS ARE CHANGED MODELS See Table 1 TABLE 1 HOT SURFACE IGNITION MODULES NO IGNITER IGNITION IGNITION SENSOR LOCKOUT ACTIVATION PREPURGE MODEL TRIALS TYPE TIMING PERIOD TIMING S89C Loud 4 6 11 or 15 sec Not None nom as ordered special S89D IAP model S8G 3 Combination seod 3 Separate S89J af Geben eem a S890C pv qa 4 6 11 or 15 sec Not 30 sec min nom as ordered special S890D E IAP model S890G Combination S890H 5890 Combination 4 sec nom 2sec max 6 sec nom 4 sec max gnition activation period IAP is the time both the igniter and the gas control are powered following warmup T
14. Honeywell THE S89 AND S890 PROVIDE OPERATING CON TROL AND SYSTEM SHUTDOWN ON LOSS OF MAIN BURNER FLAME IN DIRECT IGNITION CENTRAL HEAT FURNACES AND HEATING APPLIANCES WITH HOT SURFACE IGNITER 89C G J and S890C G J are for systems with a combination igniter sensor C 890D H and S890D H are for systems with separate igniter and sensor S89C D J and S890C D J lock out after one try for ignition S89G H and S890G H provide three tries for ignition before lockout with 30 sec min purge before second and third tries LJ S89J and S890J provide 2 or 4 sec depending on model max ignition activation periods C S890 provides 30 sec min prepurge on initial trial for ignition C Compatible with Norton 201 and 271 or equivalent hot surface igniters S89D H and S890D H require a separate sensor mounted on burner Q354 recommended C Available with leadwires for line voltage connections O Available with Molex plug for connecting 0800 Vent Damper Modules can be used on either natural or LP gas they provide 100 percent shutoff of gas on lockout O Modules have relay contacts for use with any direct ignition gas control with max 2 0 A 24 Vac rating Modules use rectification principle for flame sensing L Minus 40 F to 175 F minus 40 C to 79 C temperature rating J A Form Number 68 0070 1 Rev 9 89 O Honeywell Inc 1989 HOT SURFACE IGNITION MODULES Honeywell 1665 OQU
15. ITION CONTROL COMBINATION GAS CONTROL STAGE 1 STAGE 2 ALVE ic 4 HOT SURFACE IGNITER SENSOR AIR PROVEN GND BURNER SWITCH VENT 3 DAMPER PLUG THERMOSTAT SY LIMIT CONTROLLER 4 1 L1 M d UN YS HOT N I D o HOT A COMBUSTION COMBUSTION AIR BLOWER AIR BLOWER MOTOR RELAY POWER SUPPLY PROVIDE DISCONNECT MEANS A FOR MODULE WITH TH W TERMINAL AND VENT DAMPER AND OVERLOAD PROTECTION AS REQUIRED PLUG JUMPER TH W AND 24V TERMINALS DO NOT A ALTERNATE LIMIT CONTROLLER LOCATION REMOVE VENT DAMPER PLUG A FACTORY TEST TERMINAL DO NOT USE A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER A LEADWIRE MODEL IS COLOR CODED AS SHOWN FIG 7 S89C G J AND S890C G J IN A TWO STAGE FAN ASSISTED COMBUSTION HEATING SYSTEM A THERMOSTAT 2 L1 L HOT LIMIT ONTROLLER DUAL VALVE R8239 COMBUSTION COMBINATION S89G J S890G J HOT SURFACE FAN CENTER AIR GAS CONTROL IGNITION CONTROL HOT SURFACE IGNITER SENSOR PROVING SWITCH J BURNER GROUND f X FAN MOTOR N POWER SUPPLY PROVIDE DISCONNECT MEANS N FOR MODULE WITH TH W TERMINAL AND VENT AND OVERLOAD PROTECTION AS REQUIRED DAMPER PLUG JUMPER TH W AND 24V TERMINALS DO NOT REMOVE VENT DAMPER PLUG A FACTORY TEST TERMINAL DO NOT USE A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GORUND LEG TO TRANSFORMER A LEADWIRE MODEL IS COLOR CODED AS SHOWN FIG 8 S89C G H AND S890C G H IN A FAN
16. PROVIDE DISCONNECT MEANS A FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG AND OVERLOAD PROTECTION AS REQUIRED JUMPER TH W AND 24V TERMINALS DO NOT REMOVE VENT DAMPER PLUG A ALTERNATE LIMIT CONTROLLER LOCATION A FACTORY TEST TERMINAL DO NOT USE A CONTROLS IN 24V CIRCUIT MUST NOT BE IN A LEADWIRE MODEL IS COLOR CODED AS SHOWN GROUND LEG TO TRANSFORMER CONNECT COLORS OF WIRE AS SHOWN FIG 5 S89C G J AND S890C G JIN AN ATMOSPHERIC BURNER HEATING SYSTEM WITH D80B VENT DAMPER DUAL VALVE COMBINATION S89C G J S890C G J HOT GAS CONTROL SURFACE IGNITION CONTROL HOT SURFACE IGNITER SENSOR AIR PROVING SWITCH L BURNER LIMIT GROUND CONTROLLER ALi A lt 4 12 COMBUSTION COMBUSTION AIR BLOWER AIR BLOWER THERMOSTAT