68-0085 - Intermittent Pilot Modules S8600A,B,F,H,M
Contents
1. 58600 58610 86600 586700 lock out on shutoff Manual reset is required VOS p n WESS Ore 2 2 S8600M waits 6 minutes nom following shutoff then 0 4 1 reinitiates the pilot ignition sequence The ignition trial 1 2 22 shutoff wait cycle repeats until the pilot lights or the call for heat ends UTERE ANANN 52224 SIENY x Models of 8600 58610 58660 58670 replace S86 590 and 5860 Remote reset provided 100 percent shutoff mod els 1 System uses rectification principle for flame sensing Capacitive discharge spark output 8 600 F L Temperature ratings are 58600 58660 40 F to 4175 F 40 C to 479 C 58610 8670 40 F to 4175 F 40 C to 79 C when G8 6 1 0 A R used with 1 0 or less main valve 40 F to 165 pos to 74 C when used with over 1 010 2 0 main S8 6 60 D z 58670 D J A Form Number 68 0085 2 Rev 12 89 O Honeywell Inc 1989 IMPORTANT THE SPECIFICATIONS GIVEN IN THIS PUBLICATION DO NOT INCLUDE NORMAL MANUFACTURING TOL ERANCES THEREFORE AN INDIVIDUAL UNIT MAY NOT MATCH THE LISTED SPECIFICATIONS EXACTLY ALSO THIS PRODUCTIS TESTED AND CALIBRATED UNDER CLOSELY CONTROLLED CONDITIONS AND SOME MINOR DIFFERENCES IN PERFORMANCE CAN BE EXPECTED IF THOSE CONDITIONS ARE2. Shutoff tockout timing is stamped on module POWER INTERRUPTION System shuts off restarts when power is restored PILOT FLAME FAILURE Main valve closes Module starts trial for ignition FIG 12 58600 58610 NORMAL OPERATING SEQUENCE 15 68 0085 2 TRIAL FOR IGNITION Pilot Ignition Following prepurge timing 58660 58670 or on the call for heat 58600 58610 the module energizes the first main valve operator The first main valve opens which allows gas to flow to the pilot burner At the same time the electronic spark generator in the module produces a high voltage spark pulse output The voltage generates a spark at the igniter S8600A B S8610A B or igniter sensor 58600 S8610F H 58660 58670 that lights the pilot If the pilot does not light or the pilot flame current is not atleast 1 0 LA and steady the module will not energize the second main valve and the main burner will not light 58600 S8610A F will continue to spark as long as the thermostat calls for heat or until the pilot lights Safety Lockout S8600B H 58610 S8660D S8670D These modules provide 100 percent shutoff and 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 goes into safety lockout Lockout de energizes the first main valve operator and closes the first main pi
3. a am am I I AIRPROVING RELAY COIL CONTROLLER m x ZA TRANSFORMER ARC GAP GND D gt 4 1 SENSOR BURNER GROUND MAIN 1K1 1K2 3K2 VALVE PILOT 2K2 VALVE pee nen A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION 3K RELAY ON 100 PERCENT SHUTOFF MODELS ONLY ON NON SHUTOFF MODELS PV AND WIRED AS FOLLOWS TO 24V TO 24V GND INTERNAL WIRING MAIN EXTERNAL WIRING AE PILOT Nes mE M1168B FIG 21 SCHEMATIC FOR S8600F H M S8610F H IN FAN ASSISTED COMBUSTION SYSTEM SEE FIG 6 26 L1 HOT L2 COMBUSTION AIR BLOWER MOTOR 1 L1 ee LIMIT 5 CONTROLLER SWITCH ar aum uum anar au IA gt gt E E J AIR BLOWER THERMOSTAT OR AIR PROVING RELAY COIL CONTROLLER A 24V SWITCH EP sn ER EE i n eus mn i GND o gt 1 BUR IGNITER NER SENSOR BURNER GROUND 1K1 1K2 3K2 VALVE 2K2 3K1 VALVE i POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED INTERNAL WIRING EXTERNAL WIRING T 1 ALTERNATE LIMIT CONTROLLER LOCATION FIG 22 SCHEMATIC FOR 866
4. CHANGED TRADELINE MODELS Tradeline models are selected and packaged for ease of handling ease of stocking and maximum replacement value TRADELINE model specifications are the same as those of standard models except as noted below TRADELINE MODELS AVAILABLE S8610A B F H Ignition Modules without prepurge _ 586700 Ignition Module with prepurge ADDITIONAL FEATURES Main valve max load rating of 2 0 A run 20 0 A inrush Temperature rating With main valve current of 1 0 A or less 40 F to 175 F 40 C to 479 C With main valve current between 1 0 A and 2 0 A 40 F to 165 F 40 C to 474 Ignition cable converter Allows use of existing ignition cable with Rajah connector TRADELINE pack with cross reference label and special instruction sheet MODELS See Table 1 TABLE 1 INTERMITTENT IGNITION MODULES IGNITER TYPE 100 SENSOR PREPURGE PERCENT LOCKOUT IGNITION MODEL TYPE GAS TIMING SHUTOFF TIMING SEQUENCE Spark on until pilot lightoff or manual shutdown pilot valve open until manual shutdown 15 or 90 sec max as ordered Spark on until lightoff or lockout pilot valve closes on lockout S8600B Nat S8610B or LP S8610H S8600M Combination Nat or LP S8660D Combination Nat S8670D or LP 58610 58610 Spark and pilot gas on until shutoff After 5 minutes min 6 min nom delay ignition starts again Ignition wait retry
5. 24V OPEN DO NOT REMOVE VENT DAMPER PLUG LEAVE TP Z AND Z W JUMPERS IN PLACE M1181A FIG 10 58600 58610 S8660D OR 586700 CONNECTIONS IN HYDRONIC HEATING SYSTEM WITH A D80D VENT DAMPER 13 68 0085 2 GNO MV PV BURNER 58600 S8610F H 86600 586700 VENT DAMPER PLUG OPT r 24V TH W lior 1ST 2ND OPERATOR OPERATOR DUAL VALVE COMBINATION GAS CONTROL POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION MAXIMUM CABLE LENGTH 3 0 9 m CONTROLS 24V CIRCUIT MUST NOT BE IN GROUND LEG TRANSFORMER A FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG CONNECT THERMOSTAT TO TH W LEAVE 24V OPEN DO NOT REMOVE VENT DAMPER PLUG Q345 Q346 Q348 Q362 Q381 PILOT BURNER IGNITER SENSOR PILOT BURNER GROUND PILOT GAS A SUPPLY FIG 11 S8600F H M S8610F H 586600 86700 CONNECTIONS IN A COMMERCIAL WATER HEATER CONTROL SYSTEM CHECKOUT Check out the gas control system At initial installation of the appliance 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 time work is done on the system ED THESE WARNINGS MAY CAUSE FIRE OR EXPLOSION WITH PROPERTY DAMAGE INJURY
6. 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 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 Any control should 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 Protective enclosures as outlined under Planning the Installation are recommended regardless of checkout frequency MOUNT IGNITION MODULE Select a location close enough to the burner to allow a short 3 ft O 9 m max direct cable route to the igniter Ambient temperature at the module must be within the range listed under Specifications page 3 The module must be protected from water moisture corrosive chemi cals and excessive dust and grease We re
