68-0161 - S8910U Universal Hot Surface Ignition Module
Contents
1. CONTROLLER POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED MAKE SURE L1 AND L2 ARE NOT REVERSED ALTERNATE LIMIT CONTROLLER LOCATION SENSE ROD WILL BE PRESENT IF REMOTE SENSE HS780 MODEL SEE TABLE 3 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 TO SENSE SEE TABLE 3 CUT 1 4 IN QUICK CONNECT OFF WIRE AND REPLACE WITH 3 16 IN QUICK CONNECT SUPPLIED bb bee gt USE GREEN GROUND ADAPTER SUPPLIED TO CONNECT 589100 GND BURNER TO APPLIANCE CHASSIS M7998 Fig 5 Typical hookup when S8910U replaces Robertshaw HS780 13 68 0161 1 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE TERMINAL CROSS REFERENCE 8910U 89 S890 GND BURNER GND BURNER 24V GND 24V GND AWARNING Explosion hazard Can cause serious injury or death This device can malfunction if it gets wet Never try to use a device that has been wet replace it VALVE GND VALVE GND 24V 24V VALVE VALVE 1 BURNER 24v GND BURNER L GROUND Pulsing Heart Honeywell 8910U HOT SURFACE IGNITION 8910U HOT SURFACE IGNITER CONTROL MPLS MN 55422 AUTO IGNITION INPUT VOLTAGES 120 amp 24 VAC 60HZ SYSTEMS HSI 120V 6 5A MAX ANSI 221 20 VALVE 24V 1A MAX TOTAL 24V LOAD 0 2 VALVE LOAD i Ignition Lockout Flash Weak Fi al 3 Flash In2. 4 Installation 4 Startup and Checkout 14 Maintenance EE 16 Mc 16 Troubleshooting eee 18 68 0161 1 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE SPECIFICATIONS IMPORTANT The specifications given in this publication do not include normal manufacturing tolerances Therefore this unit may not exactly match the listed specifica tions Also this product is tested and calibrated under closely controlled conditions and some minor differences in performance can be expected if those conditions are changed Super TRADELINE Models The SUPER TRADELINE S8910U package contains the 589100 control and easy to use instructions plus 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 connects four selection tabs and seven wiring labels The wiring labels are included to assure proper marking of the wires attached to the existing module A complete listing of the specific Honeywell and other modules that the SUPER TRADELINE 589100 is designed to replace is provided in Tables 2 through 4 NOTE The S8910U is intended to replace only defective ignition controls The service technician should make sure that the ot
3. CHECK FOR HIGH GAS PRESSURE EXCESS PRIMARY AIR OR DRAFT BURNER KIN VN WAVING FLAME CHECK FOR POOR DRAFT EXCESS DRAFT HIGH VELOCITY OR SECONDARY AIR SMALL INSTALL SHIELD IF NECESSARY BLUE FLAME CHECK FOR U CLOGGED PORTS OR ORIFICE FILTER WRONG SIZE ORIFICE LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM DIRTY PRIMARY AIR OPENING LARGE PORTS GOOD OR ORIFICES RECTIFYING FLAME 1 4 TO 1 2 IN 6 TO 18 MM I4 3 4 TO 1 IN 19 TO 25 MM M8446 Fig 7 Check burner flame condition 68 0161 1 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE 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 applications that place a heavy load on system controls such as those used in the commercial cooking and agricultural and industrial industries because In many such applications particularly commercial cooking the equipment operates 100 000 to 200 000 cycles per year This 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 contami nants See Electronic Ignition Service manual form 70 6604
4. OO R o Reo OO R EH Es N o 9 68 0161 1 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE Table 4 Honeywell Control to Honeywell S8910U Cross Reference 8910U Between Local L or Lockout Igniter Trial Model Selection Remote R Time IgnitionT PrePurge Warmup Purge Numbers Tab Sensing EN i sec sec 589100 Local or Specifications B Remote E a Se9c1087 pve foe I fo a L s89C1012 Er ES FET S89C1046 EE NE ME ar S89C1103 EENE A 4 30 589G1047 89H1003 3 S89H1011 89H1029 89J1008 8900 1007 5890D1006 5890G1003 890G1011 5890G1029 589091037 589091002 589091010 589091028 O oe an a o o wolw o UIl wlj z ziziolo QD WOlTwoloalos ws lo wo o wo R QD 69 wo RB QD g QD o secs fo jssgciorez sectae secu fa sew f 58901005 f sei 58901021 58901007 f seenos f PME seno D ERA seen f D seu f _ s 589061007 Le sete MS NN 58900103 f 589001011 589001029 589001087 f 589091002 f a seio f 1 E ED 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 locko
