Honeywell Y8610U User's Manual
Contents
1. IMPORTANT Do not mount with terminals facing up Xe VZ AW XEN VI Ad 2H 09 031 Anoy snonunuo 01985 oaan ui pejquiessy NW UOPIOD M29889 Fig 14 Incorrect mounting 68 0291 03 12 Wire the System N CAUTION ELECTRICAL SHOCK OR EQUIPMENT DAMAGE HAZARD Disconnect the power supply before making wiring connections to prevent electrical shock or equipment damage All wiring must comply with local codes and ordinances Refer to Fig 15 and Table 5 on page 13 for typical connections IMPORTANT 1 As shown in the wiring diagrams a common ground is required on The pilot burner mounting bracket and the GND BURNER terminal on the ignition control module Failure to use the GND BURNER terminal may result in intermittent loss of spark and or loss of flame current sensitivity 2 Make sure the transformer has adequate VA The ignition control module requires at least 0 1 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 Add this total to 2 4 VA for the ignition control module The result is the minimum transformer VA rating Use a Class Il transformer if replacement is required Connect Vent Damper Optional If the ignition control module is to be used with2. 8 Align the ground rod so the clip hugs the pilot burner and keeps the ground rod from rotating See Fig 9 2 Loosen the setscrews on the mounting bracket and slide the igniter sensor mounting bracket over the top of the ground rod See Fig 9 3 Tighten the setscrews on the mounting bracket using the hex wrench provided See Fig 9 4 Adjustthe electrode position so the electrode tip and gap are in the pilot flame Push pull the ground rod to move the igniter sensor up and down 5 Check that the chosen position allows room to connect the ignition cable to the stud terminal Rotate the igniter sensor as necessary 6 Tighten the setscrews on the mounting bracket using the hex wrench provided Y8610U INTERMITTENT PILOT RETROFIT KIT SCREW IN TYPE CLAMP TYPE PUSH IN TYPE ADD ADAPTER INSERT GROUND ROD IN PILOT SLIP NUT OFF ADAPTER AND CLAMP GROUND ROD IN PILOT WITH SHOULDER ABOVE CLAMP AS SHOWN INSERT TIGHTEN NUT GROUND ROD BE SURE THE GROUND CLIP IS SNAPPED ONTO THE PILOT BURNER OR ITS GAS LINE M24902 Fig 8 Mount ground rod on pilot burner GROUND ROD C ELECTRODE ELECTRODE ELECTRODE SETSCREW 2 MOUNTING BRACKET IGNITER SENSOR TIN C ID KAV LN PILOT BURNER STUD TERMINAL PILOT GAS GROUND TUBING ROD CLIP M6863A Fig 9 Fasten igniter sensor to ground rod 68 0291 03 Y8610U INTERMITTENT PILOT RETROFIT KIT In
3. if necessary b If the flame rod or bracket is bent out of position restore to correct position STEP 3 Check Spark Ignition Circuit You will need a short jumper wire made from ignition cable or other heavily insulated wire 1 Close the manual gas valve 2 Disconnect the ignition cable at the SPARK terminal on the ignition control A WARNING Electrical Shock Hazard Can cause severe injury death or property damage When performing the following steps do not touch the stripped end of jumper or SPARK terminal The ignition circuit generates over 10 000 volts and electrical shock can result 3 Energize the ignition control module and immediately touch one end of the jumper firmly to the GND terminal on the ignition control module Move the free end of the jumper slowly toward the SPARK terminal until a spark is established 4 Pull the jumper slowly away from the terminal and note the length of the gap when sparking stops Check Table 8 Table 8 Arc Troubleshooting Arc Length No arc or arc less than 1 8 in 3 mm Action Check external fuse if provided Verify power at the ignition control module s control input terminal Replace control if fuse and power are okay Arc 1 8 in 3 mm Voltage output is okay or longer 68 0291 03 Y8610U INTERMITTENT PILOT RETROFIT KIT STEP 4 Check Pilot and Main Burner Lightoff 1 Set the thermostat to Call for Heat 2 Watch t
4. on page 6 are recommended regardless of checkout frequency Perform the Pre installation Safety Inspection The pre installation checks described below must be completed before the Y8610U Intermittent Pilot Retrofit Kit is installed If a condition that could result in unsafe operation is detected the appliance should be shut off and the owner advised of the unsafe condition Correct any potentially unsafe condition before proceeding with the installation See Exhibit A on page 22 The following safety checklist should be followed in making the safety inspection 1 Conducta Gas Leakage Test of the appliance piping and control system downstream of the shut off 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 unsafe 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 supply line to each appliance If a manual gas valve is not in the gas supply line within 6 feet of the appliance in an accessible location one shall be installed 4 Inspect burners and crossovers for blockage and corro sion 68 0291 03 Y8610U INTERMITTENT PILOT RETROFIT KIT 10 11 12 13 14 Applicable only to warm air heating appliances Inspect heat exchangers
5. outlet if necessary Connect the pipe to the gas control inlet and outlet Tighten the inlet and outlet connections using a wrench on the gas control projecting wrench boss See Fig 3 or Fig 4 on page 5 depending on the valve used Connect Pilot Gas Tubing 1 NOTE Cut the pilot gas tubing and bend as necessary for rout ing to the pilot burner Do not make sharp bends or deform the tubing Do bend the tubing at the gas control after the compression nut has been tightened gas leakage at the connection can result Square off and remove the burrs from the tubing end Unscrew the brass compression fitting from pilot gas out let see Fig 3 or Fig 4 on page 5 depending on the valve used Slip the fitting over the pilot gas tubing and slide out of the way When replacing a gas control cut off the old compres sion fitting and replace with the new compression fit ting provided on the new gas control Never use the old compression fitting as it might not provide a gas tight seal See Fig 13 GAS CONTROL TIGHTEN NUT ONE TURN BEYOND FINGER TIGHT PILOT TUBING FITTING BREAKS OFF AND CLINCHES TUBING AS NUT IS TIGHTENED M6868A Fig 13 Always use new compression fitting Push pilot gas tubing into the pilot gas tapping until it bot toms While holding the tubing all the way in slide the compression fitting into place and engage the threads Turn the fitting until finger tight Use a wrench t
6. sensing Valve Current Rating 24 Vac 1 0 A Pilot and 2 0 A Main Prepurge Timing field selectable 0 zero or 30 seconds 0 zero seconds recommended Trial for Pilot Ignition field selectable 15 or 90 seconds 90 seconds recommended Ignition Sequence Type Retry Ignition Sequence After prepurge if prepurge is selected Spark and pilot gas ON until lightoff or trial for ignition ends If established flame is lost trial for ignition restarts immediately If pilot fails to light pilot gas and spark turned off 10096 shutoff After 5 minute delay a new trial for ignition is initiated This sequence continues until lightoff or Call for Heat is removed Integral Damper Connector Included for use as needed If initially installed and powered up with damper attached unit must always have a vent damper connected SPECIFICATIONS IMPORTANT The specifications given in this publication do not include normal manufacturing tolerances Therefore units might not match the listed specifications exactly Also units are tested and calibrated under closely controlled conditions and some minor differ ences in performance can be expected if those con ditions are changed Y8610U Intermittent Pilot Retrofit Kit Electrical Ratings Voltage and Frequency 24 Vac 60 Hz Current Rating 0 7A includes both module and gas control Thermostat