MOTOR RELAY OR CONTROLLER A POWER SUPPLY PROVIDE DISCONNECT MEANS A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND AND OVERLOAD PROTECTION AS REQUIRED LEG TO TRANSFORMER MAKE SURE L1 AND L2 ARE NOT REVERSED THIS WOULD PREVENT FLAME DETECTION A ALTERNATE LIMIT CONTROLLER LOCATION FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG JUMPER TH W AND 24V TERMINALS DO NOT REMOVE VENT DAMPER PLUG A FACTORY TEST TERMINAL DO NOT USE A POWER SUPPLY PROVIDE DISCONNECT MEANS A LEADWIRE MODEL IS COLOR CODED AS SHOWN AND OVERLOAD PROTECTION AS REQUIRED FIG 6 S89C G J AND S890C G J IN A FAN ASSISTED COMBUSTION HEATING SYSTEM 89C G J S890C G J HOT SURFACE IGN
17. ROCEDURE NS CHECK LINE VOLTAGE POWER CHECK LOW VOLTAGE TRANSFORMER CHECK LIMIT CONTROLLER CHECK AIR PROVING SWITCH IF USED CHECK THERMOSTAT CHECK WIRING NO CHECK THAT CONTROL IS S890 TYPE CHECK AIR PROVING SWITCH REPLACE S890 NO NO CHECK FOR 120 VAC CHECK AND CORRECT WIRING AT L1 L2 ON 59015890 FUSE OR CIRCUIT BREAKER YES CHECK FOR 120 VAC NO REPLACE ACROSS HSI TERMINALS 89 5890 YES CHECK WIRES TO IGNITER IF OK REPLACE IGNITER NO CHECK FOR 24 VAC ACROSS VALVE TERMINALS ON S89 S890 DURING TRIAL FOR IGNITION TIMING IF NO VOLTAGE REPLACE 589 5890 CHECK IGNITER POSITION CHECK ELECTRICAL CONNECTIONS BETWEEN 589 5890 AND GAS CONTROL IF OKAY REPLACE GAS CONTROL NO CHECK CONTINUITY OF GROUND WIRE MAKE SURE L1 AND L2 ARE NOT REVERSED THIS WOULD PREVENT FLAME DETECTION CHECK THAT BURNER FLAME COVERS IGNITER SENSOR OR SENSOR CHECK INSULATION ON IGNITER SENSOR LEADS C G AND J MODELS CHECK INSULATION ON SENSOR LEADS AND CHECK SENSOR POSITION D AND H MODELS IF CHECKS ARE OKAY REPLACE 89 890 MODULE NO CHECK CONTINUITY OF GROUND WIRE NOTE IF GROUND IS POOR OR ERATIC SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT CHECK FOR EXCESSIVE HEAT AT IGNITER CERAMIC BASE TEMPERATURE ABOVE 1000 F 538 C CAUSES SHORTS TO GROUND IF CHECKS ARE OKAY REPLACE 89 S890 MODULE NO CHECK FOR PROPER TEMPERATURE CONTROLLER OPERATION REMOVE VALVE LEAD AT 89
18. T USE A LEADWIRE MODEL IS COLOR CODED AS SHOWN FIG 10 S89C G J AND S890C G J IN A COMMERCIAL WATER HEATING SYSTEM CHECKOUT Check out the control system At initial installation of the appliance As part of regular maintenance procedures Mainte nance intervals are determined by the application See PLANNING THE INSTALLATION page 4 for more information As the first step in troubleshooting Any time work is done on the system FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH 1 If you smell gas or suspect a gas leak turn off gas at manual service valve and evacuate the house Do not try to light any appliance do not touch any electrical switch or telephone in the bullding until you are sure no spilled gas remains Gas leak test must be done as described in Steps 1 and 5 below on initlal installation and any time work is done involving the gas pip ing STEP 1 Perform Visual Inspection With power off make sure all wiring connections are clean and tight O Turn on power to appliance and ignition module O Open manual shutoff valves in the gas line to the appliance D Do gas leak test upstream of gas control if piping has been disturbed GAS LEAK TEST Paint pipe joints with rich soap and water solution Bubbles indicate gas leak Tighten joints to stop leak STEP 2 Review Normal Operating Sequence Fig 12 and Module Specifications O See OPERATION page