7. in Figs 4 and 5 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 1 4 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 1 4 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 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 NOTE Earth g
8. instructions after the gas control is installed module must be mounted near moisture or water provide suitable waterproof enclosure PERFORM PREINSTALLATION SAFETY INSPECTION The preinstallation checks described in ANSI Standard 221 71 on page 28 must be done before the replacement module is installed 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 Environments Regular preventive maintenance is important in any ap plication but especially so in commercial cooking agricul tural and industrial applications because many such applications particularly commercial cooking the equipment operates 100 000 200 000 cycles per year Such heavy cycling can wear outthe gas control in one to two years normal forced air furnace for which the controls were originally in tended typically operates less than 20 000 Es per year Exposure to water dirt 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 maintenance program should include regular checkout of the system as outlined under Checkout page 14 FIRE OR EXPLOSION
9. operating condition b Test low water cutoffs automatic feed water controls pressure and temperature limit control lers and relief valves in accordance with the manufacturer s recommendation to determine they are in operating condition 16 Add the labels see 1 6 1 n and o on the ance EXHIBIT B OF ANSI STANDARD Z21 71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD INSTALLATION 29 68 0085 2
10. repeats until pilot lights or system is shut down manually Yes 15 or 90 Ignition trial follows prepurge at sec max spark on until lightoff or lockout lockout as ordered pilot valve closes on lockout continuous established flame is lost all models restart ignition trial continued on page 3 D 26060604 DOO WHEN PURCHASING REPLACEMENT AND MODERNIZATION PRODUCTS FROM YOUR TRADELINE WHOLESALER OR YOUR DISTRIBUTOR REFER TO THE TRADELINE CATALOG OR PRICE SHEETS FOR COM PLETE ORDERING NUMBER OR SPECIFY 1 Order number TRADELINE if desired 3 Other components as required 2 Lockout timing 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 gt 26 5 64 25167 ONLY MODELS WITH VENT DAMPER PLUG limo 32186 2 3 6 5 2 1 APPROXIMATE IGNITION MODULE DIMENSIONS IN in mm ELECTRICAL RATINGS Voltage and frequency 20 5 to 28 5 V 24 V nom 60
11. replacement instructions If old module had vent damper plug use equivalent S8610F with vent damper plug If the old module had TH R and TH W terminals see Wire the System page 6 for replacement instructions If old module had vent damper plug use equivalent S8610F with vent damper plug The original S86H continued ignition spark after lockout More recent S86H models andthe S8610H stop ignition spark on lockout If old module had vent damper plug use equivalent S8610H with vent damper plug 21 68 0085 2 LIMIT ON OFF 12 CONTROLLER SWITCH 4 I BE CONTROLLER A waa 24V TRANSFORMER p eae a ARC GND gt 4 4 BUR IGNITER NER SENSOR T BURNER GROUND MAIN 1 1 1K2 3K2 VALVE PILOT 2K2 3K1 one 1 POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION 3K RELAY ON 100 PERCENT SHUTOFF MODELS ONLY ON NON SHUTOFF MODELS PV AND WIRED AS FOLLOWS TO 24V TO 24V GND MAIN INTERNAL WIRING 1K1 Eug EXTERNAL WIRING PILOT 2K2 VALVE e M1165B FIG 17 SCHEMATIC FOR S8600F H M S8610F H SEE FIG 2 FOR HOOKUP 22 L1 L2 HOT ON OFF LIMIT SWITCH CONTROLLER 1 1 4 M sl THERMOSTAT A f i I 6 9 4 amp T
12. 0 9 m RELAY 3 J CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER 4 A FOR MODULE WITH TH W TERMINAL AND VENT Anci DAMPER PLUG CONNECT THERMOSTAT TO TH W 1177 LEAVE 24V OPEN DO NOT REMOVE VENT DAMPER FIG 6 58600 S8610F H S8660D 586700 CONNECTIONS IN A HEATING SYSTEM WITH A FAN LI COMBUSTION fumi PLUG ASSISTED COMBUSTION BURNER HOT AIR BLOWER CONTROLLER N MOTOR 0345 0346 0348 0362 0381 PILOT BURNER IGNITER SENSOR PILOT BURNER L2 L1 A HOT PILOT GAS SUPPLY 9 68 0085 2 58600 S8610F H 586600 586700 A VENT GND 24V TH W DAMPER MV MV PV PV BURNER GND 24V OPT PLUG OPT MAIN VALVE VALVE STAGE 2 STAGE 1 PROVING SWITCH TWO STAGE DUAL VALVE COMBINATION GAS CONTROL Q345 Q346 Q348 Q362 Q381PILOT i BURNER E IGNITER E COMBUSTION SENSOR AIR BLOWER RELAY H L1 COMBUSTION HOT A AIR BLOWER MOTOR LIMIT CONTROLLER L1 L2 HOT N POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION A MAXIMUM CABLE LENGTH 3 ft 0 9 m A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER A FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG CONNECT THERMOSTAT TO TH W LEAVE 24V OPEN DO NOT REMOVE VENT DAMPER PLUG M1178A FIG 7 58600 S861
13. 00 586700 IN FAN ASSISTED COMBUSTION SYSTEM SEE FIG 6 27 68 0085 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 recognizedthat generalized test procedures cannot an ticipate 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 instal lation b If it is determined there is a condition which could result in unsafe operation the appliance should be shut off and the owner advised of the unsafe condi tion Thefollowing 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 proper size and horizontal pitch and determine there is no blockage or restrictions leakage or corrosion or other deficiencies which could cause an un
14. 0F H 586600 OR 586700 CONNECTIONS IN A HEATING SYSTEM WITH A TWO STAGE GAS CONTROL AND A FAN ASSISTED COMBUSTION BURNER 10 58600 S8610F H 586600 586700 VENT GND 24V TH W DAMPER MV MV PV PV BURNER GND 24V OPT PLUG OPT 1 1ST 2ND OPERATOR OPERATOR DUAL VALVE COMBINATION GAS CONTROL THERMOSTAT OR CONTROLLER E 15 mm TRANSFORMER _ LIMIT T CON Q345 Q346 1542 MOER Q348 Q362 0381 PILOT BURNER pur PILOT BURNER 1 4 CONTROLLER IGNITER SENSOR s La PILOT GAS y SUPPLY L2 L1 A on AN POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION MAXIMUM CABLE LENGTH 3 ft 0 9 m CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER A FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG CONNECT THERMOSTAT TO TH W LEAVE 24V OPEN DO NOT REMOVE VENT DAMPER PLUG COLORS REFER TO WIRE HARNESS IF USED M1180A FIG 8 58600 S8610F H S8660D OR S8670D IN A HEATING SYSTEM WITH A D80B VENT DAMPER 11 68 0085 2 S8600F H M S8610F H 86600 586700 A VENT GND 24V TH W DAMPER MV MV PV PV BURNER GND 24V OPT PLUG OPT Ore lior 15 2 0 OPERATOR OPERATOR DUAL VALVE COMBINATION GAS CONTROL L1 THERMOSTAT HOT L2 PILOT A 9 G BURNER U HOT L2 w COM