5. lt o al o olo gt lt 2 gt o lt 2 gt jojo Jojo o lt lt 2 gt gt gt lt 2 gt o o lt i o o lt Continued 7 68 0161 1 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE Table 2 White Rodgers Control to Honeywell S8910U Cross Reference Continued NOTE White Rodgers product information was obtained from the 1991 White Rodgers Product Catalog R3700 NOTE This list is for reference only Honeywell reserves the right to add or delete models at any time based on new or updated information See the Installation Instructions packed with the S8910U for the most current list of models recommended for replacement 589100 Between Local L or Lockout Igniter Trial Model Selection Remote R Time Ignition PrePurge Warmup Purge Numbers Tab Sensing sec Trials sec sec sec 8910U A Local or Specifications Remote C2 N QD Z gt A a a NIN z N gt gt gt A 50F47 70 thru 79 50F47 101 thru 109 Z gt AB gt 50F47 110 thru 119 2 gt 50F47 120 thru 129 gt 50F47 130 thru 139 A e 50F47 60 thru 69 N 50F47 330 thru 339 BR RB BR e 2 2 gt gt gt gt A A A 2 2 gt gt gt N 2 A A k NIN N N N N
6. NO IGNITER WARMS UP AND CONFIRM THAT 120V HOT LEAD CHECK AND CORRECT WIRING FUSE ewe RED mms CONNECTS TO L1 AND 120V NEUTRAL dad ae LEAD CONNECTS TO L2 REPLACE S8910U YES MAIN BURNER LIGHTS CHECK FOR 24 VAC ACROSS VALVE TERMINALS ON S8910U DURING TRIAL FOR IGNITION TIMING IF NO VOLTAGE REPLACE S8910U CHECK ELECTRICAL CONNECTIONS BETWEEN S8910U AND GAS CONTROL YES IF OK REPLACE GAS CONTROL CHECK IGNITER POSITION CHECK GAS PRESSURE TO MAIN BURNER NOTE IF 589100 GOES INTO LOCKOUT RESET SYSTEM NO MAIN BURNER REMAINS 5 CHECK CONTINUITY OF GROUND WIRE GROUND PATH FROM MAIN BURNER TO POWERED AND LIT GND BURNER TERMINAL OF S8910U CONFIRM THAT 120 VAC HOT LEAD IS CONNECTED TO L1 AND 120 VAC NEUTRAL LEAD vES 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 589100 GOES INTO LOCKOUT RESET SYSTEM SYSTEM RUNS UNTIL CALL FOR HEAT ENDS EEE 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
7. ROD CERAMIC BASE TEMPERATURE ABOVE 1000 F 538 C CAUSES SHORT TO GROUND IF CHECKS ARE OKAY REPLACE 589100 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 9 589100 troubleshooting sequence 19 68 0161 1 Home and Building Control Home and Building Control Honeywell Asia Pacific Inc Honeywell Inc Honeywell Limited Honeywell Limit e Room 3213 3225 Honeywell Plaza 155 Gordon Baker Road Sun Hung Kai Centre P O Box 524 North York Ontario No 30 Harbour Road Minneapolis MN 55408 0524 M2H 2C9 Wanchai Hong Kong Honeywell Latin American Division Honeywell Europe S A Miami Lakes Headquarters 3 Avenue du Bourget 14505 Commerce Way Suite 500 B 1140 Brussels Belgium Miami Lakes FL 33016 Honeywell Helping You Control Your World Printed on recycled paper containing at 68 0161 1 J S Rev 7 96 Printed in U S A least 10 post consumer paper fibers customer honeywell com
8. are suspended in air as in some industrial or agricultural applications A NEMA 4 enclosure is recommended 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 Manual 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 Assure that proper insulation or shielding was provided by the appliance manufacturer verify proper air circulation is maintained when the appliance is installed INSTALLATION en Installing this Ignition System Read these instructions carefully Failure to follow them could damage the components or cause a hazardous condition 2 Check Tables 2 3 and 4 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 WARNING FIR
9. gas control if the piping has been disturbed GAS LEAK TEST Paint the gas 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 the component to stop a gas leak Recheck with soap and water solution e 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 7 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 the pilot flames go out S8910U UNIVERSAL HOT SURFACE IGNITION MODULE 15 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 Never attempt to change the appliance flame sensing single rod or dual rod from the type originally established by the appliance manufacturer 3 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
10. the ceramic insulator on the flame sensor Excessive temperature can cause a short to ground d Check for cracked igniter sensor or sensor ceramic insulator which can cause short to ground and replace unit if necessary Make sure electrical connections are clean and tight Replace damaged wire with moisture resistant No 18 wire rated for continuous duty up to 221 F 105 C e If the 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 e 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 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE START TURN THERMOSTAT TO NOTE BEFORE TROUBLESHOOTING BECOME FAMILIAR WITH STARTUP CALL FOR HEAT AND CHECKOUT PROCEDURES NO DOES 8910U GET POWER CHECK LINE VOLTAGE POWER 24 VAC NOMINAL CHECK LOW VOLTAGE TRANSFORMER YES CHECK LIMIT CONTROLLER CHECK AIR PROVING SWITCH IF USED CHECK THERMOSTAT CHECK WIRING NO S EGER E MINIMUM mrs CHECK AIR PROVING SWITCH REPLACE 589100 YES