19. cations required over the life of the igniter e igniter must reach 1000 C 18329 F within 34 seconds with 102 Vac applied Igniter must maintain at least 500M ohms insulation resistance between the igniter leadwires and the igniter mounting bracket Igniter must not develop an insulating layer on its surface over time which would prevent flame sensing Igniter surface area immersed in flame must not exceed 1 4 of the grounded area immersed in flame This would prevent flame sensing Igniter current draw at 132 Vac must not exceed 5 A SENSOR Separate sensor required for all S89D H and S890D H Honeywell Q354 recommended IGNITER WIRING Provide wiring harness to suit applica tion Leadwires No 18 AWG stranded copper with 105 C rated 1 16 in PVC insulation e Terminals Insulated 1 4 in female quick connects or solderless connectors to module depending on module and suitable connector to igniter TRANSFORMER Add current ratings of module gas control vent damper and any other components of the control system to determine transformer size require ment THERMOSTAT Compatible with any Honeywell 24 V thermostat and with competitive 24 V thermostats that are powered independently of the module HIGH LIMIT AND OTHER AUXILIARY CONTROLS As specified by the heating appliance manufacturer 1 N QC 5 j PP 61193 FIG 1 APPROXIMATE S89 S890 DIMENSIONS IN In mm IN BRACKETS 68 0070
20. d will not vent upward naturally e Donotoperate electric switches lights or appliances until you are sure the ap pliance area is free of gas CAUTION 1 Disconnect power supply before beginning wiring to prevent electrical shock or equipment damage 2 lf a new gas control is to be installed turn off gas supply before starting installation Conduct Gas Leak Test according to gas control manufac turer s instructions after the gas control is in stalled If module must be mounted near moisture or water provide suitable waterproof enclosure PERFORM PREINSTALLATION SAFETY INSPECTION If this is a replacement installation check the appliance and venting system carefully before installing new module If a condition which could result in unsafe operation is detected the appliance should be shut off and the owner advised of the unsafe condition Any potentially unsafe condition must be corrected before proceeding with the installation MAINTENANCE REQUIREMENTS IN SEVERE ENVI RONMENTS Regular preventive maintenance is important in any ap plication but especially so in agricultural and industrial applications because n many such applications the equipment operates 100 000 200 000 cycles per year Such heavy cy cling can wear outthe gas control inonetotwo years A normal forced air furnace for which the controls were originally intended typically operates less than 20 000 cycles per year e Exposure to water dir
21. ed complete gas leak test GAS LEAK TEST Paint gas control gasket edges and all pipe connections downstream of gas control with rich soap and water solution Bubbles indicate gas leaks Tighten joints and screws or replace componentto stop gas leak Turn thermostat or controller below room temperature Make sure flame goes out STEP 6 Check Burner Flame Condition The igniter sensor or sensor must be constantly im mersed in flame Check burner flame condition as shown in Fig 11 If necessary improve the flame condition or relocate the sensor to a place on the main burner where condition is better Do not relocate igniteror igniter sensor a hot surface igniter They provide operating control and 100 percent shutdown on ignition failure or loss of main burner flame in central heat furnaces and heating appli ances Module operation is in four phases prepurge S890 only igniter warmup trial for ignition and burner opera tion Modules offer either one or three trials for ignition Fig 12 shows the normal operating sequence PREPURGE When the S890 is used in a fan assisted combustion system the combustion air blower starts on a call for heat from the thermostat On proof of airflow the air proving switch closes and energizes the S890 When the S890 is used in an atmospheric system the call for heat energizes the module In either case the S890 first initiates a30 sec minimum delay to allow system prepurge After