7. 03 Y8610U INTERMITTENT PILOT RETROFIT KIT Automation and Control Solutions Honeywell International Inc 1985 Douglas Drive North Golden Valley MN 55422 Honeywell Limited Honeywell Limit e Honeywell 35 Dynamic Drive U S Registered Trademark Toronto Ontario M1V 479 2011 Honeywell International Inc 68 0291 03 M S Rev 02 11 customer honeywell com Printed in U S A
8. 2 Setthermostat or controller above room temperature to Call for Heat 3 Watch for spark at pilot burner Time spark from start to shutoff Spark should shut off after 90 seconds See device label and Settings on page 14 4 Wait 5 minutes Ignition sequence should start again fol lowed by shutoff 5 Setthermostat below room temperature and wait one minute before continuing Step 6 Check Normal Operation 1 Turn on the gas supply at the appliance manual shutoff valve 2 Turn gas control knob to ON and make sure that no gas is flowing to the pilot or main burner 3 Setthermostat or controller above room temperature to Call for Heat 4 Make sure pilot lights smoothly when gas reaches the pilot burner 5 Make sure main burner lights smoothly without flash back 6 Make sure burner operates smoothly without floating lift ing or flame rollout to the furnace vestibule or heat buildup in the vestibule 68 0291 03 Y8610U INTERMITTENT PILOT RETROFIT KIT 7 Perform a gas leak test in the appliance including both the inlet and outlet sides of the gas control GAS LEAK TEST Paint the gas control gasket edges and all pipe connections downstream of the gas control including the pilot tubing connections with a rich soap and water solution Bubbles indicate gas leaks Tighten the joints and screws or replace component to stop gas leak Recheck with soap and water solution 8 Turn the thermostat or controller b
9. adjustment All pipe must comply with local codes and ordinances or with screw so that the top of the screw is flush level with the the National Fuel Code ANSI 2223 1 NFPA No 54 top of the regulator Turn the pressure regulator adjust whichever applies Tubing installation must comply with ment screw clockwise six complete turns This provides approved standards and practices preliminary pressure setting of about 10 0 in we 2 5 1 Use new properly reamed pipe free from chips If tubing kPa for LP regulator and 3 5 in wc 0 9 kPa for natural is used ensure that ends are square deburred and gas regulator clean All tubing bends must be smooth and without 6 Check the regulator setting either with a manometer or deformation by clocking the gas meter See Checkout on page 15 2 Run the new pipe or tubing to the gas control When tub 7 Install the new cap screw ing is used obtain a tube to pipe coupling to connect the 8 Mount the conversion label on the control tubing to the gas control 9 Install the control and appliance according to the appli 3 Install a sediment trap in the gas supply line See Fig 11 ance manufacturer instructions on page 11 68 0291 03 10 1 PIPED HORIZONTAL GAS SUPPLY ISER DROP PIPED GAS SUPPLY 3 IN 76 MM MINIMUM TUBING GAS SUPPLY 3 IN 76 MM MINIMUM TTA A ALL BEND
10. an existing vent damper and harness to be connected to the module s integral damper connector in an atmospheric appliance perform the following to connect it to the module IMPORTANT After the initial power up the ignition control module senses the presence of the vent damper connection If the vent damper is connected the ignition control module permanently configures itself to operate only with the damper connected Once an ignition control module powers up with a vent damper connected the module will not function without a vent damper being connected Using the wiring harness on the appliance insert the matching 6 pin plug into the connector labeled P1 see Fig 15 on page 13 on the S8610U ignition control module and connect the other end to the vent damper NOTE The connector P1 accepts a Molex 03 06 2061 plug on the existing vent damper harness Connect Ignition Cable Use the provided ignition cable to connect the S8610U module to the pilot burner Be sure the ignition cable is not exposed to high temperature while the appliance is operating NOTE The cable must not run in continuous contact with a metal surface or spark voltage may be greatly reduced Use ceramic or plastic standoff insulators as required To install 1 Connect one end of the cable to the male quick connect SPARK terminal on the ignition module 2 Connectthe other end of the cable to the igniter or igniter sensor stud on the pilot burner
11. for ignition Flash code If system fails to light on next trial for ignition Flame failed during run will remain through the ignition trial until check gas supply pilot burner flame sense flame is proved wiring contamination of flame rod burner ground connection 4 Flame sensed out of If situation self corrects within 10 Check for pilot flame Replace gas valve if sequence seconds control module returns to pilot flame present If no pilot flame cycle Call normal sequence If flame out of for Heat If error repeats replace control sequence remains longer than 10 seconds control will resume normal operation 1 hour after error is corrected 5 Damper Error If damper error corrects ignition control Check damper connection damper wiring Damper required but resumes normal operation and 24V connection on control not present Damper failed to open Replace damper if necessary within 60 seconds Damper failed to close within 60 seconds 6 Control Internal Error Control module remains in wait mode Cycle Call for Heat If error repeats replace When the fault corrects control module control resumes normal operation 7 Flame rod shorted to Control module remains in wait mode Check flame sense lead wire for damage or ground When the fault corrects control module shorting Check that flame rod is in proper resumes normal operation position Check flame rod ceramic for cracks damage or tracking 8 Low
12. main gas lights The system is now in the run mode with the presence of the pilot flame continuously monitored by the flame rectification circuit If the pilot flame goes out the ignition control module senses loss of pilot flame and shuts off both the pilot valve relay and the main valve relay Flow of gas to pilot and main burners stops as the valves close 100 shutoff 68 0291 03 Failed Trial for Pilot Ignition The S8610U control module provides multiple trials for ignition TFI If the pilot is not lit or sensed before the end of the trial for ignition time the ignition control shuts off the spark and pilot gas 100 shutoff There is a five minute delay before another TFI is initiated The pattern of TFI followed by a five minute delay continues until the pilot lights and is proved or the Call for Heat ends The five minute delay time can be bypassed by cycling the system thermostat or removing and restoring system power OPERATING SEQUENCE IDLE NOT POWERED CALL FOR HEAT RECEIVED FROM THERMOSTAT POWER TO MODULE AND SELF CHECK RETRY DELAY 5 MINUTES TRIAL FOR IGNITION TIMER STARTED FLAME PROVED MORE THAN 5 FLAME LOSSES IN THIS CALL FLAME FOR HEAT STABILIZATION 2 SECONDS CLOSE MAIN GAS CLOSE MAIN GAS VALVE AND PILOT GAS VALVE M24903 Fig 19 Normal operating sequence without vent damper TROUBLESHOOTING A WARNING F
13. 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 procedure may be necessary to determine safe operation of the equipment The following steps should be followed in making the modifications 1 2 apo 10 11 12 13 14 15 16 Perform a safety inspection of the existing appliance installation See Exhibit A for a recommended procedure for such a safety inspection Shut off all gas and electricity to the appliance To shut off gas use the shutoff valve in the supply line to the appliance Ifa manual gas valve is not in the gas supply line within 6 feet of the appliance in an accessible location one shall be installed Do not use the shutoff valve which is provided as part of a combination control Install the automatic intermittent pilot system in strict accordance with the manufacturer s installation instructions Turn on all gas and electricity to the appliance Determine that the appliance transformer has adequate capacity by following the steps outlined below a Compute the approximate current draw by adding the current draw of the automatic intermittent 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 trans former b Mu