15. 7 IGNITER MODULE LENGTH END END 30 in 1 4 in quick Rajah connector connect receptacle 90 insulated deg rubber boot 1 4 in quick Rajah connector connect receptacle straight insulated rubber boot CABLE PART NUMBER 394800 30 394801 30 TABLE 4 RECOMMENDED IGNITION CABLE FOR FIELD ASSEMBLY TEMPERATURE CABLE VOLTAGE RATING TYPE RATING rms UL Style 3217 10 000 150 UL Style 3257 TRANSFORMER Add current ratings of module pilot valve main valve vent damper and any other compo nents of the control system to determine transformer size requirement THERMOSTAT Use open close switch type or independ ently powered electronic 24V thermostat capable of switching rated control system load Before using elec tronic thermostat powered through the heating cooling controls consult thermostat manufacturer to ensure proper control system operation HIGH LIMIT AND OTHER AUXILIARY CONTROLS As specified by the heating appliance manufacturer Intermittent pilot systems are used on a wide variety of central heating equipment and on heating appliances such as commercial cookers agricultural equipment industrial heating equipment and pool heaters Some of these appli cations may make heavy demands on the controls either because of frequent cycling or because of moisture corrosive chemicals dust or excessive heat in the environ ment In these situations spe
16. AN GAS ASSOCIATION DESIGN CERTIFIED 20 14D3 OTHER SYSTEM COMPONENTS These modules provide operating control of an intermit tent pilot system Additional components required to complete the system must be ordered separately They include Dual valve combination gas control designed for intermittent pilot Combination pilot burner igniter sensor S8600F H M S8610F H and S8670D Separate igniter and sensor on pilot burner bracket S8600A B Ignition cable e Transformer 24V thermostat High limit and other auxiliary controls as required DUAL VALVE COMBINATION GAS CONTROL Any that meets current ratings listed below VR8204 VR8440 or VR8520 recommended 58600 58660 1 0 A pilot 1 0 A main valve 58610 58670 1 0 A pilot 2 0 A main valve PILOT BURNER IGNITER SENSOR See Table 2 TABLE 2 PILOT BURNER IGNITER SENSORS PILOT BURNER FLOW RATE IGNITER SENSOR MODULE S8600F H M Q345 58610 0 03 S8660D 0 04 586700 0 014 0 014 58600 Q354 with Q345 0346 0348 0362 or 0381 With natural gas at 7 0 in 1 7 kPa 68 0085 2 IGNITION CABLE Use Honeywell preassembled cable see Table 3 or assemble locally Use cable recom mended in Table 4 or equivalent insulated female 1 4 in quick connect and insulated Hajah connector re ceptacle Maximum recommended length is 36 in 914 mm TABLE 3 HONEYWELL PREASSEMBLED IGNITION CABLES UL STYLE 325
17. AXIMUM CABLE LENGTH 3 ft 0 9 m CONTROLS 24V CIRCUIT MUST NOT BE GROUND LEG TO TRANSFORMER FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG CONNECT THERMOSTAT TO TH W LEAVE 24V OPEN DO NOT REMOVE VENT DAMPER PLUG LIMIT CON TROLLER GROUND un IGNITER L1 PILOT GAS A HOT L2 SUPPLY FIG 4 S8600A B S8610A B CONNECTIONS IN A HEATING SYSTEM S8600A B 58610 VENT GND 24V DAMPER MV MV PV PV BURNER GND 24V TH W PLUG SENSE SPARK MAIN i VALVE 1ST 2ND OPERATOR OPERATOR DUAL VALVE COMBINATION GAS CONTROL A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION LIMIT MAXIMUM CABLE LENGTH 0 9 CONTROLLER A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND GROUNO LEG TO TRANSFORMER L1 L2 IGNITER HOT PILOT GAS REMOVE PLUG ONLY IF USING VENT DAMPER SUPPLY FIG 5 S8600A B 58610 WITH VENT DAMPER PLUG IN AN ATMOSPHERIC BURNER HEATING SYSTEM WITH A D80D VENT DAMPER S8600F S8610F H 586600 586700 VENT GND 24V TH W MV PV PV BURNER 24V OPT PLUG AIR THERMOSTAT py VALVE PROVING SWITCH d A POWER SUPPLY PROVIDE DISCONNECT MEANS 1ST 2ND AND OVERLOAD PROTECTION AS REQUIRED OPERATOR OPERATOR A ALTERNATE LIMIT CONTROLLER LOCATION DUAL VALVE COMBINATION m COMBUSTION GAS CONTROL A AIR BLOWER MAXIMUM CABLE LENGTH 3
18. BUSTION GROUND R8239 X AIR BLOWER FAN MOTOR BURNER IGNITER CENTER uw TROLLER iit COMBUSTION ov PO COIL aa AIR PROVING SWITCH A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION MAXIMUM CABLE LENGTH 3 ft 0 9 m J CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER A FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG CONNECT veer THERMOSTAT TO TH W LEAVE 24V OPEN DO NOT REMOVE VENT DAMPER PLUG FIG 9 58600 S8610F H S8660D OR 586700 CONNECTIONS IN HEATING COOLING SYSTEM WITH A FAN ASSISTED COMBUSTION BURNER 12 58600 5861 86600 586700 A VENT GND 24V TH W DAMPER MV MV PV PV BURNER GND 24V OPT PLUG OPT I 1 Lenor 1ST 2ND OPERATOR OPERATOR DUAL VALVE COMBINATION GAS CONTROL D80D Q345 Q346 Q348 Q362 Q381PILOT BURNER BURNER GROUND IGNITER SENSOR PILOT GAS Jj SUPPLY Ue io mm mb am me amp um auo j ud CABLE lt BLUE YELLOW ME PONE THERMOSTAT E A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED CUT PLUG OFF MODULE END OF 0800 WIRE HARNESS CONNECT LEADWIRE COLORS AS SHOWN MAXIMUM CABLE LENGTH 3 ft 0 9 A FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG CONNECT THERMOSTAT TO TH W LEAVE
19. EFERENCE TERMINAL ON NEW MODULE GND Burner 2 M1175A FIG 2 58600 S8610F H 586600 586700 CONNECTIONS IN A HEATING SYSTEM WITH AN ATMOSPHERIC BURNER 68 0085 2 15 2 0 OPERATOR OPERATOR DUAL VALVE COMBINATION GAS CONTROL POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION N MAXIMUM CABLE LENGTH 3 ft 0 9 m A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER A REMOVE PLUG ONLY IF USING VENT DAMPER FUSE BLOWS ON STARTUP WHEN PLUG 15 REMOVED THEN MODULE WILL OPERATE ONLY WHEN VENT DAMPER IS CONNECTED 58600 S8610F H A VENT GND 24V DAMPER MV MV PV PV BURNER GND 24V TH W PLUG WIRING HARNESS T 0800 DAMPER MAIN cd ay VALVE THERMO CON TROLLER 9 LI 12 A PILOT BURNER Q345 0346 GROUND Q348 Q362 Q381 PILOT BURNER El PILOT GAS IGNITER SENSOR SUPPLY FIG 3 58600 S8610F H WITH VENT DAMPER PLUG IN A HEATING SYSTEM WITH AN ATMOSPHERIC BURNER AND A D80D VENT DAMPER MV MV PV PV BURNER S8600A B S8610A B VENT DAMPER PLUG SENSE GND 24V TH W GNO 24V OPT SPARK MAIN VALVE 15 2ND OPERATOR OPERATOR DUAL VALVE COMBINATION GAS CONTROL N POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION M