22. faces A common ground is required for the 589 5890 and the main burner The 24 V GND terminal internally grounds one side of the transformer Any auxiliary controls or limits must not be in the grounded leg In addition the appliance should be earth grounded 4 Makesurethetransformer has adequate VA The ignition module requires at least 0 2 at 24 Vac Add the current draws of all other devices in the control circuit including the gas control and multiply by 24 to determine the total VA require ment of these components Add this total to 4 8 VA forthe ignition module The result isthe mini mum transformer VA rating Use a Class Il trans former if replacement is required 5 Checkthat L1 hot and L2 neutral are wired to the proper terminals If L1 and L2 are inter changed the 889 5890 will not detect the flame and will go into safety shutdown Connect igniter Prepare wiring harness See Igniter wiring page 3 1 On models with quick connects use insulated 1 4 in female quick connects to connect the wiring harness leads to the HSI terminals on the ignition module 2 On models with leadwires use solderless connectors to connect the wiring harness leads to the blue leads from the module 3 Connect the wiring harness to the igniter 68 0070 1 Connect Vent Damper The D80B Vent Damper can be used with all ignition modules although the Molex plug provided on some modules simplifies wiring connections when
23. for the module igniter flame sensor and main burner Check for good metal to metal contact between the igniter bracket and the main burner Check the ground lead from the GND BURNER terminal on the module to the igniter bracket Make sure connections are clean and tight If the wire is damaged or deteriorated replace it with No 14 18 gauge moisture resistant thermoplastic insulated wire with 105 C 2219 F minimum rating Use a 14 shield if necessary to protect the ground wire from radiant heat Check temperature at the igniter ceramic or flame sensor insulator Excessive temperature will permit leakage to ground Provide shield if tempera ture exceeds rating of igniter or sensor lf flame sensor or bracket is bent out of position restore to correct position Replace igniter and sensor or igniter sensor with identical unit if insulator is cracked STEP 3 Check flame sensing circuit O Make sure burner flame is capable of providing a good rectification signal See Fig 11 Make sure about 3 4 to 1 in of the flame sensor or igniter sensor is continuously immersed in the flame for best flame signal See Fig 11 Bend the bracket or flame sensor or relocate the sensor as necessary Do not relocate an igniter or combination igniter sensor D Check for excessive over 1000 F 538 C tempera ture at ceramic insulator on flame sensor Excessive temperature can cause short to ground move sensor to c
24. he gas control remains open 0 75 sec min after igniter turns off to allow flame sensing i continued on page 3 WHEN PURCHASING REPLACEMENT AND MODERNIZATION PRODUCTS FROM YOUR TRADELINE WHOLESALER OR YOUR DISTRIBUTOR REFER TO THE TRADELINE CATALOG OR PRICE SHEETS FOR COMPLETE ORDERING NUMBER OR SPECIFY 1 Order number 4 Molex plug for vent damper connection if required 2 Lockout timing 5 Other components as required 3 Leadwires if desired IF YOU HAVE ADDITIONAL QUESTIONS NEED FURTHER INFORMATION OR WOULD LIKE TO COMMENT ON OUR PRODUCTS OR SERVICES PLEASE WRITE OR PHONE 1 YOUR LOCAL HONEYWELL RESIDENTIAL SALES OFFICE CHECK WHITE PAGES OF YOUR PHONE DIRECTORY 2 RESIDENTIAL DIVISION CUSTOMER SERVICE HONEYWELL INC 1885 DOUGLAS DRIVE NORTH MINNEAPOLIS MINNESOTA 55422 4386 612 542 7500 IN CANADA HONEYWELL LIMITED HONEYWELL LIMITEE 740 ELLESMERE ROAD SCARBOROUGH ONTARIO M1P 2V9 INTERNATIONAL SALES AND SERVICE OFFICES IN ALL PRINCIPAL CITIES OF THE WORLD ELECTRICAL RATINGS Voltage and frequency 20 5 to 28 5 V 24 V nom 60 Hz Current rating 0 2 A Gas control contact ratings at 24 Vac 2 0 A running 20 0 A inrush IGNITER WARM UP PERIOD 34 sec nom THERMOSTAT ANTICIPATOR SETTING 0 2 A plus gas control current rating AMBIENT TEMPERATURE RATING Minus 40 F to 175 F minus 40 C to 79 C RELATIVE HUMIDITY RATING 5 to 90 percent at 95 F FLAME FAILURE RESPONSE TIME