14. out the gas control system Atinitial appliance installation As part of regular maintenance procedures Maintenance intervals are determined by the application See Planning the Installation on page 6 Asthe first step in troubleshooting Anytime work is done on the system WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH 1 If you smell gas or suspect a gas leak turn off the gas at the manual service valve and evacuate the building Do not try to light any appliance and do not touch any electrical switch or telephone in the building until no spilled gas remains 2 A gas leak test must be done as described in the steps below on initial installation and any time work is done involving the gas piping Step 1 Perform Visual Inspection 1 With power off make sure all wiring connections are clean and tight 2 Turn on power to appliance and ignition control module 3 Open manual shutoff valves in the gas line to the appli ance 4 Perform a gas leak test ahead of the gas control GAS LEAK TEST Paint the 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 component to stop gas leak Recheck with soap and water solution 15 Y8610U INTERMITTENT PILOT RETROFIT KIT Step 2 Verify Ignition Control System Ground The igniter flame sensor a
15. 0 to 750 mV pilot systems A WARNING FIRE OR EXPLOSION OR ELECTRICAL SHOCK HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Follow these warnings exactly 1 Disconnect the power supply before wiring to prevent electrical shock or equipment damage 2 To avoid dangerous accumulation of fuel gas turn off gas supply at the appliance service valve before starting Installation and perform the Gas Leak Test immediately following the installation See Checkout on page 15 3 Never install where water can flood drip or condense on module or gas control Never use a module or gas control that has been wet If wet controls can malfunction and lead to an accumulation of explosive gas 4 Do not light or operate electric switches lights or appliances until you are sure the appliance area is free of gas Liquefied petroleum LP gas is heavier than air and does not vent upward naturally Maintenance Requirements in Severe Environments Regular preventive maintenance is important in any application but especially so in commercial cooking agricultural and industrial applications because n many such applications particularly commercial cooking the equipment operates 100 000 200 000 cycles per year Such heavy cycling can wear out the gas control in one to two years A normal forced air furnace for which the controls were originally intended typically operates less than 20 000 cycles per year Y8610U INTERMITTE
16. Anticipator Setting 0 7A plus current ratings of other devices in the thermostat control circuit ORDERING INFORMATION When purchasing replacement and modernization products from your TRADELINE wholesaler or distributor refer to the TRADELINE Catalog or price sheets for complete ordering number S8610U Intermittent Pilot Gas Ignition Control Specifications Control Voltage Line 24 Vac 18 30 Vac 50 60 Hz Trial for Ignition See Table 1 above Prepurge See Table 1 above Flame Failure Response Time 2 seconds maximum LEDs The green LED provides system status error codes and indicates flame sensing Operating Temperature Minimum ambient temperature rating is 40 F 40 C Maximum ambient temperature rating when used with 2 0 A main valve is 165 F 74 C Relative Humidity 0 to 9596 non condensing Dimensions See Fig 2 on page 4 Thermostat Compatibility Compatible with any Honeywell 24V thermostat and with competitive 24V thermostats that are powered indepen dently of the module 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 Automation and Control Products Sales Office check white pages of your phone directory 2 Honeywell Customer Care 1885 Douglas Drive North Minneapolis Minnesota 55422 4386 3 http customer honeywell com or http customer honeywell ca In Canada Honeyw
17. CE GAS CONTR YES NOTE IF MODULE GOES INTO RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE NOTE IF GROUND IS POOR OR ERRATIC SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL NO AT THE TIME OF CHECKOUT CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF CHECKS ARE OKAY REPLACE MODULE SYSTEM RUNS UNTIL CALL FOR HEAT ENDS YES CALL FOR HEAT ENDS CHECK FOR PROPER THERMOSTAT CONTROLLER OPERATION NO REMOVE MV LEAD AT MODULE IF VALVE CLOSES RECHECK TEMPERATURE CONTROLLER AND WIRING IF NOT REPLACE GAS CONTROL YES REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED M24904 Fig 22 Troubleshooting Guide 21 68 0291 03 Y8610U INTERMITTENT PILOT RETROFIT KIT ANSI STANDARDS Exhibit A Recommended Procedure for Safety Inspection of an Existing Appliance Installation as a Preliminary Step to Applying an Automatic Intermittent Pilot System The following procedure is intended as a guide to aid in determining that an appliance is properly installed and is in a safe condition for continuing use This procedure is predicated on central furnace and boiler installations equipped with an atmospheric gas burner s and not of the direct vent type It should be recognized that generalized test procedures cannot anticipate all situations Accordingly in some cases deviation from this p
18. ERMOSTAT M6858 Fig 6 Wiring connections on standing pilot gas controls Remove Standing Pilot Gas Control 1 If the gas control has a common terminal s remove the wires connected to the common terminal s and splice together with one of the wire nuts provided 2 Label and remove the remaining wires WARNING FIRE OR EXPLOSION HAZARDCAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Do not bend the pilot gas tubing at the gas control or at the pilot burner to prevent gas leakage at the connection 3 Disconnect the pilot tubing at the gas control Cut off and discard the compression fitting Do not disturb the com pression fitting or pilot tubing at the pilot burner Disconnect the thermocouple lead at the gas control Disconnect the gas piping at the gas control Discard the gas control Remove Thermocouple Unscrew or snap the thermocouple out of the pilot burner and discard See Fig 7 NOTE It could be necessary to pull out the main burner for access to the pilot burner Do not move or relocate the pilot burner Do not bend tubing near the pilot burner REMOVE THERMOCOUPLE TUBING M6862 Fig 7 Remove thermocouple from pilot burner Install Igniter Sensor Assembly 1 Install the ground rod See Fig 8 Mount adapter to the ground rod if needed Insert the ground rod in place of the thermocouple on the pilot burner Push the ground rod all the way up and fasten as shown in Fig
