69-0845-2 - Super Tradeline S8910U Universal Hot
Contents
1. YES CHECK FOR 120 VAC ACROSS HOT no SURFACE IGNITER TERMINALS p REPLACE S8910U YES CHECK WIRES TO IGNITER IF OK REPLACE IGNITER MAIN BURNER LIGHTS CHECK FOR 24 VAC ACROSS VALVE TERMINALS ON S8910U DURING TRIAL FOR IGNITION TIMING IF NO VOLTAGE REPLACE 589100 CHECK ELECTRICAL CONNECTIONS BETWEEN S8910U AND GAS CONTROL IF OK REPLACE GAS CONTROL CHECK IGNITER POSITION CHECK GAS PRESSURE TO MAIN BURNER NOTE IF S8910U GOES INTO LOCKOUT RESET SYSTEM CHECK CONTINUITY OF GROUND WIRE AND GROUND PATH FROM MAIN BURNER TO GND BURNER TERMINAL OF S8910U CONFIRM THAT 120 VAC HOT LEAD IS CONNECTED TO L1 AND 120 VAC NEUTRAL LEAD IS CONNECTED TO L2 CHECK THAT BURNER FLAME COVERS IGNITER SENSOR OR SENSOR CHECK INSULATION ON IGNITER SENSOR LEADS CHECK IGNITER SENSOR OR FLAME ROD FOR CONTAMINATION OR DAMAGE REPLACE IF NECESSARY CHECK INSULATION ON SENSOR LEADS AND CHECK SENSOR POSITION IF CHECKS ARE OK REPLACE 589100 MODULE NOTE SYSTEM FAILURE AFTER MAIN FLAME LIGHTS HAS A LOW PROBABILITY OF BEING THE S8910U NO NOTE IF S8910U GOES INTO LOCKOUT RESET SYSTEM E E TS GALE 4 CHECK CONTINUITY OF GROUND WIRE NOTE IF GROUND IS POOR OR ERRATIC SHUTDOWNS CAN OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT YES CHECK FOR EXCESSIVE HEAT AT IGNITER OR FLAME ROD CERAMIC BASE TEMPERATURE ABOVE 1000 F 538 C CAUSES SHORT TO GROUND IF CHECKS ARE OKAY REPLACE 589102. LIMIT CONTROLLER L1 THERMOSTAT OR VAN CONTROLLER HOT 12 POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED MAKE SURE L1 AND L2 ARE NOT REVERSED VAN ALTERNATE LIMIT CONTROLLER LOCATION SENSE ROD WILL BE PRESENT IF REMOTE SENSE HS780 MODEL SEE TABLE 3 A WHEN HS780 IS A REMOTE SENSE MODEL REMOVE JUMPER QUICK CONNECT FROM S8910U CUT WIRE AT CIRCUIT BOARD AND DISCARD CONNECT FLAME ROD LEAD WIRE O SENSE SEE TABLE 2 A CUT 1 4 IN QUICK CONNECT OFF WIRE AND REPLACE WITH 3 16 IN QUICK CONNECT SUPPLIED USE GREEN GROUND ADAPTER SUPPLIED CONNECT 589100 GND BURNER TO APPLIANCE CHASSIS M8529B Fig 4 Typical hookup when S8910U re 69 0845 2 10 places Robertshaw HS780 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE TERMINAL CROSS REFERENCE 589100 589 5890 589100 HOT SURFACE IGNITER CONTROL GND BURNER GND BURNER 24V GND 24V GND VALVE GND VALVE GND 24V 24V Honeywell wis mn 55422 589100 HOT SURFACE IGNITION ANWARNING E INPUT VOLTAGES 120 amp 24 VAC 60HZ IS HSI 120V 6 5A MAX Explosion hazard cause VALVE 24V 1A MAX TOTAL 24V LOAD serious injury or death This device can malfunction if STATUS LED it gets wet Never try to use a device that has been wet replace it 0 2 VALVE LOAD 2 VALVE VALVE L2 12 1 1
3. BURNER L GROUND HOT SURFACE IGNITER THERMOSTAT OR CONTROLLER A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED MAKE SURE L1 AND L2 ARE NOT REVERSED A ALTERNATE LIMIT CONTROLLER LOCATION A REMOVE JUMPER QUICK CONNECT FROM S8910U CUT WIRE AT CIRCUIT BOARD AND DISCARD A USE ADAPTER PLUG WITH BLACK AND ORANGE WIRES SUPPLIED A CUT 3 16 IN QUICK CONNECT OFF WIRE AND REPLACE WITH 1 4 IN QUICK CONNECT SUPPLIED A CUT 3 16 IN QUICK CONNECT OFF WIRE AND REPLACE WITH 3 16 IN QUICK CONNECT SUPPLIED Fig 3 Typical hookup when S8910U replaces White Rodgers 50E F47 9 69 0845 2 589100 UNIVERSAL HOT SURFACE IGNITION MODULE TERMINAL CROSS REFERENCE S8910U S8910U HOT SURFACE IGNITER CONTROL d GND BURNER V TR GND CLIP 24V GND VALVE GND Honeywell A WARNING 589100 HOT SUI Explosion hazard Can cause INPUT VOLTAGES 120 amp 24 VAC 60HZ Sem HSI 120V 6 5A MAX VALVE 24V 1 MAX TOTAL 24V LOAD 0 2 VALVE LOAD MN 55422 IRFACE IGNITION serious injury or death This device can malfunction if itgets wet Never try to use a device that has been wet replace it 24V VALVE Prepurge Time Taner Warmup Tim L2 1 BURNER GND TAVAT H A BURNER L GROUND MV COMBINATION SURFACE IGNITER
4. Igniter Warmup 34 seconds Between Trial Purge 96 seconds three trial mode only Flame Failure Response Time 1 5 seconds maximum Ignition Sequence The number of trials for ignition and trial time are deter mined by the selection tab See Table 1 If a selection tab is not installed the module will operate at four seconds trial time and one ignition trial Ambient Operating Temperature 40 F to 175 40 C to 79 C Accessory Bag Assembly White Rodgers adapter Robertshaw ground lead Four 1 4 in female 032 quick connects One 3 16 in female 032 quick connect Four selection tabs Seven wire labels Approval Bodies IAS Design Certified Certification Report No C2027002 Table 1 White Rodgers Control to Honeywell S8910U Cross Reference NOTES This list is for reference only Honeywell reserves the right to add or delete models at any time based on new or updated information White Rodgers product information was obtained from the 1991 White Rodgers Product Catalog R3700 8910U Remove Local L or Model Selection Black Remote R Numbers Tab Jumper Sensing S8910U Local or B PpP Specifications Remote Igniter Between soe47 tthrug f ves R 4 1J o m7 1 o 50E47 10 thru 19 50E47 20 thru 29 50E47 30 thru 39 50E47 40 thru 49 50E47 50 thru 59 50E47 60 thru 69 50E47 70 thru 79 50E47 101 thru 109 50E47 110 thru 119 50E47 12