25. le followed by warmup and a second trialfor ignition If flame is not established the purge warmup trial for ignition cycle is repeated a third time If flame is still not established following the third trial the gas control closes and the module locks out It must be manually reset by removing power or setting the thermo stat below room temperature for at least 45 sec If the burner goes out during the run cycle the gas control closes and the module checks for the number of ignition trials performed during the current call for heat If the number is less than three the module initiates a purge warmup and trial for ignition After the third trial during a single call for heat the module locks out The module must be manually reset following lockout START THERMOSTAT CALLS FOR HEAT INTERNAL SAFE START FLAME SYSTEM WILL CHECK BEGINS SIMULATING NOT START FAILURE SIMULATING FAILURE PURGE PURGE S890 ONLY S890 MODELS ONLY SINGLE TRY MODELS IGNITER IGNITER WARMS UP WARMUP SINGLE TRY TRIAL FOR GAS CONTROL OPENS MODULES LOCKOUT OCCURS IGNITION FOR TIMED TRIAL SYSTEM MUST FOR IGNITION BE RESET IGNITER OFF GAS FLAME SENSING FLAME ud BEGINS CLOSES LESS THAN THREE FLAME PRESENT THREE TRY MODULES ER GAS CONTROL STAYS OPEN FLAME ko MAIN BURNER RUNS EE CLOSES THIS CALL FOR HEAT THREE TRY MODELS CALL FOR HEAT THREE IS SATISIFED Bo GAS CONTROL CLOSES LOCKOUT OCCURS MAIN BURNER OFF SYSTEM MUST
26. ooler location or shield insulator Do not relocate an igniter or combination igniter sensor Check for cracked igniter sensor or sensor ceramic insulator which can cause short to ground and replace unit if necessary Make sure electrical connections are clean and tight Replace damaged wire with moisture resistant No 18 wire rated for continuous duty up to 105 C 221 F If the igniter is other than a Norton 201 or 271 make sure it meets the following specifications e Igniter must reach 1000 C 18329 F within 36 seconds with 102 Vac applied Igniter must maintain at least 500 M ohms insula tion resistance betweenthe igniter leadwires andthe igniter mounting bracket e Igniter must not develop an insulating layer on its surface overtime which would preventflame sens ing Igniter surface area immersed in flame must not exceed 1 4 ofthe grounded area immersed in flame This would prevent flame sensing Igniter current draw at 132 Vac must not exceed 5 START TURN THERMOSTAT TO CALL FOR HEAT DOES 589 5890 GET POWER 24 VAC NOMINAL YES 30 SEC MIN PURGE S890 MODELS ONLY YES IGNITER WARMS UP AND GLOWS RED YES MAIN BURNER LIGHTS MAIN BURNER REMAINS POWERED AND LIT I m SYSTEM RUNS UNTIL CALL FOR HEAT ENDS YES CALL FOR HEAT ENDS SYSTEM SHUTS OFF YES TROUBLESHOOTING ENDS NOTE BEFORE TROUBLESHOOTING FAMILIARIZE YOURSELF WITH START UP AND CHECKOUT P
27. rols to protect them from splashing water A NEMA 4 enclosure is recom mended forthe ignition module see the Electronic Ignition Service Manual form 70 6604 HIGH HUMIDITY OR DRIPPING WATER Over time dripping water or high ambient humidity can create unwanted electrical paths on the module circuit board causing the module to fail Never install an appli ance where water can drip on the controls In addition high ambient humidity can cause the gas control to corrode and finally to fail Wherethe appliance may be installed in ahumid atmos phere 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 for the ignition module see the Electronic Ignition Service Manual form 70 6604 CORROSIVE CHEMICALS Corrosive chemicals can also attack the module and gas control and eventually cause a failure Where chemi cals may be used routinely for cleaning make sure the cleaning solution cannot reach the controls Where chemi cals are likely to be suspended in air as in some industrial and agricultural applications protect the ignition module from exposure with a NEMA 4 enclosure see the Elec tronic Ignition Service Manual form 70 6604 DUST OR GREASE ACCUMULATION Heavy accumulation of dust or grease may cause the controls to malfunction Where dust or grease may be a problem provide covers forthe