11. the normal operating modes including prepurge warmup ignition trial between trial purge or normal run One flash indicates the S8910U is in an ignition lockout mode The most probable cause is the main 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 68 0161 1 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 igniter wire harness Make sure a Ignition cable does not run in contact with any metal surfaces b Connections to the ignition module and to the igniter or igniter sensor are clean and
12. ARD 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 IMPORTANT The S8910U is not designed to replace the following e 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 e 120 Vac timed warmup hot surface ignition controls with Ignition trial time shorter than four seconds Ignition trial time longer than twelve seconds Edge connectors rather than male quick connects 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 may be required to prevent nuisance shut downs and control failure due to frequent cycling and 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 preca
13. E OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH 1 If the ignition module gets wet it can malfunction leading to accumulation of explosive gas Never install where water can flood drip or condense on the module Never use a module that has been wet Replace it 2 Liquefied petroleum LP gas is heavier than air and can 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 3 Do not attempt to disassemble or clean the module Improper reassembly and cleaning can cause unreliable operation A 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 Conduct a Gas Leak Test according to the gas control manufacturer instructions after the gas control is installed 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 wires before disconnecting Wiring errors can cause improper appliance operation and create 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
14. G IMPORTANT 1 The following service procedures are provided as a general guide Follow the appliance manu facturer service instructions if available 2 Meter readings between gas control and ignition module must be taken within the trial for ignition period Once the ignition module shuts off wait for retry or reset at the thermostat 3 If any component does not function properly make sure it is correctly installed and wired before replacing it 4 The ignition module cannot be repaired If it malfunctions 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 9 to determine the exact 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 thermo stat satisfied or system power switched off the LED goes off and the status information is lost e Pulsing heartbeat is the normal operating mode during a call for heat 24V terminal is powered The system can be in any of
15. Honeywell 589100 Universal Hot Surface Ignition Module MPLS MN 55422 S8910U HOT SURFACE IGNITION APPLICATION The SUPER TRADELINE S8910U Universal Hot Surface Ignition Module is designed to provide easy field replacement of 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 U S Registered Trademark Copyright 1996 Honeywell Inc All Rights Reserved PRODUCT DATA FEATURES Replaces many White Rodgers Robertshaw and Honeywell hot surface ignition models See Tables 2 3 and 4 For 120 Vac up to 5 0A surface igniter Norton 201 271 or equivalent Forlocal single rod or remote dual rod rectification type flame sensing Contains easy to use instructions plus the accessories required to adapt the existing hot surface ignition module Provides one or three ignition trials four second or seven second trials per call for heat prepurge of 32 seconds or less up to 96 seconds between purge trial times Temperature range is 40 to 175 F 40 to 79 Contents AP DIC At OM M 1 Features iine der petrae eee antes 1 Specifications dier n e eaen EAE Sei 2 Ordering Information srennnrnonvnnonvnnnvonenrnnnnnnenrnnsnrnenvnnennnnn 2 Review the Installation