5. SENSOR d FA BURNER L GROUND COMBINATION GAS CONTROL Mmv SURFACE IGNITER CONTROLLER THERMOSTAT OR CONTROLLER POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED MAKE SURE L1 AND L2 ARE NOT REVERSED VAN ALTERNATE LIMIT CONTROLLER LOCATION A SENSE ROD WILL BE PRESENT IF REMOTE SENSE 589 5890 MODEL SEE TABLE 3 A WHEN S89 S890 IS A REMOTE SENSE MODEL REMOVE JUMPER QUICK CONNECT FROM S8910U CUT WIRE AT CIRCUIT BOARD AND DISCARD CONNECT FLAME ROD LEAD WIRE TO SENSE SEE TABLE 3 M8530B A CUT QUICK CONNECTS OFF WIRES AND REPLACE WITH 1 4 IN QUICK CONNECTS PROVIDED Fig 5 Typical hookup when S8910U replaces Honeywell S89 S890 Step 1 Perform visual inspection STARTUP AND CHECKOUT a With power off make sure all wiring connections are clean and tight Check out the gas control system b Turn on the power to the appliance and the S8910U Atinitial installation of the appliance c Open the manual shutoff valves in the gas line to the As part of regular maintenance procedures appliance Atmaintenance intervals determined by the application d Test for a gas leak upstream of the gas control if Asthe first step in troubleshooting piping has been disturbed Any time work is done on the system GAS LEAK TEST Paint the gas control gasket edges and Maintenance frequency must be determined individually all the pipe connecti
6. circuit determines if the main burner flame is present If so the gas control remains open and the burner operation phase begins Burner Operation When the main burner is lit a flame rectification circuit is completed between the flame sensor igniter on local sense systems or flame rod on remote sense systems and the main burner burner ground The S8910U flame sensing circuit detects the flame current and holds open the gas control The main flame is monitored continuously during the call for heat Safety Shutdown One Trial Selection Tabs A and C If flame is not sensed by the end of the timed trial for ignition the gas control closes and the module locks out It must be manually reset by removing power or setting the thermostat below the room temperature for at least 30 seconds If the burner lights and flame is proved 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 Selection Tabs B and D If flame is not sensed by the end of the first timed trial for ignition the gas control closes and the module initiates a second 96 seconds between trial purge cycle followed by igniter warmup and a second trial for ignition If flame is not established the between trial purge warmup trial for ignition cycle is repeated a third time If
7. Fig 2 Separating and installing selection tab Wire the Module N CAUTION 1 Check the wiring diagram furnished by the appliance manufacturer if available and compare with Table 4 Carefully follow any special instructions affecting the general procedures outlined in this section 2 Disconnect the power supply before making wiring connections to prevent electrical shock or equipment damage IMPORTANT 1 All wiring must comply with applicable electrical codes and ordinances 2 Hot surface igniter leadwires should not be allowed to rest against grounded metal surfaces 3 A common ground is required for the S8910U and the main burner The 24V 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 69 0845 2 589100 UNIVERSAL HOT SURFACE IGNITION MODULE 4 Make sure the transformer has adequate VA 1 Connect the wires to the 589100 Ignition Module as The ignition module requires 0 4A at 24 Vac shown in Table 4 Make sure that adequate system Aad the current draws of all other devices in ground is provided as indicated in the wiring table the control circuit including the pilot and main See Fig 3 through 5 Where a change in quick valves in the gas control and multiply by 24 to connect is required cut off the original quick determine the total VA requirement of these connect strip the leadwi
8. 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 thermostat below the room temperature for at least 30 seconds 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 between trial 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 the lockout 69 0845 2 MAINTENANCE A WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Do not attempt to take apart the module or to clean it Improper assembly and cleaning can cause unreliable operation Regular preventive maintenance is important in applica tions that place a heavy load on system controls such as those used in the commercial cooking and agricultural and industrial industries because n many such applications particularly commercial cooking the equipment operates 100 000 to 200 000 cycles per year Such heavy cycling can wear out the gas control in one to two years Exposure to water dirt chemicals and heat can damage the gas control and shut down the control system A NEMA 4 enclosure can reduce exposure to environmental contaminants See Electronic