20. EMATIC FOR S8600A B S8610A B SEE FIG 4 FOR HOOKUP 24 ERO ERO waar D anar WE mam mam amas ama uma THERMOSTAT HOT ON OFF LIMIT L2 L1 5 I SWITCH CONTROLLER TRANSFORMER Qo Es um om m n g a DAMPER PLUG ARC GAP SENSOR 5 GND gt lt BUR IGNITER NER BURNER GROUND L2 _ J DO su YELLOW M 1K1 1K2 3K2 VALVE N PILOT 2K2 3K1 VALVE O Diaa A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED A ALTERNATE LIMIT CONTROLLER LOCATION 1 5 NONREPLACEABLE FUSE FUSE BLOWS WHEN VENT DAMPER IS PLUGGED IN A 3K RELAY ON 100 PERCENT SHUTOFE MODELS ONLY ON NON SHUTOFF MODELS PV AND MV WIRED AS FOLLOWS TO 24V TO 24V GND MAIN INTERNAL WIRING 1 1 1 2 e EXTERNAL WIRING PILOT M11678 FIG 20 SCHEMATIC FOR S8600A B S8610A B WITH D80D VENT DAMPER SEE 5 FOR HOOKUP 25 60 0085 2 L1 HOT L2 COMBUSTION AIR 5 5 BLOWER MOTOR 1 TW a ee 1 COAT i LIMIT ON OFF HOT 12 jE 4 CONTROLLER SWITCH 4 FAS REX i THERMOSTAT OR 1 gt ra em an am mum umm
21. GE 3 MAIN BURNER OPERATION THERMOSTAT CALLS FOR HEAT 2 PREPURGE Combustion air blower starts SPARK GENERATOR POWERED First valve pilot operator opens 9 PILOT BURNER OPERATION Pilot burner lights S8660 S8670 senses flame Current FLAME CURRENT SENSED Spark generator off Second valve operator main opens 6 MAIN BURNER OPERATION Module monitors pilot flame current 7 THERMOSTAT SATISFIED Valves close pilot and main burners are off FIG 13 58660 58670 NORMAL OPERATING SEQUENCE 16 Pilot burner does not light After 15 or 90 sec system locks out must be manually reset ockout timing is stamped on module POWER INTERRUPTION System shuts off restarts when power is restored PILOT FLAME FAILURE Main valve closes 58660 58670 starts trial for ignition M1171A IMPORTANT 1 The following service procedures are provided as a general guide Follow appliance manufac turer s service instructions if available Onlockout and retry models meter readings be tween 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 lf any component does not function properly make sure it is correctly installed and wired before
22. Honeywell INTERMITTENT THESE IGNITION MODULES PROVIDE IGNITION PIL T SEQUENCE FLAME MONITORING AND SAFETY SHUTOFF FOR INTERMITTENT PILOT CENTRAL FURNACES AND KEATING APPLIANCES M D U L S 58600 58660 provide upto 1 0 A pilot and 1 0 main valve current rating 8610 S8670 provide upto 1 0 A pilot and 2 0 A main valve current rating E A Dum 58660 8670 provide prepurge cycle _ o ee S8600A B S8610A B use separate igniter and sen x sor Q179C with igniter and sensor mounted on one 1122 o bracket or Q354 sensor with Q345 Q346 Q348 Q362 1717 7 7 70 or Q381 igniter sensor recommended yyy Sion ente UAE Sine DUET SEDE E 22 P 1 S8600F H M S8610F H S8660D S8670D use 2 _ y combination igniter sensor Q345 0346 Q348 Q362 or a o o o Q381 igniter sensor recommended _ e S8600A F S8610A F are for use on natural gas only NE Pp they continue ignition until the pilot lights or the system is WARNING 13 mos bp manually shut down Ce das omo x 29 no Met tubos t STAPS MAX MAN WER NEER LY u MAE duet 1 S8600B H M S8610B H S8660D S8670D can be used on natural or LP gas they provide 100 percent shutoff on ignition failure CONNU
23. Hz Current rating 0 2 Valve contact ratings at 24 Vac 58600 58660 Run Inrush Run 10 0A 10A 100A 20 0 A SPARKGENERATOR OUTPUT 13kV peak at 25 pf load THERMOSTAT ANTICIPATOR SETTING 0 2 A plus pilot valve rating plus main valve rating AMBIENT TEMPERATURE RATING 58600 58660 40 F to 4175 F 40 C to 79 C 58610 58670 40 F to 4175 F 40 C to 479 C with main valve rated 1 0 A or less 40 F to 165 F 40 C to 474 C with main valve rated over 1 0 Ato 2 0 A RELATIVE HUMIDITY RATING 5 to 90 percent RH at 95 F FLAME FAILURE RESPONSE TIME 0 8 sec at 1 0 pA flame current CONTINUOUS RETRY TIMING S8600M only 5 minute min 6 minute nom off time between trials for ignition TERMINALS SENSE S8600A B S8610A B only 3 16 in male quick connect All other terminals including ignition 1 4 in male quick connects Models available with Molex plug for connec tion to Honeywell 0800 Vent Damper FLAME CURRENT 1 LA min MOUNTING Mounts in any position except with terminals up However recommended mounting position is with terminals down to provide maximum protection from dripping water or dust accumulation Fasten with No 6 32 machine or No 8 sheetmetal screws of appropriate length UNDERWRITERS LABORATORIES INC COMPONENT RECOGNIZED File No MH15564 Guide No MCCZ2 8610 58670 Inrush CANADIAN GAS ASSOCIATION CERTIFIED 1029 ABI 6269 AMERIC
24. OR LOSS OF LIFE 1 If you smell gas or suspect a gas leak turn off gas at manual service valve and evacuate the building Do not try to light any appliance do not touch any electrical switch or telephone in the building until you are sure no spilled gas remains Gas leak test must be done as described in Steps 1 and 5 below on initial installation and any time work is done Involving the gas pip ing STEP 1 Perform Visual Inspection J With power off make sure all wiring connections are clean and tight Turn on power to appliance and ignition module C Open manual shutoff valves in the gas line to the appliance Do gas leak test ahead of gas control if piping has been disturbed 14 GAS LEAK TEST Paint pipe joints with rich soap and water solution Bubbles indicate gas leak Tighten joints to stop leak Recheck with soap and water STEP 2 Review Normal Operating Sequence and Module Specifications See OPERATION page 15 and SPECIFICATIONS page 2 STEP 3 Reset the Module Turn the thermostat to its lowest setting Wait one minute As you do Steps 4 and 5 watch for points where operation deviates from normal Hefer to Troubleshooting Chart to correct problem STEP 4 Check Safety Shutoff Operation This step applies to lockout and continuous retry mod ules only Turn gas supply off J Setthermostat or controller above room temperature to call for heat Watch for spark at pilot
25. RANSFORMER m j GND p Bur IGNITER NER SENSOR BURNER GROUND VENT b 4 DAMPER YELLOW MAIN PLUG 1K1 1K2 3K2 VALVE PILOT 2K2 3K1 A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION 1 5 NONREPLACEABLE FUSE FUSE BLOWS WHEN VENT DAMPER IS PLUGGED IN AN 3K RELAY ON 100 PERCENT SHUTOFF MODELS ONLY ON NON SHUTOFF MODELS PV AND MV WIRED AS FOLLOWS TO 24V TO 24V GND MAIN 1K1 Pr INTERNAL WIRING EXTERNAL WIRING PILOT 2K2 VALVE 1170 FIG 18 SCHEMATIC FOR S8600F H M S8610F H WITH D80D VENT DAMPER SEE FIG 3 FOR HOOKUP 23 68 0085 2 L1 LIMIT ON OFF 12 CONTROLLER SWITCH THERMOSTAT OR NEM CONTROLLER was 24V TRANSFORMER R um w SENSOR S P 4 GND J 9 E BUR F IGNITER NER BURNER GROUND 1K1 1K2 3K2 2K2 3K1 VALVE NUN I2 A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION A 3K RELAY ON 100 PERCENT SHUTOFF MODELS ONLY ON NON SHUTOFF MODELS PV AND MV WIRED AS FOLLOWS oo TO 24V GND _ INTERNAL WIRING MAIN EXTERNAL WIRING 1K1 1K2 VALVE PILOT 2K2 VALVE Q scel deed M1166B FIG 19 SCH
