Honeywell SmartValve Q3450A Operation manual

PRODUCT DATA
Copyright © 1995 Honeywell Inc. • All Rights Reserved
68-0125-2
Q3450A,B,C,D,E,F,G and Q3480B,C
SmartValve™System Pilot Burners
FEATURES
•Used with SV9500/SV9600 SmartValve™ System.
•Replaceable Igniter-Flame Rod Assembly (Q3400A).
•Integral keyed plug provides quick, convenient
connection of igniter and sensor to SV9500/SV9600.
•Q3450 has front or 20 degree right, left flame pattern.
•Q3480 has dual-wing flame pattern.
•Natural and LP gas orifices available.
•Variety of target styles available.
•Variety of mounting brackets available.
CONTENTS
Description .......................................................................... 1
Features .............................................................................. 1
Specifications ...................................................................... 2
Ordering Information ........................................................... 2
Installation ........................................................................... 6
Startup and Checkout ......................................................... 7
Service ................................................................................ 7
DESCRIPTION
These SmartValve™ System pilot burners provide pilot flame
ignition and sensing for SV9500/SV9600 Systems. They
consist of replaceable igniter-flame rod assembly, bracket
assembly, pilot target, ground electrode, orifice assembly,
compression fitting and spring clip. The igniter lights the pilot
burner. The flame rod proves the pilot flame and the pilot
flame lights the main burner.
Q3450
Q3480

Q3450A,B,C,D,E,F,G AND Q3480B,C, SmartValve
™
SYSTEM PILOT BURNERS
68-0125—2 2
SPECIFICATIONS
IMPORTANT
The specifications given in this publication do not
include normal manufacturing tolerances. Therefore,
this unit may not exactly match the listed
specifications. Also, this product is tested and
calibrated under closely controlled conditions, and
some minor differences in performance can be
expected if those conditions are changed.
Models:
Q3450A,B,C,D,E,F,G and Q3480B,C SmartValve™ System
Pilot Burner. See Table 1 for model specifications.
Table 1. Model Specifications.
Models Type of Gas Target Style Standard Orifice
Q3450 Natural LP L,F,K BCR18 (P/N 390685-4)
BBR11 (P/N 390688-36)
Q3480 Natural LP Dual-
wing NE22 (P/N 388146NE) KR14 (P/N 388146KP)
Target Styles and Flame Patterns:
Refer to Fig. 1.
Mounting Brackets and Dimensions:
Refer to Fig. 2 through 4.
Type of Gas:
Models available for Natural and LP gas.
Maximum Temperature Ratings:
Ground Electrode Tip: 1800°F (982°C).
Target Tip: 1575°F (857°C).
Orifice: 800°F (427°C).
Flame Rod Tip: 1800°F (982°C).
Igniter Insulator: 905°F (485°C).
Flame Rod Insulator: 1250°F (677°C).
Electrode Flame Rod Material:
Kanthal.
Wiring Connection:
18-inch integral keyed connector for attaching to SV9500/
SV9600.
Approvals:
American Gas Association design certified: U70-24A
Canadian Gas Association design certified:
1029-ABI/CC-9203
Accessory:
Q3400A Replacement Igniter-Flame Rod Assembly.
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.
1. Model
2. Tip style
3. Type of gas
4. Accessories
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 Relations
Honeywell, 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386
In Canada—Honeywell Limited/Honeywell Limitee, 35 Dynamic Drive, Scarborough, 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.
Q3480
SENSORMAIN BURNER
IGNITER FLAME (2)
M9052
Q3450
STRAIGHT 20 DEGREES
RIGHT
20 DEGREES
LEFT
SENSOR
Fig. 1. Pilot burner/igniter sensor target styles
and flame patterns.