19. Honeywell Y8610U Intermittent Pilot Retrofit Kit 1 GENERAL The Y8610U is a complete kit for converting conventional standing pilot systems to intermittent pilot systems It is used on gas fired atmospheric furnaces boilers and heating appliances Not for use on direct vent induced draft or power burner equipment Meets ANSI 221 71 standard for automatic intermittent pilot ignition systems on central furnaces and boilers FEATURES Y8610U kits can be used with either natural or LP gas The S8610U ignition control provides a 90 second maximum ignition trial shuts off waits five minutes nominal then re initiates the pilot ignition sequence The ignition trial shutoff and wait cycle repeat until the pilot lights or the call for heat ends Each kit includes 586100 Intermittent Pilot Module VR8304M Dual Valve Combination Gas Control or VR8204A Dual Valve Combination Gas Control Automatic Ignition Systems ANSI 221 20 PRODUCT DATA 392431 Igniter Sensor 394800 30 Ignition Cable 393691 Natural to LP Gas Conversion Kit Wiring Harness 393690 14 Straight Flange Kit 3 4 in Reducer adapters for gas control with VR8304M Installation hardware Temperature Ratings 8610U 40 F to 165 F 40 C to 74 C VR8304M 40 F to 175 F 40 C to 79 C VR8204A 0 F to 175 F 18 C to 79 C Intermittent Pilot Gas Ignition Control Module Uses flame recti
20. K NO REPLACE MODULI PULL IGNITION LEAD AND CHECK SPARK AT MODULE YES SENSOR GAP Y CHECK IGNITION CABLE GROUND WIRING CERAMIC INSULATOR AND GAP AND CORRECT YES CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING TAKE PROTECTIVE ACTION TO SHIELD CABLE AND BOOT FROM EXCESSIVE TEMPERATURES TURN GAS SUPPLY ON AND RECYCLE CALL FOR HEAT CHECK THAT ALL MANUAL GAS VALVES ARE OPEN SUPPLY TUBING AND GAS PRESSURES ARE TO SPECIFICATION AND gt PILOT BURNER ORIFICE IS NOT BLOCKED NO 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 NOT REPLACE MODULE NOTE IT MAY BE NECESSARY TO RECYCLE THE CALL FOR HEAT TO CLEAR THE PILOT SUPPLY TUBING OF AIR NOTE IF MODULE GOES INTO RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE CLEAN FLAME ROD NO CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF NECESSARY IF PROBLEM PERSISTS REPLACE MODULE PILOT IS LIT YES MAIN BURNER LIGHTS CHECK FOR 24 VAC ACROSS PV MV PV TERMINALS ON MODULE IF NO VOLTAGE REPLACE MODULE CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL IF OKAY REPLA
21. NT PILOT RETROFIT KIT Exposure to water dirt chemicals and heat can damage the ignition control module or the gas control and shut down the control system A NEMA 4 enclosure can reduce exposure to environmental contaminants The maintenance program should include regular checkout of the system as outlined under Checkout on page 15 WARNING FIRE OR EXPLOSION HAZARDCAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Do not attempt to disassemble or clean the module Improper reassembly and cleaning can cause unreliable operation Maintenance frequency must be determined individually for each application based on Cycling frequency Appliances that cycle more than 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 is high the system should be checked more often Dusty wet or corrosive environment Because these environments can cause the controls to deteriorate more rapidly the system should be checked more often Any ignition control module or gas control should be replaced if it does not perform properly on checkout or troubleshooting In addition replace any ignition control module or gas control if it is wet or looks like it has ever been wet Protective enclosures as outlined under Planning the Installation
22. S IN METALLIC TUBING SHOULD BE SMOOTH A CAUTION SHUT OFF THE MAIN GAS SUPPLY BEFORE REMOVING END CAP TO PREVENT GAS FROM FILLING THE WORK AREA TEST FOR GAS LEAKAGE WHEN INSTALLATION IS COMPLETE M3077A Fig 11 Install sediment trap Mount Gas Control 1 2 3 The gas control can be mounted from 0 to 90 degrees in any direction including vertically from the upright posi tion of the gas control knob Mount the gas control so the gas flow is in same direc tion as the arrow on the gas control bottom Thread the pipe as listed in Table 3 NOTE See Table 3 for maximum pipe threading depth If the pipe is inserted too deeply into the gas control the second main valve or safety valve can distort or mal function Table 3 NPT pipe thread length in Pipe Overall Maximum Depth Pipe Can Be Size Thread Length Inserted Into Gas Control 3 8 9 16 3 8 1 2 3 4 1 2 3 4 13 16 3 4 5 6 Y8610U INTERMITTENT PILOT RETROFIT KIT Apply a moderate amount of good quality pipe com pound to pipe only leave the two end threads bare Do not use teflon tape In LP installations use a compound resistant to LP gas See Fig 12 TWO IMPERFECT THREADS GAS CONTROL THREAD PIPE CORRECT LENGTH APPLY A MODERATE AMOUNT OF PIPE COMPOUND TO PIPE ONLY LEAVE TWO END THREADS BARE M3312 Fig 12 Use moderate amount of pipe compound Remove protective seals over the gas control inlet and
23. SEMBLY E Tn e v ou i PA wf ALSO INCLUDED 394800 30 IGNITION CABLE 30 IN 760 mm IGNITER SENSOR in T 393690 14 STRAIGHT FLANGE KIT E T 0 393691 NATURAL GAS TO LP CONVERSION KIT REDUCER ADAPTERS FOR GAS CONTROL WITH VR8304M ADAPTER SCREWS WIRE NUTS 3 M325189 Fig 1 Y8610U retrofit kit components 3 16 5 x2 4 2061 11 32 26 ge 3 3 8 86 x 2 5 1 2 140 M32363 Fig 2 S8610U module dimensions in inches mm 68 0291 03 4 Y8610U INTERMITTENT PILOT RETROFIT KIT 4 IN 102 MAX SWING RADIUS 1 4 INCH QUICK CONNECT TERMINALS PRESSURE REGULATOR 3 15 16 ADJUSTMENT WIRING 99 UNDER CAP SCREW TERMINALS 3 INLET OUTLET PRESSURE TAP PRESSURE TAP INLET gt Doumer PILOT OUTLET GAS PILOT ADJUSTMENT CONTROL UNDER CAP SCREW 4 1 16 104 KNOB M24885 4 2 11 16 69 M24886 Fig 3 VR8304M mounting dimensions in inches mm 3 5 8 91 MAX SWING RADIUS 1 4 INCH QUICK CONNECT TERMINALS PRESSURE REGULATOR 3 1 2 ADJUSTMENT WIRING 89 UNDER CAP SCREW TERMINALS 3 INLET OUTLET PRESSURE TAP PRESSURE Z TAP INLET Douret 1 7 16 36 PILOT OUTLET GAS PILOT ADJUSTMENT CONTROL UNDER CAP SCREW KNOB M24887 lt 4 1 8 108 gt 2 11 16 69 M24888 Fig 4 VR8204A mounting
24. as Controls Specifications Model Capacity Pipe Size Ambient Temperature Rating Dimensions VR8204A 150 ft3 hr 4 2 m hr with or 1 2 in X 1 2 in NPT 0 to 175 F 18 to 79 C See Fig 4 on page 5 without 1 2 x 3 4 adapter inlet x outlet VR8304M 270 ftS hr 7 6 m hr 1 2 Wow 3 4 ee 40 to 175 F 40 to 79 C See Fig 3 on page 5 inlet x outle Based on 1 000 Btu ft 0 64 specific gravity natural gas at 1 in wc pressure drop 37 3 MJ m 0 64 specific gravity natural gas at 0 25 kPa pressure drop P 3 4 in straight flange included to provide 3 4 NPT outlet if needed Mounting Can be mounted from 0 to 90 degrees in any direction from the gas control upright position Pressure Rating 1 2 psig 3 45 kPa inlet pressure Terminals 1 4 in male quick connect terminals Igniter Sensor Specifications Model 392431 Igniter Sensor includes igniter sensor assembly ground rod and adapter refer to Fig 1 on page 4 Electrode Flame Rod Material Kanthal Maximum Temperature Ratings Ground Rod Tip 1775 F 968 C Ceramic Insulator 1250 F 677 C Dimensions See Fig 5 on page 6 Mounting Attach the supplied ground rod and adapter which replace the thermocouple on the existing pilot burner 68 0291 03 Y8610U INTERMITTENT PILOT RETROFIT KIT VR8304 586100 INTERMITTENT PILOT MODULE WITH WIRING HARNESS 392431 IGNITER SENSOR AS
25. decrease or counterclockwise to increase pilot flame Following adjustment always replace pilot adjust ment cover screw and tighten firmly to assure proper gas control operation j Set thermostat below room temperature to end Call for Heat 4 Recheck ignition sequence as follows 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 control module 68 0291 03 e If main burner doesn t light or if main burner lights but system locks out check the ignition control module s ground wire and the gas control as described in Igni tion System Checks on page 17 and refer to the Troubleshooting Guide Fig 22 on page 21 APPEARANCE SMALL BLUE FLAME LAZY YELLOW FLAME WAVING BLUE FLAME D NOISY LIFTING BLOWING FLAME i HARD SHARP FLAME i CAUSE CHECK FOR LACK OF GAS FROM CLOGGED ORIFICE FILTER CLOGGED PILOT FILTER LOW GAS SUPPLY PRESSURE PILOT ADJUSTMENT AT MINIMUM CHECK FOR LACK OF AIR FROM DIRTY ORIFICE DIRTY LINT SCREEN IF USED DIRTY PRIMARY AIR OPENING IF THERE IS ONE PILOT ADJUSTMENT AT 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 M2233B F