26. RT TURN GAS SUPPLY OFF TURN THERMOSTAT TO CALL FOR HEAT Check line voltage power low voltage transformer limit controller thermostat and wiring Also check air proving switch on combustion air blower system and that vent damper if used is open and end switch is made POWER TO MODULE 24V NOMINAL YES 45 SECOND DELAY gt Replace S8660 S8670 YES SPARK ACROSS IGNITER SENSOR GAP E Replace module YES Pull ignition lead and check spark at 58660 58670 Spark okay YES Check ignition cable ground wiring ceramic insulator and gap and correct Check boot of the ignition cable for signs of melting or buckling Take protective action to shield cable and boot from excessive temperatures Check that manual gas cocks 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 no voltage replace module TURN GAS SUPPLY ON PILOT BURNER LIGHTS YES NOTE if module goes into lockout reset system Check continuity of ignition cable and ground wire SPARK STOPS WHEN Clean flame rod PILOT IS LIT Check electrical connections between flame rod and module YES Check for cracked ceramic flame rod insulator Check that pilot flame covers flame rod a
27. TROLLER TO CALL Check line voltage power low voltage transformer limit controller thermostat controller and wiring Also FOR HEAT check air proving switch on combustion air blower system if used and that vent damper if used is open and d switch i POWER TO MODULE end switch is made 24V NOMINAL YES On models with vent damper plug make sure vent damper has not been installed then removed Replace vent damper if necessary On other models replace module Pull ignition lead and Check spark at module Spark okay YES Check ignition cable ground wiring ceramic insulator and gap and correct Check boot of the ignition cable for signs of melting or buckling Take protective action to shield cable and boot excessive temperatures SPARK ACROSS IGNITER SENSOR GAP YES TURNGASSUPPLYON TURNGASSUPPLYON SUPPLY ON Check that all manual gas valves are open supply tubing and pressures are good and pilot burner orifice PILOT BURNER LIGHTS 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 voltage is okay replace gas control not replace module NOTE If S8600B H 88610 goes into lockout reset system For S8600M wait 6 min nom for retry or reset system es ile 2 Check continuity of ignition cable and ground wire Clean r
28. a Visually determine that main burner gas is burning properly i e no floating lifting or flash back Adjust the primary air shutter s as re quired b If appliance is equipped with high and low flame control or flame modulation check for proper main burner operation at low flame 11 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use a draft gauge the flame of a match or candle or smoke from a cigarette cigar or pipe 12 Return doors windows exhaust fans fireplace dampers and all other fuel burning appliances to their previous conditions of use 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 determining 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 manufac turer s recommendations and instructions to de termine they are in operating condition EXHIBIT A OF ANSI STANDARD Z21 71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD INSTALLATION EXHIBIT B PROCEDURE FOR INSTALLING AUTOMATIC INTERMITTENT PILOT SYSTEMS Prior to begi
29. burner either immediately or following prepurge See SPECIFICATIONS page 2 Time spark from start to shutoff See SPECIFICA TIONS page 2 On continuous retry models wait 6 min nom Ignition sequence should start again followed by shutdown after 90 sec max Open manualgas cock and make sure no gas is flowing to pilot or main burner Set thermostat below room temperature and wait one minute before continuing STEP 5 Check Normal Operation Setthermostat or controller above room temperature to call for heat Make sure pilot lights smoothly when gas reaches the pilot burner E sure main burner lights smoothly without flash ack C Make sure burner operates smoothly without floating lifting or flame rollout to the furnace vestibule or heat buildup in the vestibule If gas line has been disturbed complete gas leak test GAS LEAK TEST Paint gas control gasket edges and all pipe connections downstream of gas control including pilot tubing connections with rich soap and water solution Bubbles indicate gas leaks Tighten joints and screws or replace component to stop gas leak Recheck with soap and water L Turn thermostat or controller below room temperature Make sure main burner and pilot flames go out Module operation can be conveniently divided into two phases for 58600 58610 andthree for 58660 58670 The phases are Prepurge 58660 58670 only Trial for ignition all models Main burn
30. cial steps may be required to prevent nuisance shutdowns and premature control fail ure These applications require Honeywell Residential Division Engineering review contact your 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 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 controls to protect them from splashing water ANEMA 4 enclosure is recom mended for the 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 hig
31. commend mounting the module with the termi nals down to protect them from dripping water and dust It can also be mounted with the terminals on either side DO NOT MOUNT with terminals pointing up Fasten securely with four No 6 32 machine or No 8 sheetmetal screws MOUNT THE SYSTEM CONTROLS Mount any required controls such as the gas control spark igniter flame sensor thermostat limit and trans former according to manufacturer s instructions 68 0085 2 WIRE THE SYSTEM CAUTION 1 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 As shown in the wiring diagrams a common ground is required on a The pilot burner mounting bracket and b The GND BURNER terminal on the ignition module Failure to use the GND BURNER termi nal may result in intermittent loss of spark and or loss of flame current sensitivity 2 Make sure the transformer has adequate VA The ignition module requires at least 0 2 A at 24 Vac Add the current draws of all other devices in the control circuit including the pilot and main valves in the gas control and multiply by 24 to determine the total VA requirement of these components Ad