9. 0 MODULE NOTE SYSTEM FAILURE DURING A RUN CYCLE HAS A LOW PROBABILITY OF BEING THE S8910U CHECK FOR PROPER TEMPERATURE CONTROLLER OPERATION REMOVE VALVE LEAD AT S8910U IF VALVE CLOSES RECHECK TEMPERATURE CONTROLLER CALL FOR HEAT ENDS SYSTEM SHUTS OFF YES AND WIRING IF NOT REPLACE GAS CONTROL TROUBLESHOOTING ENDS REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED M8531A Fig 8 589100 troubleshooting sequence Honeywell Home and Building Control Home and Building Control Helping You Control Your World Honeywell Inc Honeywell Limited Honeywell Limit e Honeywell Plaza 155 Gordon Baker Road P O Box 524 North York Ontario Minneapolis MN 55408 0524 M2H 2C9 69 0845 2 J S Rev 7 96 Printed in U S A
10. 0 thru 129 50E47 130 thru 139 50E47 140 thru 149 50E47 150 thru 159 50E47 160 thru 169 50E47 170 thru 179 50E47 201 thru 209 50E47 210 thru 219 50E47 220 thru 229 50E47 230 thru 23 50E47 240 thru 249 50E47 250 thru 259 50E47 260 thru 269 ejojoj ojojo joj ojoj ojoj oj o ojo o o o o o o o o6 olo oj jo j oj o j ojo oj o o o oj o o o o o o o o 69 0845 2 2 a 2 gt a gt a 2 gt AR A a a gt Aaj gt gt N NJaj 2 gt gt ALA A N N N NININ N 5 z gt gt ALA Ww ow A EN l continued S8910U UNIVERSAL HOT SURFACE IGNITION MODULE Table 1 White Rodgers Control to Honeywell 589100 Cross Reference Continued NOTES This list is for reference only Honeywell reserves the right to add or delete models at any time based on new or updated information White Rodgers product information was obtained from the 1991 White Rodgers Product Catalog R3700 8910U Remove Local L or Igniter Between Model Selection Black Remote R Ignition PrePurge Warmup Trial Purge Numbers Tab Jumper Sensing Trials sec sec sec 3 8910U Local or Specifications Remote N a A N A o w are a A N w N e w 12 ayn ojo m m ALA NIN w RlO ojo e re x m oS Ww ow RIO ajaja ojojo m m m A X
11. 3 If a module must be mounted where it can be exposed to moisture or water provide a suitable waterproof enclosure 4 Using the wire labels provided label all the wires before disconnecting Wiring errors can cause improper appliance operation and dangerous conditions such as bypassing safety features Perform Preinstallation Safety Inspection A preinstallation safety check of the appliance and venting System must be done before the replacement module is installed If a condition is detected that could result in unsafe operation shut off the appliance and advise the owner of the unsafe condition Correct any potentially unsafe condition before proceeding with the installation Remove Old Module Disconnect the power supply before doing any work on the unit Disconnect and tag the wires from the old module using the wire labels provided Remove the old module from its mounting location Mount New Ignition Module Mount the S8910U Module in the same location as the old module Protect the module from exposure to water moisture corrosive chemicals and excessive dust and grease Assure that ambient temperature at the module is within the range listed in the Application section Mount the module with the terminals down to protect from dripping water and dust The module can also be mounted with terminals on either side Do not mount with the terminals pointing up Refer to Fig 1 for mounting recom mendations When it is necessary t
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13. Honeywell 589100 Universal Hot Surface Ignition Module SUPER TRADELINE Installation Instructions for the Trained Service Technician APPLICATION The SUPER TRADELINE S8910U Universal Hot Surface Ignition Module is designed to provide easy field replacement for a wide range of hot surface ignition modules manufactured by Honeywell Robertshaw and White Rodgers The S8910U Module provides operating control of a direct ignition system using a 120 Vac hot surface igniter The S8910U replaces existing flame rectification type hot surface ignition modules with the following characteristics 120 Vac up to 5A timed warmup hot surface ignition elements Single rod local sense or dual rod remote sense hot surface ignition One or three ignition trials per call for heat Four second or seven second ignition trials Prepurge of 32 seconds or less Up to 96 seconds between trial purge times three trial mode only Natural or LP gas The S8910U is not designed to replace Intermittent pilot ignition controls Direct spark ignition controls Proven 120 Vac hot surface ignition controls 24 Vac element hot surface ignition controls 240 Vac input 120 Vac element hot surface ignition controls 120 Vac timed warmup hot surface ignition controls with Jgnition trial time shorter than four seconds Jgnition trial time longer than twelve seconds Edge connectors rather than male quick connect
14. Ignition Service manual form 70 6604 The maintenance program should include regular check out of the system as outlined in the Startup and Checkout section and checkout of the control system as described in the appliance manufacturer literature Maintenance frequency must be determined individually for each application Some considerations are Cycling frequency Appliances that may cycle 20 000 times annually should be checked monthly Intermittent use Appliances that are used seasonally should be checked before shutdown and again before the next use Consequence of unexpected shutdown Where the cost of an unexpected shutdown would be high the system should be checked more often Dusty wet or corrosive environment Because these environments can cause the gas control 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 replace any module if it is wet or looks like it has ever been wet Protective enclosures as described in the Planning the Installation section are recommended regardless of checkout frequency TROUBLESHOOTING IMPORTANT 1 The following service procedures are provided as a general guide Follow appliance manu facturer service instructions if available Meter readings between gas control and ignition module must be taken within the trial for ignition period Once the ig