16. NIN re A a Aj N N N N EIE N N N 68 0161 1 8 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE Table 3 Robertshaw Control to Honeywell S8910U Cross Reference NOTE Robertshaw product information was obtained from the 1993 1994 Robertshaw Uni Line Catalog 2 064 8910U Between Local L or Lockout Igniter Trial Model Selection Remote R Time Ignition PrePurge Warmup Purge Numbers Tab Sensing WE sec S8910U Local or Specifications ee MER HS780 17NL 108A NA m r E N HS780 17NL 304A HS780 17NL 308A HS780 17NR 104A HS780 17NR 306A HS780 17NR 308A HS780 34NL 108A HS780 34NL 304A Eee M D M Se Ys D Ye D Ys c No HS780 34NL 806A D No 2 cp Ness Be M BE Ys D Ye Ys D Ye 1 NIN HS780 34NL 308A HS780 34NL 312A HS780 34NR 104A HS780 34NR 306A HS780 34NR 308A HS780 34NR 312A HS780 34PL 308A The 589100 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 N o E M M ME
17. R POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED MAKE SURE L1 AND L2 ARE NOT REVERSED ALTERNATE LIMIT CONTROLLER LOCATION REMOVE JUMPER QUICK CONNECT FROM S8910U CUT WIRE AT CIRCUIT BOARD AND DISCARD USE ADAPTER PLUG WITH BLACK AND ORANGE WIRES SUPPLIED CUT 3 16 IN QUICK CONNECT OFF WIRE AND REPLACE WITH 1 4 IN QUICK CONNECT SUPPLIED CUT 3 16 IN QUICK CONNECT OFF WIRE AND REPLACE WITH 3 16 IN QUICK CONNECT SUPPLIED M8528B gt gt gt gt gt Fig 4 Typical hookup when S8910U replaces White Rodgers 50E F47 68 0161 1 12 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE TERMINAL CROSS REFERENCE S8910U S8910U HOT SURFACE IGNITER CONTROL GND BURNER 6 TR GND CLIP 24V GND VALVE GND Explosion hazard Can cause serious injury or death TANTER This device can malfunction if igniter Warmup Time 34 sec it gets wet Never try to use a 2 Flash Weak Flame Signal 4 Flash Internal Error Heplace Control device that has been wet replace it Pulsing Heartbeat Normal Operation Honeywell MPLS MN 55422 8910U HOT SURFACE IGNITION AWAR NING INPUT VOLTAGES 120 amp 24 VAC Seren 120 A ANSI 721 20 FLAME SENSOR NUM OF TRIALS CONFIGURATION PLUG GND BURNER 24V GND VALVE BURNER LL GROUND MV COMBINATION SURFACE IGNITER LIMIT CONTROLLER L1 HOT gt
18. See Tables 1 through 4 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 3 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 a four second trial time and one ignition trial 68 0161 1 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE A WARNING Wire the Module EXPLOSION HAZARD CAN CAUSE N CAUTION INJURY OR EQUIPMENT DAMAGE Only trained professional gas appliance service 1 Check the wiring diagram furnished by the technicians should install and check out the S8910U appliance manufacturer if available and compare and selection tabs Use only the selection tab with Fig 4 through 6 Carefully follow any special specified in Tables 2 3 and 4 for the existing module instructions affecting the general procedures being replaced Always remove all unused selection outlined in this section 9 tabs from the job site and discard them at a remote 2 Disconnect the power supply before making wiring location Improper use of the selection tabs can result connections to prevent electrical shock or in appliance malfunction equipment damage IMPORTANT 1 Be sure all wiring complies with applicable electrical codes and ordinances 2 Assure that hot surface igniter leadwires are not allowed to rest aga
19. The maintenance program should include regular checkout of the system as outlined in the Startup and Checkout section and checkout of the control system as described in the appliance manufacturer literature Determine the maintenance frequency individually for each application 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 Replace any control if it does not perform properly on checkout or troubleshooting In addition replace any module if itis wet or looks like it has ever been wet Use protective enclosures as described in Planning the Installation section regardless of checkout frequency OPERATION The S8910U is a direct ignition control used with 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 S8910
20. U provides one or three trials for ignition depending on which selection tab is installed Fig 8 shows the normal operating sequence Purge Prepurge When the S8910U is used a fan assisted combustion system the combustion air blower starts on a call for heat from 68 0161 1 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 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 the gas control is closed during this period 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 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 f