32. d this total to 4 8 VA for the ignition module The result is the minimum transformer VA rating Use a Class If transformer if replacement is required Connect Ignition Cable Use Honeywell ignition cable or construct an ignition cable that conforms to suitable national standards such as Underwriters Laboratories Inc See SPECIFICATIONS section Tables 3 and 4 page 4 To construct the cable fit one end with 1 4 in diameter Rajah connector receptacle and the other with a 1 4 in female quick connect Protect both ends with insulated boots NOTE Cable length must be 36 in 0 9 m or less The cable must not run in continuous contact with a metal surface or spark voltage will be greatly reduced Use ceramic or plastic standoff insulators as required 1 Connect one end of the cable to the male quick connect SPARK terminal on the ignition module 2 Connect the other end of the cable to the igniter or igniter sensor stud on the pilot burner igniter sensor 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 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 A non replaceable fuse in the module blows on initial power up Oncethis fuse has blownthe module won t work unless the vent damper
33. ding 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 Checkthe ratings given inthe 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 FIRE OR EXPLOSION HAZARD CAN CAUSE SERIOUS INJURY OR DEATH 1 The ignition module can malfunction if it gets wet leading to accumulation of explosive gas Never install where water can flood drip or condense on module e Never try to use a module that has been wet replace it Liquefied petroleum LP gas is heavier than air and will not vent upward naturally Do not light pilot or operate electric switches lights or appliances until you are sure the appliance area is free of gas CAUTION Disconnect power supply before beginning wir ing to prevent electrical shock or equipment damage If anew gas control is to be installed turn off gas supply before starting installation Conduct Gas Leak Test according to gas control manufacturer s
34. er operation all models Figs 12 and 13 summarize the normal operating se quences of the modules THERMOSTAT CONTROLLER CALLS FOR HEAT STAGE 1 TRIAL FOR IGNIITION First valve pilot operator opens SPARK GENERATOR POWERED PREPURGE 58660 58670 ONLY When the S8660 is used in a fan assisted combustion system the combustion air blower starts on a call for heat On proof of airflow the air proving switch closes and energizes the 58660 58670 When the module is used in an atmospheric system the call for heat energizes the module In either case the module first initiates a 45 sec delay to allow system prepurge After prepurge the module starts the pilot ignition sequence PILOT BURNER OPERATION Pilot burner lights Module senses flame current 4 FLAME CURRENT SENSED Spark generator Second valve operator main opens STAGE 2 MAIN BURNER OPERATION e MAIN BURNER OPERATION Module monitors pilot flame current 6 THERMOSTAT CONTROLLER SATISFIED Valves close pilot and main burners are off Pilot burner does not light OR SB600A F 8610A F ignition spark continues pilot valve remains open until system is reset After 15 90 sec system locks out must be manually reset After 90 sec system shuts off after 5 minutes min 6 minutes nom module restarts trial for ignition ignition trial shutoff wait sequence repeats until pilot lights or Call for heat ends
35. h ambient humidity can cause the gas control to corrode and finally to fail Where the appliance may be installed in a humid 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 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 for the module and the gas control that will limit environmental contamination A NEMA 4 enclosure is recommended for the 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 If the appliance normally operates at very high temperatures insulation shiel
36. in burner lightoff Set the thermostat to call for heat oun the pilot burner during the ignition sequence ee if e Ignition spark continues after the pilot is lit The pilot lights and the spark stops but main burner does not light 8600B H M S8610B H S8660D S8670D only The pilot lights the spark stops and main burner lights but the system locks out If so ensure adequate flame current as follows Turn off furnace at circuit breaker or fuse box Clean the flame rod with emery cloth Make sure electrical connections are clean and tight Replace damaged wire with moisture resistant No 18 wire rated for continuous duty up to 105 C 221 F e Check for cracked ceramic insulator which cause short to ground and replace igniter sensor if necessary e At the gas control disconnect main valve wire from the TH or MV terminal 68 0085 2 power and setthermostatto for heat The pilot should light but the main burner will remain off because the main valve actuator is disconnected e Check the pilot flame Make sure it 5 blue steady and envelops 3 8 to 1 2 in 10 to 13 mm of the flame rod See Fig 14 for possible flame problems and their causes f necessary adjust pilot flame by turning the pilot adjustment screw on the gas control clockwise w to decrease or counterclockwise sN to increase pilot flame Following adjustment al ways replace pilot adjustment cover
37. 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 8 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 11 Fig 2 is a basic circuit for a heating only atmos pheric burner with S8600F H M S8610F H 586600 86700 Fig 3 shows S8600F H M S8610F H with vent damper plug in a heating only atmospheric burner system with D80D vent damper Never use a vent damper in an LP gas system or in a fan assisted combustion system Figs 4 and 5 show S8600A B S8610A B with separate sensor and igniter with and without the D80D vent damper Figs 6 11 show S8600F H M S8610F H 586600 586700 in a variety of systems with alternate connections for modules with vent damper plug Remember however that a vent damper should not be used in an fan assisted combustion system or an LP gas system and that the vent damper plug must not be removed except to connect the module to a D80D with the plug in cable 58600 can be substituted in these drawings by simply connecting the igniter and sensor as shown