15. N When Installing this Ignition System 1 Read these instructions carefully Failure to follow them could damage the components or cause a hazardous condition 2 Check Tables 1 through 3 to confirm that the S8910U is a direct replacement for the existing module 3 Installer must be a trained experienced service technician 4 After installation is complete check out component and appliance operation as provided in these instructions 69 0845 2 A WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH 1 If the ignition module gets wet it can malfunc tion leading to accumulation of explosive gas Never install where water can flood drip or condense on the module Never use a module that has been wet Replace it 2 Liquefied petroleum LP gas is heavier than air and will not vent upward naturally Donotlight the pilot or operate electric Switches lights or appliances until you are sure the appliance area is free of gas 3 Do not attempt to disassemble or clean the module Improper reassembly and cleaning can cause unreliable operation CAUTION Disconnect the power supply before beginning wiring to prevent electrical shock or equipment damage 2 If a new gas control is to be installed turn off the gas supply before starting the installation After the gas control is installed conduct a Gas Leak Test according to the gas control manu facturer instructions
16. TER OFF FLAME SENSING BEGINS FLAME PRESENT GAS CONTROL STAYS OPEN MAIN BURNER RUNS MAIN BURNER OPERATION FAILURE CALL FOR HEAT IS SATISFIED GAS CONTROL CLOSES END MAIN BURNER OFF SIMULATING ONE TRIAL TABS A AND C In either case the S8910U first initiates a 32 second delay to allow system prepurge Igniter Warmup After prepurge the S8910U energizes the igniter to start the igniter warmup The module energizes the hot surface igniter for a 34 second warmup period during which the gas control is closed SYSTEM WILL NOT START ONE TRIAL TABS A AND C LOCKOUT OCCURS SYSTEM MUST BE RESET THREE TRIALS TABS B AND D PLANE CON HOW MANY IGNITION Ri CLOSES TRIALS COMPLETED THIS CALL FOR HEAT THREE TRIALS TABS B AND D THREE LOCKOUT OCCURS SYSTEM MUST BE RESET 8527 Fig 7 589100 normal operating sequence 69 0845 2 589100 UNIVERSAL HOT SURFACE IGNITION MODULE Trial for Ignition At the end of the warmup period the gas control opens for the ignition trial time determined by the selection tab The hot surface igniter stays powered for an ignition activation period of one second if the four second trial time is used or four seconds if the seven second trial time is used The igniter turns off after the ignition activation period Near the end of the ignition trial time the flame rectification sensing
17. TS OR ORIFICE FILTER WRONG SIZE ORIFICE LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM DIRTY PRIMARY AIR OPENING LARGE PORTS GOOB OR ORIFICES RECTIFYING FLAME I 3 4 TO 1 IN 19 TO 25 MM 1 4 TO 1 2 IN 6 TO 13 MM M8446 Fig 6 Check burner flame condition OPERATION The S8910U is a direct ignition control used with a 120 Vac timed warmup hot surface igniter The control provides operating control and shuts off all gas flow on ignition failure or loss of main burner flame in central heat furnaces and other heating appliances Module operation is in three phases prepurge igniter warmup trial for ignition and burner operation The S8910U provides one or three trials for ignition depending on which selection tab is installed Fig 7 shows the normal operating sequence S8910U UNIVERSAL HOT SURFACE IGNITION MODULE Purge Prepurge When the S8910U 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 S8910U When the S8910U is used in an atmospheric system the call for heat energizes the module START PREPURGE IGNITER WARMUP CALL FOR HEAT 24V TERMINAL POWERED INTERNAL SAFE START CHECK BEGINS FAILURE NO FLAME SIMULATING FAILURE PREPURGE IGNITER WARMS UP GAS CONTROL OPENS FOR TIMED TRIAL FOR IGNITION TRIAL FOR IGNITION IGNI
18. al or B Specifications Remote Oo Igniter Between Warmup Trial Purge sec sec Ignition PrePurge Trials z gt wo e No t 6 _ 34 m lo 89C1012 lo 89C1046 89C1087 89C1103 58901002 2 ojo C No B D EB w D No Yes D Ye D Yes No D No D j D No 8 Ye D Yes D Ye 4 4 NA e a The S8910U and the original control lockout times are different The S8910U lockout time is within the design tolerance lockout time of the original control b The lockout time of the S8910U is shorter than the original control Be sure to observe the appliance operation under a variety of input conditions to assure reliable operation REVIEW THE INSTALLATION A WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Follow these warnings exactly 1 Review the installation as outlined in this section 2 Plan for frequent maintenance as described in the Maintenance section When hot surface ignition systems are used on central heating equipment in barns greenhouses and commercial properties and on heating appliances such as commercial cookers agricultural equipment industrial heating equipment and pool heaters heavy demands are made on the controls Special steps can