26. dimensions in inches mm 5 68 0291 03 Y8610U INTERMITTENT PILOT RETROFIT KIT 1 1 8 29 M6860 Fig 5 392431 Igniter sensor mounting dimensions in inches mm PLANNING THE INSTALLATION A WARNING Fire or Explosion Hazard Can cause severe injury death or property damage 1 Plan the installation as outlined below 2 Plan for frequent maintenance as described in the Maintenance section 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 applications may make heavy demands on the controls either because of frequent cycling or because of moisture corrosive chemicals dust or excessive heat in the environment In these situations special steps may be required to prevent nuisance shutdowns and premature control module failure These applications require special Honeywell 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 68 0291 03 Frequent Cycling These controls are designed for use on appliances that typically cycle three to four times an hour only during the heating season In year round applications with greater cycling rates the control module can wear out more quickly perform a monthly ch
27. eckout Water or Steam Cleaning If the control module 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 so they do not get wet during normal cleaning procedures Use a NEMA 4 enclosure for the ignition control module High Humidity or Dripping Water Dripping water can cause the control module and the gas control to fail Never install an appliance where water can drip on the controls In addition high ambient humidity can cause the control module and the gas control to corrode and fail 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 control module Corrosive Chemicals Corrosive chemicals can attack the ignition control module and gas control eventually causing a failure If chemicals are used for routine cleaning make sure they do not reach the controls Where chemicals are suspended in air as in some industrial or agricultural applications use a NEMA 4 enclosure for the ignition control module 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 ignition control module and the gas control to
28. ee Igni tion System Checks below to isolate and correct the problem 5 Following troubleshooting perform the Checkout on page 15 again to be sure system is operating normally Ignition System Checks Step 1 Check Ignition Cable Make sure 1 Ignition cable is not damaged cracked burned or dirty Replace if necessary 2 Ignition cable does not run in contact with any metal sur faces 3 Ignition cable is no more than 36 in 0 9 m long 4 Connections to the ignition control module and to the igniter or igniter sensor are clean and tight 5 Ignition cable provides good electrical continuity 17 Y8610U INTERMITTENT PILOT RETROFIT KIT STEP 2 Check Ignition System Grounding Nuisance shutdowns are often caused by a poor or erratic ground A common ground is required for the ignition control module and the pilot burner bracket 1 Check for good metal to metal contact between the pilot burner bracket and the main burner 2 Check the ground circuit from the GND BURNER termi nal on the ignition control module to the pilot burner Make sure connections are clean and tight If the wire is damaged or deteriorated replace it with 14 to 18 gauge moisture resistant thermoplastic insulated wire with 221 F 105 C minimum rating a Check the ceramic flame rod insulator for cracks or evidence of exposure to extreme heat which can permit leakage to ground Replace pilot burner igniter sensor and provide shield
29. ell Limited Honeywell Limit e 35 Dynamic Drive Toronto Ontario M1V 4Z9 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 0291 03 2 Transformer Sizing Add current ratings of Y8610 vent damper and any other control system components Multiply this total by 24V to determine the transformer VA requirement Mounting Mounts in any position except with terminals up Recom mended mounting position is with terminals down to provide maximum protection from dripping water or dust accumula tion Refer to Fig 14 on page 12 Fasten with No 6 32 machine screws or No 8 sheet metal screws or 8 18 x 5 8 pan head tapping screws of appropri ate length VR8204A and VR8304M Dual Valve Combination Gas Controls Specifications Y8610U INTERMITTENT PILOT RETROFIT KIT Wiring Connections Between the module and gas control 30 762 mm wiring harness with 1 4 in quick connect terminals Between the module and the igniter sensor 30 in 762 mm ignition cable with stud terminal and 1 4 in quick connect terminal Terminals 1 4 in male quick connects S8610U has Molex plug for connection to a vent damper harness Once the S8610U has powered a vent damper the module works only if the vent damper is connected Table 2 VR8204A and VR8304M Dual Valve Combination G
30. elow the room temper ature Make sure the main burner and pilot flames go out OPERATION Fig 19 summarizes the normal operating sequence for installations without vent dampers The ignition control module s operation can be conveniently divided into two phases Trial for pilot ignition Main burner operation Trial for Pilot Ignition On a Call for Heat the ignition control module energizes the spark source and the pilot valve relay simultaneously The pilot valve opens allowing gas to flow to the pilot burner for the ignition trial time The spark lights the pilot flame when pilot gas is present A flame rectification circuit confirms the presence of the pilot flame shuts off the spark source and energizes the main valve relay The ignition control module uses a two level pilot flame proving sequence When a sufficient flame current is sensed the spark is turned OFF However the pilot flame must generate a higher level of flame current to energize the main valve This approach assures a stable pilot flame to support reliable burner lightoff If the pilot flame is weak or unstable the spark may turn back ON However the trial for pilot ignition will not exceed the stated ignition trial time Main Burner Operation When the main valve opens gas flows to the main burner where it is lit by the pilot flame There is a short flame stabilization period as the main valve opens to allow the pilot flame to stabilize as the
31. fication for flame sense Internal spark generator lights pilot gas main burner lights after pilot flame lights and proves 100 shutoff of pilot and main gas if burner fails to light Continuous retry ignition sequence prevents nuisance lockouts Two LEDs indicate system status and flame signal strength Gas Control Valve Straight through body pattern VR8304M capacity is 270 ft hr 7 6 m hr e VR82044A capacity with or without 1 2 x 3 4 adapter is 150 4 2 m3 hr Manual ON OFF valve blocks gas flow into the gas control when in the OFF position Two main automatic valves one solenoid operated and one a servo operated diaphragm system Igniter Sensor Single electrode made of Kanthal provides both ignition and flame sensing Rated for 1775 F 968 C at electrode tip 1250 F 677 C at ceramic insulator Contents General EE 1 eeepc 2 Planning the Installation 6 Installation 7 NIMM M 14 Checkout 15 16 Troubleshooting ttn 17 Ansi Standards sse 22 68 0291 03 Y8610U INTERMITTENT PILOT RETROFIT KIT Table 1 S8610U Universal Intermittent Pilot Gas Ignition Control Module Igniter Sensor Type Combination one rod local flame