38. lot valve in the gas control stopping pilot gas flow The control system must be reset by setting the thermostat below room temperature for one minute or by turning off power to the module for one minute Safety Shutoff with Continuous Retry 58600 The S8600M provides 100 percent gas shutoff fol lowed by retry for ignition Operation on ignition failure is the same as lockout modules except that a timer starts timing immediately following shutoff Six minutes nom five minutes min after shutoff the module restarts the ig nition sequence The ignition trial shutoff wait sequence continues until eitherthe pilot lights or the thermostat is set below room temperature to end the call for heat The module can also be reset by setting down the thermostat for one minute MAIN BURNER OPERATION When the pilot flame is established aflame rectification circuit is completed between the sensor and burner ground Theflame sensing circuit inthe module detects the flame current shuts off the spark generator and energizes the second main valve operator 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 control close STAGE 1 PREPURGE STAGE 2 TRIAL FOR IGNITION STA
39. ly determinethat main burneris burning properly i e no floating lifting or flashback Adjust the primary air shutter s as required 10 the appliance is equipped with high and low flame control or flame modulation check for proper main burner operation at both high and low flame 11 Determine that the pilot is igniting and burning properly and that main burner ignition is satisfactory by interrupting and re establishing the electrical supply to the appliance in any convenient manner Make this de termination with the appliance burner both cold and hot Perform this step as many times as is necessary to satisfy yourself that the automatic intermittent pilot system is operating properly 12 Test the pilot safety device 1 to determine if it is operating properly and 2 forturndown characteristics according to the manufacturer s installation instruc tions No adjustments should be made other than those recommended 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
40. nd is steady and blue Adjust pilot flame checks are okay replace module Check for 24 Vac nominal across MV MV PV terminals if no voltage replace module MAIN BURNER LIGHTS Check electrical connections between module and gas control okay replace gas control YES NOTE module goes into lockout reset system C AU n Check continuity of ignition cable and ground wire NOTE If ground is poor or erratic shutdowns may occur occasionally even though operation is normal at the YES time of checkout checks are okay replace module CALL FOR KEAT ENGS Check for proper thermostat controller operation SYSTEM SHUTS OFF YES Remove MV lead at module if valve closes recheck temperature controller and wiring not replace gas control TROUBLESHOOTING ENDS Repeat procedure until troublefree operation is obtained TOES FIG 16 58660 58670 TROUBLESHOOTING GUIDE 20 The 58610 and 58670 replace earlier Honeywell ignition modules as follows OLD REPLACEMENT MODEL MODEL NUMBER NUMBER 986A 58610 586 58610 586 58610 5860 58610 586 58610 586 58610 5866 8610H S86H 58610 590 58610 S90B 8610B S860C 8670D 58600 586700 COMMENTS If the old module had TH R and TH W terminals see Wire the System page 6 for replacement instructions If the old module had TH R and TH W terminals see Wire the System page 6 for
41. nning this procedure a preliminary ex amination of the appliance and the automatic intermit tent 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 making the modifications 1 Perform a safety inspection of the existing appli ance installation See Exhibit A for a recommended pro cedure for such a safety inspection 2 Shutoff all gas and electricity to the appliance To shut off gas use the shutoff valve in the supply line to the appliance Do not use the shutoff valve which is provided as part of a combination control 3 Install the automatic intermittent pilot system in strict accordance with the manufacturer s installation instructions 4 Turn on all gas and electricity t
42. o the appliance 5 Determine that the appliance transformer has adequate capacity by following the steps outlined be low a Compute the approximate current draw by adding the current draw of the automatic intermit tent pilot system to 1 the current draw of the associated valving and 2 the current draw of any relays or other devices operated by the transformer b Multiply the total current draw as computed above by 24 V to determine the total VA volt ampere required c Thetotal V volt ampere required should be equal to or less than the rating of the trans former d Ifthetotal VA volt ampere required is greater than the V rating of the transformer the trans former must be replaced with a Class 2 trans former of adequate rating 6 Checkthe heat anticipator 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 Make 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 downstream of the shutoff valve in the supply line to the appliance 9 a Adjust the thermostat to its highest tempera ture setting and test manifold pressure and ad justthe pressure regulator to match original input as required refer to Exhibit A step 9b b Visual
43. od YES Check electrical connections between flame rod and module Check lor cracked ceramic flame rod insulator Check that pilot flame covers flame rod and is steady and blue Adiust pilot flame problem persists replace module Check for 24 Vac across MV MV PV terminals if no voltage replace module MAIN BURNER LIGHTS Check electrical connections between module and gas control okay replace gas control or gas control operator YES NOTE If 86108 i wai in SYSTEM RUNS UNTIL 0 86008 H 58610 goes into lockout reset system For S8600M wait 6 min nom for retry or reset system CALL FOR HEAT ENDS Check continuity of ignition cable and ground wire YES NOTE 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 checks are okay replace module CALL FOR HEAT EN CALLFORHEATENDS Check for proper thermostat controiler operation SYSTEM SHUTS OFF Remove lead at module if valve closes recheck temperature controller and wiring if not replace gas control TROUBLESHOOTING Repeat procedure until troublefree operation is obtained ENDS 1174 FIG 15 S8600 58610 TROUBLESHOOTING GUIDE 19 68 0085 2 NOTE Before troubleshooting familiarize yourself with the startup and checkout procedure STA