19. as control gasket edges and all pipe connections downstream of the gas control with a rich soap and water solution Bubbles indicate a gas leak Tighten the joints and screws or replace component to stop a gas leak Recheck with soap and water solution Check the burner flame condition The igniter sensor or sensor must be constantly immersed in flame Check the burner flame condition as shown in Fig 6 Do not relocate the hot surface igniter or flame rod f Turn the thermostat or controller below the room temperature Make sure the main burner and pilot flames go out 69 0845 2 12 A WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Improper location of the 120 Vac hot surface igniter or any flame sensing rod can result in appliance malfunction 1 Never attempt to relocate the 120 Vac hot surface igniter or the flame sensing rod from the original position established by the appliance manufacturer 2 Be sure the 120 Vac hot surface igniter or the flame sensing rod is replaced in exactly the original position after removal for inspection service or replacement CHECK BURNER FLAME CONDITION NOISY LIFTING FLAME CHECK FOR HIGH GAS PRESSURE EXCESS PRIMARY AIR OR DRAFT BURNER M yaga WAVING fe M FLAME CHECK FOR POOR DRAFT EXCESS DRAFT HIGH VELOCITY OR SECONDARY AIR INSTALL SHIELD IF NECESSARY SMALL BLUE FLAME CHECK FOR CLOGGED POR
20. be required to prevent nuisance shutdowns and control failure due to frequent cycling severe environmental conditions related to moisture corrosive chemicals dust or excessive heat These applications require Honeywell Home and Building Control Engineering review contact your Honeywell Sales Representative for assistance Review the following conditions that can apply to your specific installation and take the precautionary steps suggested Frequent Cycling These controls are designed for use on appliances that typically cycle only three to four times an hour during the heating season In year round applications with greater cycling rates the control can wear out more quickly Perform a monthly checkout Water or Steam Cleaning If a module or gas control gets wet replace it If the appliance is likely to be cleaned with water or steam cover the controls and wiring to protect from water or steam flow 69 0845 2 589100 UNIVERSAL HOT SURFACE IGNITION MODULE Mount the controls high enough above the bottom of the cabinet to avoid getting wet during normal cleaning procedures NEMA 4 enclosure is recommended for the ignition module see the Electronic Ignition Service Manual form 70 6604 High Humidity or Dripping Water Dripping water can cause the module to fail Never install an appliance where water can drip on the controls In addition high ambient humidity can cause the gas control to corrode and fail If the app
21. burner failing to light or failure to detect the flame Run the appliance through a call for heat and if the burner does not light check the gas supply input voltage hot surface igniter gas control wiring If the main burner lights but goes out at the end of ignition trial check the igniter sensor flame rod burner ground connections wiring Two flashes indicates the flame rectification signal is weak The most probable causes are contaminated or mislocated igniter sensor or flame rod poor flame sense leadwire insulation or connections poor gas pressure If the flame rectification signal is strong when the appliance lights but weak while heat is being delivered check for overheating of the igniter sensor flame rod ceramic or flame sense leadwires Three flashes indicate an internal error The most probable cause is an S8910U logic failure Start a new call for heat and if the three flash signal returns replace the S8910U Ignition System Checks Step 1 Check the igniter wire harness Make sure a b C Ignition cable does not run in contact with any metal surfaces Connections to the ignition module and to the igniter or igniter sensor are clean and tight Ignition cable provides good electrical continuity Step 2 Check the ignition system grounding Nuisance shutdowns are often caused by a poor or erratic ground a A common ground is required for the module igniter fla