32. for cracks openings or excessive cor rosion Applicable only to boilers Inspect for evidence of water or combustion product leaks Insofar as is practical close all building doors and win dows and all doors between the space in which the appli ance is located and other spaces of the building Turn on clothes dryers Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers If after completing steps 7 through 12 it is believed sufficient combustion air is not available refer to 1 3 4 of the National Fuel Gas Code 2223 1 for guidance Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Determine the following a Determine that the pilot is burning properly and that main burner ignition is satisfactory by interrupting and re establishing the electrical supply to the appli ance in any convenient manner b Determine manifold pressure in order to match input after the new control is installed Perform the following tests a Visually determine that main burner gas is burning properly i e no floating lifting or flashback Adjust the primary air shutter s as required b If appliance is equipped with high and low flame con trol or flame modulation check for proper main burner operation at low flame Test for spilla
33. ge 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 Return doors windows exhaust fans fireplace dampers and all other fuel burning appliances to their previous conditions of use Applicable only to warm air heating appliances Check both limit controller and fan controller for proper opera tion Limit controller operation can be checked by tempo rarily disconnecting the electrical supply to the blower motor and determining that the limit control acts to shut off the main burner gas ee only to boilers Determine that the circulating water pumps are in operating condition b Test low water cutoffs automatic feed controls pres sure and temperature limit controls and relief valves in accordance with the manufacturer s recommenda tions and instructions to determine they are in oper ating condition 68 0291 03 Shut Down Appliance 1 Turn off the gas supply at the appliance service valve Do not use the gas control knob 2 Turn off the electricity at the service entrance Check Appliance Wiring The existing standing pilot gas control wires are used to control Y8610U Retrofit Kit Carefully identify and tag the wires before disconnecting See Fig 6 for the most common types of terminal arrangements TO TO TRANSFORMER THERMOSTAT COMMON TO TO TRANSFORMER THERMOSTAT COMMON TO TO TRANSFORMER TH
34. h Return path to transformer 24V 1 4 inch Optional 24 Vac power connection for Vent Damper TH W 1 4 inch Connector for Call for Heat signal from thermostat P1 6 pin Connector for Vent Damper keyed plug connection used to control a connected damper in atmospheric appliances Flame Two holes Micro ammeter connector Current P4 Jumper Provides a lockout for the DIP Jumper switch settings See Jumper on page 15 SENSE Wire with Connects to the REMOTE SENSE JUMPER 3 16 inch connector for installations with a WIRE quick single spark rod local flame connect sensing REMOTE 3 16 inch Flame Sensor connector SENSE For single rod installations connect the SENSE JUMPER WIRE to this terminal connector SPARK 1 4 inch High voltage sparking electrode connection 68 0291 03 Y8610U INTERMITTENT PILOT RETROFIT KIT S8610U MV GND 24V MV PV PV BRN GND 24V TH W P1 VR8204 COMBINATION GAS CONTROL JUMPER WIRE PV PV MV THERMOSTAT LIMIT CONTROLLER PILOT BURNER IGNITER X X PILOT BURNER GROUND N POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION A MAXIMUM CABLE LENGTH 3 FT 0 9 MJ J CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER A LEAVE VENT DAMPER PLUG P1 UNCONNECTED amp N CONNECT JUMPER WIRE TO THE REMOTE SENSE CONNECTOR M32356 Fig 16 Y8610U connection
35. he pilot burner during the ignition sequence See if one of the following occurs a Ignition spark continues after the pilot is lit b The pilot lights and the spark stops but main burner does not light c The pilot lights the spark stops and main burner lights but the pilot and main gas shut down while the Call for Heat is still present 3 If so ensure adequate flame current as follows a Turn off furnace at circuit breaker or fuse box b Clean the flame rod with emery cloth c 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 d Check for cracked ceramic insulator which can cause short to ground and replace igniter sensor if necessary e Check for cracked damaged burned or dirty spark ignition cable and replace if necessary Be sure igni tion cable is not touching any flat metal surface f Atthe gas control disconnect main valve wire from the TH W or MV terminal g Turn on power and set thermostat to Call for Heat The pilot should light but the main burner will remain off because the main valve actuator is disconnected h Check the pilot flame Make sure it is blue steady and envelops 3 8 to 1 2 in 10 to 13 mm of the flame rod See Fig 20 for possible flame problems and their causes i If necessary adjust pilot flame by turning the pilot adjustment screw on the gas control clockwise to
36. her spaces of the building Turn on clothes dryers Turn on any exhaust fans such as range hoods and bath room exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers If after completing steps 7 through 12 it is believed sufficient combustion air is not available refer to 1 3 4 of the National Fuel Gas Code Z223 1 for guidance 8 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 9 Determine the following a Determine that the pilot is burning properly and that main burner ignition is satisfactory by interrupting and re establishing the electrical supply to the appliance in any convenient manner b Determine manifold pressure in order to match input after the new control is installed 10 Perform the following tests a Visually determine that main burner gas is burning properly i e no floating lifting or flashback Adjust the primary air shutter s as required b If appliance is equipped with high and low flame control or flame modulation check for proper main burner operation at low flame 11 Testfor 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 c
37. ig 20 Examples of unsatisfactory pilot flames Y8610U INTERMITTENT PILOT RETROFIT KIT LED Status and Troubleshooting Flame Status and Sense LED Indicates system operation status and senses error conditions See Table 9 on page 20 and the Trouble The ignition control module has two LEDs one for flame shooting Guide on page 21 sensing and one for system status Honeywell 25 eo 586100 Continuous Retry If module has been used with vent damper it will only work with damper connected STATUS LED M29896 Fig 21 Location of LEDs 19 68 0291 03 Y8610U INTERMITTENT PILOT RETROFIT KIT Table 9 Green LED Status Codes Green LED Flash Code Indicates Next System Action Recommended Service Action OFF No Call for Heat Not applicable None Flash Fast Power up internal check Not applicable None Heartbeat Normal startup ignition Not applicable None sequence started including prepurge 4 Seconds Device in run mode Not applicable None ON then flame current to the flashes nearest uA 2 5 minute Retry Delay Initiate new trial for ignition after retry If system fails to light on next trial for ignition Pilot flame not detected delay completed check gas supply pilot burner spark and during trial for ignition flame sense wiring flame rod contaminated or out of position burner ground connection 3 Recycle Initiate new trial