21. 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 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE START PREPURGE CALL FOR HEAT 24V IGNITER TERMINAL POWERED WARMUP FLAME SYSTEM WILL INTERNAL SAFE START SIMULATING NOT START CHECK BEGINS FAILURE NO FLAME SIMULATING FAILURE PREPURGE BETWEEN IGNITER WARMS UP TRIAL PURGE ONE TRIAL TABS A GAS CONTROL OPENS AND LOCKOUT OCCURS TRIAL FOR FOR TIMED TRIAL SYSTEM MUST BE IGNITION FOR IGNITION RESET IGNITER OFF GAS FLAME SENSING BEGINS CONTROL CLOSES FLAME PRESENT ONE TRIAL TABS A AND C THREE TRIALS TABS B AND D EEE GAS CONTROL STAYS GAS HOW MANY IGNITION OPEN MAIN BURNER FLAME CONTROL TRIALS COMPLETED THIS RUNS FAILURE CLOSES CALL FOR HEAT THREE TRIALS TABS B AND D CALL FOR HEAT IS SATISFIED MAIN BURNER OPERATION THREE q LOCKOUT OCCURS SYSTEM MUST BE RESET GAS CONTROL CLOSES END MAIN BURNER OFF M8527A Fig 8 S8910U normal operating sequence 17 68 0161 1 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE TROUBLESHOOTIN
22. 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 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 2 for mounting recommendations When it is necessary to drill new mounting holes use the S8910U as a template to mark the mounting hole pattern Drill new holes as required Fasten securely with four No 6 32 machine or No 8 sheet metal screws S8910U UNIVERSAL HOT SURFACE IGNITION MODULE MOUNT IN ONE OF THESE POSITIONS TERMINALS FACING LEFT TERMINALS FACING RIGHT DO NOT MOUNT WITH TERMINALS FACING UP Fig 2 Module mounting recommendations Install Selection Tab Four selection tabs are included with the S8910U
23. ed follow instructions on appliance label Use included quick connect terminals and wiring adaptors according to instructions Prepurge 32 seconds Igniter Warmup 34 seconds Between Trial Purge 96 seconds 3 trial mode only Flame Failure Response Time 1 5 seconds maximum Ignition Sequence The number of trials for ignition and trial time are determined by the selection tab See Table 1 If a selection tab is not installed the module operates at four seconds trial time and one ignition trial 3 3 16 81 E 2 51 gt 2 5 8 67 6 e p 3 16 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE Table 1 Selection Tab Specifications Trial Time Seconds Number of Ignition Trials Selection Tab Ambient Operating Temperature 40 F to 175 F 40 C to 79 C _ owe c cp um on O DP Dimensions See Fig 1 Accessory Kit Included e White Rodgers adapter e Robertshaw ground lead e Four 1 4 in female 032 quick connects One 3 16 in female 032 quick connect e Four selection tabs Seven wire labels Approvals IAS Design Certified Report No C2030018 5 2 3 3 8 86 2 5 7 16 138 M1123A Fig 1 Approximate ignition module dimensions in in mm 3 68 0161 1 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE REVIEW THE INSTALLATION A WARNING FIRE OR EXPLOSION HAZ
24. her parts of the appliance and control system operate safely and reliably before replacing the ignition control Super TRADELINE Model Available 589100 Universal Hot Surface Ignition Module ORDERING INFORMATION A WARNING EXPLOSION HAZARD CAN CAUSE INJURY OR EQUIPMENT DAMAGE The S8910U can be used only for direct replacement Check Tables 2 through 4 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 2 through 4 for the existing module being replaced Replacing an unlisted module or using a selection tab other than specified 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 The S8910U is to be used 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 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 e Igniter must maintain at least 500M ohm insulation resistance between the igniter leadwires and the igniter mounting bracke
25. inst 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 Be sure that auxiliary controls or limits are not in the grounded leg In addition earth ground the appliance 4 Make sure the transformer has adequate VA The ignition module requires 0 4A at 24 Vac Add together 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 Add this total to 9 6 VA for the ignition module The result is the minimum transformer VA rating Use a Class II transformer when replacement is required 5 Check that L1 hot and L2 neutral are wired to the proper terminals S8910U HOT SURFACE IGNITION CONTROL M8434 1 Connect the wires to the 589100 Ignition Module as shown in Table 5 Make sure that adequate system Fig 3 Separating and installing selection tab ground is provided as indicated in the wiring table See Fig 4 through 6 Where a change in quick connect is required cut off the original quick connect strip the leadwire and firmly crimp in place the proper quick connect supplied 2 Verify the thermostat anticipator setting as explained in the above IMPORTANT item 4 68 0161 1 6 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE Table 2 White Rodgers Control to Honeywell 589100 Cro