22. d and replace unit if necessary Make sure the electrical connections are clean and tight Replace damaged wire with moisture resistant No 18 wire rated for continuous duty up to 221 F 105 C Ifthe igniter is other than a Norton 201 or 271 make sure it meets the following specifications Igniter must reach 1832 F 1000 C within 34 seconds with 102 Vac applied Igniter must maintain at least 500M ohm insulation resistance between the igniter leadwires and the igniter mounting bracket Igniter must not develop an insulating layer on its surface over time that would prevent flame sensing Igniter surface area immersed in flame must not exceed one fourth of the grounded area immersed in flame This would prevent flame sensing Igniter current draw at 132 Vac must not exceed 5A 69 0845 2 589100 UNIVERSAL HOT SURFACE IGNITION MODULE START TURN THERMOSTAT NOTE BEFORE TROUBLESHOOTING BECOME FAMILIAR WITH STARTUP CALL FOR HEAT AND CHECKOUT PROCEDURES DOES 589100 GET POWER 24 VAC NOMINAL YES CHECK LINE VOLTAGE POWER CHECK LOW VOLTAGE TRANSFORMER CHECK LIMIT CONTROLLER CHECK AIR PROVING SWITCH IF USED CHECK THERMOSTAT CHECK WIRING NO PURGE CHECK AIR PROVING SWITCH PURGE REPLACE 589100 YES IGNITER WARMS UP AND CONFIRM THAT 120V HOT LEAD CHECK AND CORRECT WIRING FUSE WA CONNECTS TO L1 AND 120V NEUTRAL Ga CIRCA DREAMER LEAD CONNECTS TO L2 i
23. d can result in appliance malfunction Electrical Ratings Control Voltage 24V 60 Hz Maximum Valve Contact Rating 2A Current Draw 4A plus valve load Hot Surface Igniter Voltage 120 Vac 60 Hz Contact Rating At 120 Vac 5A IMPORTANT Use the S8910U only in a 60 Hz system Be sure the system is not 50 Hz Hot Surface Igniter or Igniter Sensor Norton Model 201 or 271 or equivalent NOTE Ifan igniter other than a Norton Model 201 or 271 is used the igniter must meet the following minimum specifications required over the life of the igniter Igniter must reach 1832 F 1000 C 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 that would prevent flame sensing Igniter surface area immersed in flame must not exceed one fourth of the grounded area immersed in flame This would prevent flame sensing Igniter current draw at 132 Vac must not exceed 5A 69 0845 2 589100 UNIVERSAL HOT SURFACE IGNITION MODULE Sensor A separate sensor is required for remote sensing applica tions Wiring Use the existing appliance wiring If repair or replacement of leadwires is required follow the instructions on the appliance label Use the included quick connect terminals according to the instructions Prepurge 32 seconds
24. ing section to correct problem Step 5 Check safety lockout operation a Turn off the gas supply b Set the thermostat or controller above the room temperature to call for heat c Watch for igniter warmup following prepurge Igniter starts to glow several seconds after it is powered d Time the length of time the gas control is energized measure the time by connecting a voltmeter across the gas valve terminals Selection tabs A and B 4 seconds Selection tabs C and D 7 seconds e When using a three trial ignition selection tab tabs B or D watch for the start of 96 second between trial purge followed by 34 second igniter warmup and second try for ignition After a third purge warmup and trial for ignition sequence the 589100 should lock out LED goes into one flash mode after lockout f Open the manual gas control knob and make sure no gas is flowing to the burner g Set the thermostat below the room temperature and wait one minute before continuing Step 6 Check normal operation a Setthe thermostat or controller above the room temperature to call for heat b Observe the lightoff sequence and make sure the main burner lights smoothly without flashback c Make sure the burner operates smoothly without floating lifting or flame rollout to the furnace vestibule or heat buildup in the vestibule d Test for a gas leak downstream of the gas control if piping has been disturbed GAS LEAK TEST Paint the g
25. joljoljojoljoljojojojojoljoljojoljoljoljoljolj jol o alata 5 5 ial al BLAIS wj ojojo elele jem i Vjen Ran a 3 3 3 cicic w Naa 3 69 0845 2 589100 UNIVERSAL HOT SURFACE IGNITION MODULE Table 2 Robertshaw Control to Honeywell S8910U Cross Reference NOTE Robertshaw product information was obtained from the 1993 1994 Robertshaw Uni Line Catalog 2 064 589100 Remove Local L or Igniter Between Model Selection Black Remote R Ignition PrePurge Warmup Trial Purge Numbers Tab Jumper Sensing sec sec S8910U Local or Specifications B Remote D Nw 4 L L B D D HS780 34NL 304A B Dp D i D o z gt No No No aThe S8910U and the original control lockout times are different The S8910U lockout time is within the design tolerance lockout time of the original control b The lockout time of the S8910U is shorter than the original control Be sure to observe the appliance operation under a variety of input conditions to assure reliable operation No No No No No No oj ojo o NINH 69 0845 2 4 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE Table 3 Honeywell Control to Honeywell S8910U Cross Reference 589100 Remove Local L or Model Selection Black Remote R Numbers Tab Jumper Sensing S8910U Loc
26. lace with the included 3 16 in quick connect Do not use this terminal if model being replaced does not have 120V neutral power supply connection f Use the black wire on the included adapter cable 9 Use the orange wire on the included adapter cable h On remote sense models remove jumper quick connect from S8910U sense terminal cut jumper wire at circuit board and discard On local sense models leave black jumper connected i Remove jumper from S8910U sense terminal cut jumper wire at circuit board and discard 69 0845 2 8 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE TERMINAL CROSS REFERENCE 589100 50E F47 589100 HOT SURFACE IGNITER CONTROL GND BURNER GND 24V GND R Honeywell ws mn 55422 TI lo VALVE GND 589100 HOT SURFACE IGNITION A WARNING NEUTMO TAGES era T ipldion Con ass MV NEXT TO TR HSI 120V 6 5A MAX 24V VALVE 24V 1A MAX TOTAL 24V LOAD 0 2 VALVE LOAD serious injury or death This device can malfunction if TH Propurge Time 30 Sec Igniter Warmup Time 34 sec ition Lockout Signal VALVE itgets wet Never try to use a device that has been wet replace it lace Control Replat Operation MV FLAME 120 SENSOR BURNER CS GND L COMBINATION GAS CONTROL