38. igniter sensor Wiring Connections Connect the provided harness to the ignition module and the gas control The harness ends are labeled for easy installation See Table 4 Table 4 Wiring Harness Connections Harness Wire Color S8610U Gas Control Terminal I Wire Label Terminal Tstat Load Black 25 VAC TH W Thermostat call for heat to original standing pilot valve Orange 25 VAC GND 24V GND Transformer 24 VAC ground lead to original standing pilot valve Red MV MV MV White MV PV MV PV MV PV Blue PV PV PV Green GND GND Ground terminal on gas control Use Fig 15 and Table 5 to make the remaining wiring connections NOTE The 24V terminal on the S8610U is used only when a vent damper is installed Fig 16 on page 14 illustrates the typical wiring connections in a heating system with an atmospheric burner 13 Y8610U INTERMITTENT PILOT RETROFIT KIT Honeywell Golden Valley MN 55422 Assembled in Mexico 586100 Continuous Retry 24V 60 Hz PV 1A MV 2A Max P1 VENT DAMPER 2 CONNECTOR SPARK M29890 Fig 15 S8610U Typical wiring connections Table 5 S8610U Typical Wiring Connections Connector Size or Label Type Description MV 1 4 inch Main Valve connection MV PV 1 4 inch Common terminal for gas valves PV 1 4 inch Pilot Valve connection BRN GND 1 4 inch Burner Ground 24V GND 1 4 inc
39. ire Explosion or Electrical Shock Hazard Can cause severe injury death or property damage Do not attempt to modify the physical or electrical characteristics of this device in any way Replace it if troubleshooting indicates a malfunction IMPORTANT 1 The following service procedures are provided as a general guide Follow appliance manufacturer s ser vice instructions if available 2 Meter readings between the gas control and ignition contro module must be taken within the trial for igni tion period Once the ignition control module shuts off it must be reset by setting the thermostat down for at least 30 seconds before continuing 3 If any component does not function properly make sure it is correctly installed and wired before replacing it 4 The ignition control module and the gas control can not be repaired If either malfunctions it must be replaced 5 Only trained experienced service technicians should service intermittent pilot systems 6 After troubleshooting check out the system again to be sure it is operating normally Troubleshooting Sequence The general troubleshooting sequence is as follows 1 Refer to LED Status and Troubleshooting on page 19 for LED status codes 2 Perform the Checkout on page 15 as the first step in troubleshooting 3 Check the Troubleshooting Guide Fig 22 on page 21 to pinpoint the cause of the problem 4 If troubleshooting indicates an ignition problem s
40. limit contamination A NEMA 4 enclosure is recommended for the ignition control module Heat Excessively high temperatures can damage controls Make sure the maximum ambient temperature at the control module does not exceed the rating of the control module 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 installed INSTALLATION When Installing this Product 1 Read these instructions carefully Failure to follow them could damage the product or cause a hazardous condi tion 2 Check the ratings given in these instructions and on the product to ensure the product is suitable for your applica tion 3 Installer must be a trained experienced service techni cian 4 After completing installation use these instructions to check product operation IMPORTANT 1 Installer must comply with local codes and ordinances of the National Fuel Code ANSI Z223 1 NFPA No 54 and National Electrical Code ANSI NFPA No 70 2 Installer must fill in and attach label to appliance being converted 3 Use Y8610 Retrofit Kit only with atmospheric burners Do not use on direct vent appliances appliances with induced draft or power burners 4 Do not use the Y8610 Retrofit Kit with mercury pilots or 25
41. ltiply the total current draw as computed above by 24 V to determine the total VA volt ampere required c The total VA volt ampere required should be equal to or less than the VA rating of the transformer d If the total VA volt ampere required is greater than the VA rating of the transformer the transformer must be replaced with a Class 2 transformer of adequate rating Check the heat anticipator in the comfort thermostat to determine if it is properly adjusted to the current draw of the control system Follow the thermostat manufacturer s instructions Make certain wiring connections are tight and wires are positioned and secured so they will not be able to contact high tem perature locations Conduct a Gas Leakage Test of the appliance piping and control system downstream of the shut off valve in the supply line to the appliance Perform the following a Adjust the thermostat to its highest temperature setting and test manifold pressure and adjust the pressure regulator to match original input as required refer to Exhibit A step 9b b Visually determine that main burner is burning properly i e no floating lifting or flashback Adjust the primary air shut ter s as required If 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 Determine that the pilot is igniting and burning properly and that main burner ignition is satisfacto
42. nd ignition control module must share a common ground with the pilot burner Use thermoplastic insulated wire with a minimum rating of 221 F 105 C for the ground wire asbestos insulation is not acceptable If the temperature at the wire could exceed 221 F 105 C use a shield to protect the wire from radiant heat generated by the burner Connect the ground wire as follows 1 Fitone 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 control 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 ground is not required Step 3 Review Normal Operating Sequence and Ignition Control Module Specifications See the Operation section on this page and Specifications on page 2 Step 4 Reset the Ignition Control Module 1 Turn the thermostat to its lowest setting 2 Wait one minute As you perform the remaining steps watch for points where operation deviates from normal To correct problems refer to the Troubleshooting Guide on page 21 Step 5 Check Safety Shutoff Operation 1 Turn gas supply off at the appliance manual shutoff valve
43. o tighten one more turn Do not overtighten Connect the other end of the pilot gas tubing to the pilot burner according to the pilot burner manufacturer instructions 68 0291 03 Y8610U INTERMITTENT PILOT RETROFIT KIT Locate and Mount the S8610U Intermittent Pilot Module Location Identify a mounting location for the S8610U ignition control The mounting location must provide Good clear access to the field wiring terminals Operating ambient temperatures between 40 F 40 C and 165 F 74 C Direct the cable route to the pilot burner The cable route must be 30 inches 762 mm or less and not expose the cable to excessive heat Relative humidity below 95 non condensing Protection from water steam or corrosive chemicals that are used to clean the appliance Protection from dripping water such as from an overfilled humidifier or from condensation Protection from dust or grease accumulation Mounting Mount the ignition control module with the terminals down to protect them from dripping water and dust The control module can also be mounted with the terminals on either side Do not mount with the terminals pointing up Fig 14 illustrates the incorrect mounting position Use the S8610U as a template to mark the mounting hole pattern Drill new holes as required Fasten securely with four No 6 32 machine screws or No 8 sheet metal screws or 8 18 x 5 8 Pan Head tapping screws
44. onditions of use 13 Applicable only to warm air heating appliances Check both limit controller and fan controller for proper operation Limit con troller 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 Testlow water cutoffs automatic feed controls pressure and temperature limit controls and relief valves in accordance with the manufacturer s recommendations and instructions to determine they are in operating condition Exhibit of ANSI Standard 221 71 for Automatic Intermittent Pilot Ignition Systems for Field Installation 68 0291 03 22 Y8610U INTERMITTENT PILOT RETROFIT KIT Exhibit B Procedure for Installing Automatic Intermittent Pilot Systems Prior to beginning this procedure a preliminary examination of the appliance and the automatic intermittent 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 atmospheric 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