26. lame 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 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
27. mains Perform a gas leak test as described in Steps 1 and 6 in the Startup and Checkout section for initial installation and any time work is done involving the gas piping Check out the gas control system At initial installation of the appliance As part of regular maintenance procedures At maintenance intervals determined by the application As the first step in troubleshooting Any time work is done on the system Determine maintenance frequency individually for each application see Maintenance section 68 0161 1 14 piping has been disturbed GAS LEAK TEST Paint gas control gasket edges and all pipe connections upstream of the gas control with a rich soap and water solution Bubbles indicate gas leaks Tighten the joints and screws or replace the component to stop a gas leak Recheck with soap and water solution Step 2 Verify control system ground The ignition module must share a common ground with the main burner The burner serves as the common grounding area to assure reliable flame detection If there is not good metal to metal contact between the burner and ground run a lead from the burner to ground Step 3 Review normal operating sequence and module specifications See Operation and Application sections 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 ope
28. ng 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 Remove jumper from S8910U sense terminal cut jumper wire at circuit board and discard 11 68 0161 1 589100 UNIVERSAL HOT SURFACE IGNITION MODULE TERMINAL CROSS REFERENCE S8910U HOT SURFACE IGNITER CONTROL Ce CE Honeywell MPLS MN 55422 8910U HOT SURFACE IGNITION AWA RNING f INPUT VOLTAGES 120 amp 24 VAC 60HZ HSI 120V 6 5 MAX ANER EN Explosion hazard Can cause VALVE 24V 1A MAX TOTAL 24V LOAD 0 2 VALVE LOAD serious injury or death STATUS LED Prepurge Time 30 Si um 30 Sec This device can malfunction if 1 Flash lgnition Lockout Igniter Warmup Time 34 sec it gets wet Never try to use a 2 Flash Weak Flame Signal 4 3 Flash Internal Error Heplace Control device that has been wet replace it Pulsing Heartbeat Normal Operation FLAME SENSOR TRIAL TIME NUM OF TRIALS CONFIGURATION PLUG BURNER 24V GND VALVE u ZA mm Ds 7M fo BURNER L GROUND HOT SURFACE IGNITER COMBINATION GAS CONTROL LIMIT CONTROLLER THERMOSTAT OR A CONTROLLE
29. ration deviates from normal Refer to Troubleshooting section to correct the problem Step 5 Check the 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 gas control is energized measure the time by connecting a voltmeter across the gas valve terminals Selection tabs A and B for 4 seconds Selection tabs C and D for 7 seconds e When using a three trial ignition selection tab tabs B or D watch for the start of the 96 second between trial purge followed by a 34 second igniter warmup and a second try for ignition After a third purge warmup and trial for ignition sequence the S8910U 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 Set the thermostat or the 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
30. ss Reference NOTE White Rodgers product information was obtained from the 1991 White Rodgers Product Catalog R3700 NOTE This list is for reference only Honeywell reserves the right to add or delete models at any time based on new or updated information See the Installation Instructions packed with the S8910U for the most current list of models recommended for replacement 8910U Between Local L or Lockout Igniter Trial Model Selection Remote R Time Ignition PrePurge Warmup Purge Numbers Tab Sensing sec Trials sec sec sec 8910U Local or 32 34 Specifications B Remote 96 PD 50647 1thu9 a vs R 4 1 tN 50E47 10thru19 vs R 4 1 0 4 N Yes 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 120 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 239 50E47 240 thru 249 50E47 250 thru 259 50E47 260 thru 269 50E47 270 thru 279 50E47 301 thru 309 50E47 310 thru 319 50E47 320 thru 329 50E47 330 thru 339 50E47 340 thru 349 50E47 350 thru 359 50E47 360 thru 369 50E47 370 thru 379 E gt gt AJA gt o lt 2 gt u D 2 gt gt