27. liance is in a humid atmosphere make sure air circulation around the controls is adequate to prevent condensation Also regularly check out the system NEMA 4 enclosure is recommended for the ignition module see the Electronic Ignition Service Manual form 70 6604 Corrosive Chemicals Corrosive chemicals can attack the module and gas control eventually causing a failure If chemicals are used for routine cleaning avoid contact with the controls Where chemicals are suspended in air for some industrial or agricultural applications a NEMA 4 enclosure is recom mended for the ignition module see the Electronic Ignition Service Manual form 70 6604 Dust or Grease Accumulation Heavy accumulations of dust or grease can cause controls to malfunction Where dust or grease can be a problem provide covers for the module and the gas control to limit contamination A NEMA 4 enclosure is recommended for the ignition module see the Electronic Ignition Service Man ual form 70 6604 Heat Excessively high temperatures can damage controls Make sure the maximum ambient temperature at the control does not exceed the rating of the control If the appliance operates at very high temperatures use insulation shielding and air circulation as necessary to protect the controls Proper insulation or shielding should be provided by the appliance manufacturer verify proper air circulation is maintained when the appliance is in stalled INSTALLATIO
28. me sensor and main burner Check for good metal to metal contact between the igniter bracket and the main burner Check the ground path from the GND BURNER terminal on the module to the main burner Make sure the connections are clean and tight If the wire is damaged or deteriorated replace it by following the appliance manufacturer instructions A temporary leadwire connection between the GND BURNER terminal and the main burner can help confirm a ground path problem Check the temperature at the igniter ceramic or flame sensor insulator Excessive tempera ture permits leakage to ground Contact the appliance manufacturer if the temperature exceeds the rating of the igniter or sensor Ifthe flame sensor or bracket is bent out of position restore to the correct position Replace the igniter and sensor or igniter sensor with an identical unit if the insulator is cracked STEP 3 Check the flame sensing circuit a b Make sure the burner flame is capable of providing a good rectification signal See Fig 6 Make sure about 3 4 to 1 in of the flame sensor or igniter sensor is continuously immersed in the flame for the best flame signal See Fig 6 Check for excessive higher than 1000 F 538 temperature at the ceramic insulator on the flame sensor Excessive temperature can cause a short to ground Check for a cracked igniter sensor or a sensor ceramic insulator which can cause short to groun
29. nition module shuts off wait for retry or reset at the thermo stat 3 If any component does not function properly make sure it is correctly installed and wired before replacing it S8910U UNIVERSAL HOT SURFACE IGNITION MODULE 4 The ignition module cannot be repaired If it malfunctions replace it 5 Only trained experienced service technicians should service hot surface ignition systems 6 After servicing verify proper system operation Perform the checkout steps in the Startup and Checkout section as the first step in troubleshooting Then check the troubleshooting sequence Fig 8 to pinpoint the cause of the problem After troubleshooting perform the checkout procedure again to be sure the system is operating normally Status LED used to Troubleshoot The LED can be used to check the appliance status A description of the LED signals follows IMPORTANT The LED shows system status for the current call for heat When the call for heat is interrupted thermostat satisfied or system power switched off the LED goes off and the status information is lost Pulsing heartbeat is the normal operating mode during a call for heat 24V terminal is powered The system can be in any of the normal operating modes including prepurge warmup ignition trial between trial purge normal run or One flash indicates the S8910U is in an ignition lockout mode The most probable cause is the main