44. replacing it The ignition module cannot be repaired If it malfunctions it must be replaced 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 trou bleshooting guide Fig 15 or 16 and the schematic diagram Figs 17 22 to pinpoint the cause of the prob lem If troubleshooting indicates an ignition problem see ignition System Checks below to isolate and correct the problem Following troubleshooting perform the checkout pro cedure page 14 again to be sure system is operating normally IGNITION SYSTEM CHECKS STEP 1 Check ignition cable Make sure CJ Ignition cable does not run in contact with any metal surfaces Ignition cable is no more than 36 in 0 9 m long Connections to the ignition module and to the igniter or igniter sensor are clean and tight LJ Ignition cable provides good electrical continuity STEP 2 Check ignition system grounding Nuisance shutdowns are often caused by a poor or erratic ground A common ground usually supplied by the pilot burner bracket is required for the module and the pilot burner igniter sensor e Check for good metal to metal contact between the pilot burner bracket and the main burner e Check the ground lead from the GND BURNER terminal on the module to the pilot burner Make sure connections are clean and tight If
45. round is not required REPLACING MODULE WITH TH R TH W TERMINALS On modules except those with vent damper plug the thermostat must be connected between the transformer and the 24V terminal on the module To change out a TABLE 5 TERMIN module with TH R TH W terminals 1 Remove the wires from the 25V 2 and TH R termi TERMINAL ON nals on the old module Connect these two wires with a OLD MODULE solderless connector 25V 1 2 Tag and remove the remaining wires from the old TH W module MV 3 Remove the old module and mount the new one inthe MV PV same location PV 4 Reconnect the remaining wires as shown in Table 5 GND Burner 5 Increase the thermostat anticipator setting by 0 2 A S8600F 58610 86600 86700 VENT GND 24V TH W DAMPER MV MV PV PV BURNER PLUG OPT 1 ST 2ND OPERATOR OPERATOR THERMOSTAT DUAL VALVE COMBINATION GAS CONTROL LIMIT CONTROLLER os L Li Q345 Q346 Q348 Q362 Q381 PILOT BURNER BURNER IGNITER SENSOR i GROUND TT PILOT GAS E SUPPLY POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION MAXIMUM CABLE LENGTH 3 ft 0 9 m A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER A FOR MODULE WITH TH W TERMINAL AND VENT DAMPER PLUG CONNECT THERMOSTAT TO TH W LEAVE 24V OPEN DO NOT REMOVE VENT DAMPER PLUG AL CROSS R
46. safe condition 3 Shut off all gas to the appliance and shut off any other fuel burning appliance within the same room Use the shutoff valve in the shutoff valve in the supply line to each appliance 4 Inspect burners and crossovers for blockage and corrosion 5 Applicable only to warm air heating appliances Inspect heat exchangers for cracks openings or exces sive corrosion 6 Applicable only to boilers Inspect for evidence of water or combustion product leaks 7 Insofar as is practical close all building doors and windows and all doors between the space in which the appliance is located and other spaces of the building Turn on clothes dryers Turn on any exhaustfans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer 28 exhaust fan Close fireplace dampers If after complet ing steps 7 through 12 it is believed sufficient combus tion air is not available referto 1 3 4 of the National Fuel Gas Code 7223 1 for guidance 8 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 9 a Determine that the pilot is burning properly and that main burner ignition is satisfactory by interrupting and re establishing the electrica supply to the appliance in any convenient man ner b Determine manifold pressure in order to match input after the new control is installed 10
47. screw and tighten firmly to assure proper gas control operation Set thermostat below room temperature to end call for heat 1 Recheck ignition sequence as follows e Reconnect main valve wire Set thermostat to call for heat Watch ignition sequence at burner If spark still doesn t stop after pilot lights replace ignition module If main burner doesn t light or if main burner lights but system locks out check module ground wire and gas control as described in appropriate trou bleshooting chart Fig 15 or 16 18 APPEARANCE SMALL BLUE FLAME LAZY YELLOW FLAME WAVING BLUE FLAME NOISY LIFTING BLOWING FLAME l HARD SHARP FLAME CAUSE CHECK FOR LACK OF GAS FROM e CLOGGED ORIFICE FILTER e CLOGGED PILOT FILTER e LOW GAS SUPPLY PRESSURE e PILOT ADJUSTMENT AT MINIMUM CHECK FOR LACK OF AIR FROM LARGE ORIFICE DIRTY LINT SCREEN IF USED DIRTY PRIMARY AIR OPENING THERE IS ONE e PILOT ADJUSTMENT 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 10 8298 FIG 14 EXAMPLES OF UNSATISFACTORY PILOT FLAMES ST A RT NOTE Before troubleshooting familiarize yourself with the startup and checkout procedure TURN GAS SUPPLY OFF TURN THERMOSTAT CON
48. the wire is damaged or deteriorated replace it with No 14 18 gauge moisture resistant thermoplastic insulated wire with 105 C 221 F minimum rating Check the ceramic flame rod insulator for cracks or evidence of exposure to extreme heat which can permit leakage to ground Replace 17 pilot burner igniter sensor and provide shield if necessary flame rod or bracket are bent out of posi tion 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 CJ Close the manual gas valve Disconnect the ignition cable at the SPARK terminal on the module When performing the following steps do not touch stripped end of jumper or SPARK termi nal The ignition circuit generates over 10 000 volts and electrical shock can result L Energize the module and immediately touch one end of the jumper firmly to the GND terminal on the module Move the free end of the jumper slowly toward the SPARK terminal until a spark is established 1 Pull the jumper slowly away from the terminal and note the length of the gap when sparking stops Check table below ARC LENGTH No arc or arc less than 1 8 in 3 mm ACTION Check external fuse if provided Verify power at module input terminal Replace module if fuse and power okay Arc 1 8 in 3 mm Voltage output is okay or longer STEP 4 Check pilot and ma
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