31. t 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 lgniter current draw at 132 Vac must not exceed 5A When purchasing replacement and modernization products from your TRADELINE wholesaler or distributor refer to the TRADELINE Catalog or price sheets for complete ordering number or specify 1 Order number 2 Accessories if desired 3 Order additional system components and system accessories separately 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 Home and Building Control Sales Office check white pages of your phone directory 2 Home and Building Control Customer Logistics Honeywell Inc 1885 Douglas Drive North Minneapolis Minnesota 55422 4386 In Canada Honeywell Limited Honeywell Limit e 35 Dynamic Drive Scarborough Ontario M1V 429 International Sales and Service Offices in all principal cities of the world Manufacturing in Australia Canada Finland France Germany Japan Mexico Netherlands Spain Taiwan United Kingdom U S A 68 0161 1 Sensor Separate sensor required for remote sensing applications Wiring Use existing appliance wiring If repair or replacement of leadwires is requir
32. ternal Error Replace Control tbeat Normal Operation Prepurge Time 30 Sec Igniter Warmup Time 34 sec FLAME SENSOR MV COMBINATION IGNITER CONTROLLER 1 12 gt THERMOSTAT OR CONTROLLER N A 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 SENSE ROD WILL BE PRESENT IF REMOTE SENSE S89 S890 MODEL SEE TABLE 4 WHEN 589 5890 IS A REMOTE SENSE MODEL REMOVE JUMPER QUICK CONNECT FROM 589100 CUT WIRE AT CIRCUIT BOARD AND DISCARD CONNECT FLAME ROD LEAD WIRE TO SENSE SEE TABLE 4 M7999 A CUT QUICK CONNECTS OFF WIRES AND REPLACE WITH 1 4 IN QUICK CONNECTS PROVIDED Fig 6 Typical hookup when S8910U replaces Honeywell S89 S890 STARTUP AND CHECKOUT Step 1 Perform visual inspection a With power off make sure all wiring connections are clean and tight A WARN NG b Turn on the power to the appliance and the S8910U c Open the manual shutoff valves in the gas line to the FIRE OR EXPLOSION HAZARD appliance CAN CAUSE PROPERTY DAMAGE d Test for a gas leak upstream of the gas control if the SEVERE INJURY OR DEATH 1 If you smell gas or suspect a gas leak turn off gas at the manual service valve and evacuate the building Do not try to light any appliance do not touch any electrical switch or telephone in the building until you are sure no spilled gas re
33. tight c Ignition cable provides good electrical continuity Step 2 Check ignition system grounding Nuisance shutdowns are often caused by a poor or erratic ground a A common ground is required for the module igniter flame sensor and main burner Check for good metal to metal contact between the igniter bracket and the main burner e Check the ground path from the GND BURNER terminal on the module to the main burner Make sure 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 e Check the temperature at the igniter ceramic or flame sensor insulator Excessive temperature permits leakage to ground Contact the appliance manufacturer if the temperature exceeds rating of igniter or sensor If 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 Make sure the burner flame is capable of providing a good rectification signal See Fig 7 b 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 7 Check for excessive above 1000 F B38 C temperature at
34. ut 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 68 0161 1 10 S8910U UNIVERSAL HOT SURFACE IGNITION MODULE Table 5 Replacement Wiring Terminals Replacement Control Replacement Control Original Control Terminal S8910U Honeywell White Rodgers Robertshaw Function Terminal 89 S890 Terminal C E Terminal HS780 Terminal Burner Burner Ground Connection Connection GND BURNER GND BURNER TR GND BELICE Transformer Bamer Ground cometen _ 24V GND 24V GND unswitched leg Main Valve Common VALVE GND VALVE GND 8 next to TR terminal Transformer Secondary 24va switched leg Main Valve Main Valve Operator EE 120 ein va Neutral Leg Power L2 120V mE 120V NEUTRAL Supply 120 Vac Hot Leg Power L1 120V HOT L1 120V HOT Supply Hot Surface Igniter Element HSI 120V NEUTRAL HSI 120V Hot Surface Igniter Element HSI 120V HOT HSI 120V Remove quick connect and replace with the included 1 4 in quick connect b Use green adapter cable provided to connect S8910U 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 replace with the included 3 16 in quick connect Do not use this terminal if model bei
35. utionary 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 around 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 protect cover the controls and wiring from water or steam flow Mount the controls high enough above the bottom of the cabinet to avoid getting wet during normal cleaning procedures A 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 68 0161 1 If the appliance is in a humid atmosphere make sure air circulation around the controls is adequate to prevent condensation Also regularly check out the system A 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
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