28. t chemicals and heat can damage the module or the gas control and shut down the control system A NEMA 4 enclosure can reduce exposure to environmental contaminants See Electronic Ignition Service Manual form 70 6604 The maintenance program should include regular checkout of the system as outlined under Checkout page 11 DO Otte chen acd CR s s s s Sal hat eNO Ne he a rerasan asarana ta RM MM eR apen FIRE OR EXPLOSION HAZARD MAY CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Do not attempt to take the module apart or to clean it Improper reassembly and cleaning may cause unreliable operation Maintenance frequency must be determined individu ally for each application Some considerations are e Cycling frequency Appliances that may cycle more than 20 000 times annually should be checked monthly 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 would be high the system should be checked more often Dusty wet or corrosive environment Since these environments can cause the controls to deteriorate more rapidly the system should be checked more often Protective enclosures as outlined under Planning the Installation are recommended re gardless of checkout frequency Any control sho
29. uld be replaced if it does not perform properly on checkout or troubleshooting In addition re place any module if it is wet or looks like it has ever been wet MOUNT IGNITION MODULE Select a location close enough to the burner to allow a short direct cable route to the igniter Ambient tempera ture at the module must be within the range of minus 40 F to plus 175 F minus 40 C to plus 79 C The module must be protected from water moisture corrosive chemi cals and excessive dust and grease The module can be mounted in any position Fasten securely with four No 6 32 machine or No 8 sheetmetal screws 1 in 25 mm long MOUNT THE SYSTEM CONTROLS Mount any required controls such as the gas control hot surface igniter flame sensor thermostat limit and transformer according to manufacturer s instructions WIRE THE SYSTEM CAUTION Check the wiring diagram furnished by the appli ance manufacturer if available for circuits differ ing from the wiring hookups shown Carefully follow any special instructions affecting the gen eral procedures outlined below Disconnect the power supply before making wir ing connections to prevent electrical shock or equipment damage IMPORTANT 1 All wiring must comply with applicable electrical codes and ordinances 2 When installing the hot surface igniter the lead wires should be kept as short as possible and should not be allowed to rest against grounded metal sur
30. used with the D80D Plug In Vent Damper Once a module with vent damper plug has powered a vent damper circuit it cannot be used in a gas system without a vent damper non replaceable fuse in the module blows on initial power up Oncethis fuse has blownthe module won t work unless the vent damper is connected To connect the plug in model to D80D 1 Remove the plug from the terminal strip on the ignition module case and discard 2 Using the wiring harness supplied insert the match ing pin plug into receptacle on case and other end to vent damper To connect the D80B follow the wiring diagrams sup plied with the vent damper or see Fig 5 for typical connec tions Connect Ignition Module 1 Connect remaining system components to the igni tion module terminals as shown in the appropriate wiring diagram Figs 2 to 10 e Figs 2 and 3 are basic circuits for a heating only atmospheric burner system Fig 2 shows the C G and J models with combination igniter sensor Fig 3 shows the D H models with separate igniter and sen sor Figs 4 and 5 show the C G and J models with a D80 Vent Damper Never use a vent damper in an LP gas system or in a fan assisted combustion system e Figs 6 10 show S89C G J S890C G J with combination igniter sensor in a variety of systems with alternate connections for vent damper plug models Remember however that a vent damper DUAL VALVE COMBINATION GAS CONTROL should not be used in
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