30. o drill new mounting holes use the S8910U as a template to mark the mount S8910U UNIVERSAL HOT SURFACE IGNITION MODULE ing hole pattern Drill new holes as required Fasten securely with four No 6 32 machine or No 8 sheet metal Screws Install selection tab Four selection tabs are included with the S8910U See Tables 1 through 3 Select the correct tab for the system and separate the tab from the other three tabs Install the tab on the module Be sure the selection tab is properly positioned and firmly inserted See Fig 2 Discard all unused selection tabs at a remote location so an incorrect tab cannot be used in the future Without a selection tab the module operates at four second trial time and one ignition trial MOUNT IN ONE OF THESE POSITIONS TERMINALS FACING LEFT TERMINALS FACING RIGHT DO NOT MOUNT WITH TERMINALS FACING UP M2647 Fig 1 Module mounting recommendations A WARNING EXPLOSION HAZARD CAN CAUSE INJURY OR EQUIPMENT DAMAGE Only trained professional gas appliance service technicians should install and check out the S8910U and selection tabs Use only the selection tab specified in Tables 1 through 3 for the existing module being replaced Always remove all unused selection tabs from the job site and discard them at a remote location Improper use of the selection tabs can result in appliance malfunction 589100 HOT SURFACE D d IGNITION CONTROL M8434
31. ons upstream of the gas control with a for each application see Maintenance section rich soap and water solution Bubbles indicate gas leaks Tighten the joints and screws or replace the component to A WARNING stop a gas leak Recheck with soap and water solution FIRE OR EXPLOSION HAZARD Step 2 Verify control system ground CAN CAUSE PROPERTY DAMAGE The ignition module must share a common ground with SEVERE INJURY OR DEATH the main burner The burner serves as the common 1 If you smell gas or suspect a gas leak turn off grounding area to assure reliable flame detection If gas at the manual service valve and evacuate there is not good metal to metal contact between the the building Do not try to light any appliance burner and ground run a lead from the burner to do not touch any electrical switch or telephone ground in the building until you are sure no spilled gas remains Step 3 Review normal operating sequence and module 2 Gas leak test must be done as described in specifications See Operation and Application sections following steps 1 and 6 for initial installation and any time work is done involving the gas piping 11 69 0845 2 589100 UNIVERSAL HOT SURFACE IGNITION MODULE Step 4 Reset the ignition module a Turn the thermostat or controller to the lowest setting b Turn on the system power c Wait one minute As you do Steps 5 and 6 watch for points where operation deviates from normal Refer to Troubleshoot
32. re and firmly crimp in place components Add this total to 9 6 VA for the the proper quick connect supplied ignition module The result is the minimum 2 Verify the thermostat anticipator setting as explained transformer VA rating Use a Class Il trans in the preceding IMPORTANT item 4 former when replacement is required 5 Check that L1 hot and L2 neutral are wired to the proper terminals Table 4 Replacement Wiring Terminals Replacement Control Original Control 8910U Honeywell White Rodgers Robertshaw Terminal Function Terminal 89 S890 Terminai 50E F47 Terminal HS780 Terminal Burner Ground Connection GND BURNER GND BURNER TR GND DER Tranformer Secondary 24V GND 24V GND 8 unswitched leg Main Valve Common VALVE GND VALVE GND MV next to TR terminal Transformer Secondary 24va TH switched leg Main Valve Operator VALVE VALVE VALVE 120 Vac Neutral Leg L2 120V NEUTRAL L2 120V NEUTRAL L2 Power Supply 120 Vac Hot Leg Power L1 120V HOT L1 120V HOT u L1 Supply Hot Surface Igniter Element HSI 120V NEUTRAL HSI 120V Hot Surface Igniter Element HSI 120V HOT HSI 120V a Remove quick connect and replace with the included 1 4 in quick connect b Use green adapter cable provided to connect 89100 GND BURNER terminal to chassis ground Do not use the S8910U VALVE GND terminal VALVE GND and 24V GND are interconnected in the appliance wiring d Remove quick connect and rep
33. s The SUPER TRADELINE S8910U package contains the 589100 control and easy to use instructions and the accessories required to adapt the existing hot surface ignition module The accessory bag assembly includes the White Rodgers adapter Robertshaw ground lead four 1 4 in female 032 quick connects one 3 16 in female 032 quick connect four selection tabs and seven wire labels The wiring labels are included to assure proper marking of the wires attached to the existing module A complete list of the specific Honeywell and other modules that the SUPER TRADELINE S8910U is designed to replace is provided in Tables 1 through 3 U S Registered Trademark Copyright 1996 Honeywell Inc All Rights Reserved INSTALLATION INSTRUCTIONS NOTE The S8910U is intended to replace only defective ignition controls The service technician should make sure that the other parts of the appliance and control system operate safely and reliably before replacing the ignition control A WARNING EXPLOSION HAZARD CAN CAUSE INJURY OR EQUIPMENT DAMAGE The S8910U can only be used for direct replace ment Check Tables 1 through 3 before replacing an existing hot surface module with the S8910U If the existing module is not listed do not use the S8910U to replace it Always use the selection tab specified in Tables 1 through 3 for the existing module being replaced Replacing with an unlisted module or using a selection tab not specifie
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