45. rocedure may be necessary to determine safe operation of the equipment 1 This procedure should be performed prior to any attempt at modification of the appliance or the installation 2 Ifitis determined there is a condition which could result in unsafe operation the appliance should be shut off and the owner advised of the unsafe condition The following steps should be followed in making the safety inspection 1 Conduct a Gas Leakage Test of the appliance piping and control system downstream of the shut off 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 unsafe 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 supply line to each appliance If a manual gas valve is not in the gas supply line within 6 feet of the appliance in an acces sible location one shall be installed Inspect burners and crossovers for blockage and corrosion Applicable only to warm air heating appliances Inspect heat exchangers for cracks openings or excessive corrosion Applicable only to boilers Inspect for evidence of water or combustion product leaks Insofar as is practical close all building doors and windows and all doors between the space in which the appliance is located and ot
46. ry by interrupting and rees tablishing the electrical supply to the appliance in any convenient manner Make this determination 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 Test the pilot safety device 1 to determine if it is operating properly and 2 for turndown characteristics according to the manufacturer s installation instructions No adjustments should be made other than those recommended by the system man ufacturer Sequence the appliance through at least three operating cycles 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 Applicable only to boilers a Determine that the circulating water pumps are in operating condition b Test low water cutoffs automatic feed water controls pressure and temperature limit controllers and relief valves in accordance with the manufacturer s recommendation to determine they are in operating condition Add the labels see 1 6 1 n and o on the appliance Exhibit B of ANSI Standard Z21 71 for Automatic Intermittent Pilot Ignition Systems for Field Installation 23 68 0291
47. s in a heating system with an atmospheric burner and no vent damper SETTINGS N Cu Nd DIP Switch S1 Settings jc es EE The factory default settings for the S8610U are recommended irm taue th ie has beon used with vert demper nected for retrofit applications These settings will provide the most Ss irai nas teor wet cux gh one reliable system operation Table 6 DIP Switch S1 Settings Prepurge Trial For Ignition SW1 SW2 None 90 seconds OFF OFF 51 i S1 DIP SWITCH M29894 1 Fig 18 DIP switch S1 and jumper P4 location M23587 Fig 17 DIP switch S1 shown with factory default settings OFF for SW1 and SW2 68 0291 03 14 Jumper This jumper labeled P4 is used to lock the operating sequence selected by the DIP switch settings See Fig 18 Table 7 Jumper Usage Jumper Action to lock the control s operating sequence P4 To ensure proper system operation after installation and checkout pull jumper to lock the DIP switch settings NOTE f jumper is not removed during installa tion the ignition control locks the DIP Switch settings after the 10 Call for Heat cycle IMPORTANT Once the Jumper has been pulled or the module starts the 10 Call for Heat the control operating sequence is permanently locked and cannot be reset by replacing the jumper or by resetting the Dip Switches CHECKOUT Check
48. secondary voltage Control module remains in wait mode Check transformer and AC line for proper supply When the fault corrects control module input voltage to the control Check with full resumes normal operation System load on the transformer Flash Code Descriptions Flash Fast rapid blinking Heartbeat Constant 72 second bright 4 second solid on pulse followed by mode 7 second dim cycles X 1 second flashes indicates flame current to the nearest uA This is only available in run A single flash code number signifies that the LED flashes X times at 2 Hz remains off for two seconds and then repeats the Sequence 68 0291 03 20 Y8610U INTERMITTENT PILOT RETROFIT KIT Troubleshooting Guide Refer to the Fig 22 for troubleshooting the S8610U control module START BEFORE TROUBLESHOOTING FAMILIARIZE YOURSELF WITH THE STARTUP AND CHECKOUT PROCEDURES NOTE 24 VAC CALL FOR HEAT IS ALWAYS CONNECTED TO THE TH W TERMINAL ON THE MODULE TURN GAS SUPPLY OFF TURN THERMOSTAT CONTROLLER TO CALL FOR HEAT CHECK LINE VOLTAGE POWER LOW VOLTAGE TRANSFORMER LIMIT CONTROLLER THERMOSTAT CONTROLLER AND WIRING ALSO CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM IF USED AND THAT THE END SWITCH IF USED IS MADE POWER TO TH W TERMINAL NOMINAL RECYCLE CALL FOR HEAT TO ALLOW TIME TO CHECK SPARK SPARK O
49. stall the Gas Control COLOR CODE FOR ey NATURAL GAS A WARN N G cap screw Back SILVER FIRE OR EXPLOSION HAZARDCAN CAUSE SY b SRE TAREA PROPERTY DAMAGE SEVERE INJURY OR S ADJUSTING WHITE WHITE DEATH LE STAINLESS Follow these warnings exactly p RED STEEL 1 Do not bend the pilot gas tubing at the gas control or at the pilot burner after the compression fitting is tightened Gas leakage at the connection can result 2 Always install a sediment trap in the gas supply PRESSURE line to prevent contamination of the gas control 3 Do not force the gas control knob Use only your hand to turn the gas control knob If the gas control knob does not operate by hand the gas control should be replaced by a qualified service techni cian Force or attempted repair can result in a fire or explosion IMPORTANT These gas controls are shipped with protective seals over the inlet and outlet tappings Do not remove the seals until ready to connect the piping M8083A Fig 10 Installation of conversion kit in regulated Converting Between Natural and LP Gas gas control A Install Adapters to Gas Control if used WARNING 393690 14 Straight Flange 3 4 in FIRE OR EXPLOSION HAZARDCAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR 1 Remove the seal over the gas control inlet or outlet 2 Make sure that the O ring is fitted in the flange groove If DEATH r nate 1 Do not attempt to use a gas control se
50. t for natural 1 x 3 With the O ring facing the gas control align the gas con trol threaded holes with the flange clearance holes 4 Insert and tighten the screws provided with the flange Tighten the screws to 25 inch pounds of torque to pro vide a gas tight seal 2 When making a conversion main and pilot burner orifices must be changed to meet appliance manu facturer specifications To convert from natural gas to LP use the 393691 LP Conversion Kit that is included with the Y8610U Intermittent Pilot Retrofit Kit To convert from LP to natural gas use the Bushings 394588 Natural Gas Conversion Kit ordered separately 1 Remove the seal over the gas control inlet or outlet Step opening gas controls cannot be converted 2 Apply a moderate amount of good quality pipe com pound to the bushing leaving the two end threads bare To convert control from one gas to another For an LP installation use a compound resistant to LP 1 Turn off the main gas supply to the appliance gas Do not use Teflon tape 2 Remove the regulator cap screw and pressure regulator 3 Insert the bushing in the gas control and thread the pipe adjusting screw See Fig 3 or Fig 4 on page 5 carefully into the bushing until tight 3 Remove the existing spring 4 Insertthe replacement spring with the tapered end down Install Gas Control Piping See Fig 10 5 Install the new plastic pressure regulator
Download Pdf Manuals
Related Search