Q3450A,B,C,D,E,F,G AND Q3480B,C, SmartValve
™
SYSTEM PILOT BURNERS
68-0125—2
3
AB
CD
7/8
29/32
15/16
31/32
1
2
22.2
23.0
23.8
24.6
25.4
50.8
19/32
5/8
21/32
11/16
23/32
3/4
25/32
13/16
27/32
15.1
15.9
16.7
17.5
18.3
19.1
19.8
20.6
21.4
5/16
11/32
3/8
13/32
7/16
15/32
1/2
17/32
9/16
7.9
8.7
9.5
10.3
11.1
11.9
12.7
13.5
14.3
1/32
1/16
3/32
1/8
5/32
3/16
7/32
1/4
9/32
0.8
1.6
2.4
3.2
4.0
4.8
5.6
6.4
7.1
IN. IN. IN. IN.
MM MM MM MM
1
2
3
4
5
MOUNTING HOLE, TAPPED FOR 10-32 NC SCREW.
MOUNTING HOLE, 11/64 IN. DIAMETER (4 mm)
(CLEARS NO. 8 SCREW).
MOUNTING HOLE, 13/64 IN. DIAMETER (5mm)
(CLEARS NO. 10 SCREW).
1/4 IN. COMPRESSION FITTING.
MOUNTING HOLE, TAPPED FOR 8-32 NC SCREW.
M9586A
2 (52)
(35)
1 (26)
2
4
1
3/16 (5) DOWEL
3/16 (5) DOWEL
3/16 (5) DOWEL 3/16 (5) DOWEL
3/16 (5)
3/16 (5)
14
2
4
1
1 (26)
5
4
5
3
5/8
(16)
5/8
(16)
3/8
(10)
3/8
(10)
1/5
(5)
1/5
(5)
1-1/3
5/16
(8)
5/16
(8)
5/16
(8)
1-2/3
(42)
1-2/3
(42)
4/5
(20)
4/5
(20)
4/5
(20)
7/16
(11)
1/3
(9)
23/32
(18)
1-5/6 (46)
1-5/6 (46)
1/2 (13)
1/2 (13)
7/16
(11)
7/16
(11)
7/16
(11)
7/16
(11)
1-1/2
(38)
1-1/2
(38)
1-5/6
(46)
1/6
(4)
1/4
(8)
1-1/3
(35)
2-1/5 (56)
3/4
(19)
1/5 (5)
1/5
(5)
1-2/3
(42)
3/8
(10)
Fig. 2. Mounting bracket dimensions for Q3450A,B,C and D.

Q3450A,B,C,D,E,F,G AND Q3480B,C, SmartValve
™
SYSTEM PILOT BURNERS
68-0125—2 4
EF
G
7/8
29/32
15/16
31/32
1
2
22.2
23.0
23.8
24.6
25.4
50.8
19/32
5/8
21/32
11/16
23/32
3/4
25/32
13/16
27/32
15.1
15.9
16.7
17.5
18.3
19.1
19.8
20.6
21.4
5/16
11/32
3/8
13/32
7/16
15/32
1/2
17/32
9/16
7.9
8.7
9.5
10.3
11.1
11.9
12.7
13.5
14.3
1/32
1/16
3/32
1/8
5/32
3/16
7/32
1/4
9/32
0.8
1.6
2.4
3.2
4.0
4.8
5.6
6.4
7.1
IN. IN. IN. IN.MM MM MM MM
M9587A
5
4
3/16 (5) DOWEL
3/16 (5) DOWEL
3/16 (5) DOWEL
1 (26)
1 (26)
5
5
5
43
6
4
6
3
1
2
3
4
5
6
MOUNTING HOLE, TAPPED FOR 10-32 NC SCREW.
MOUNTING HOLE, 11/64 IN. DIAMETER (4 mm)
(CLEARS NO. 8 SCREW).
MOUNTING HOLE, 13/64 IN. DIAMETER (5mm)
(CLEARS NO. 10 SCREW).
1/4 IN. COMPRESSION FITTING.
MOUNTING HOLE TAPPED FOR 8-32 NC SCREW.
MOUNTING HOLE, 0.148 DIAMETER (3.8mm).
7/16
(11)
7/16
(11)
7/16
(11)
4/5
(20)
4/5
(20)
4/5
(20)
1-4/5 (45)
1-1/3
(35)
1-1/3
(35)
1-1/3
(35)
1-2/3
(42)
1-2/3
(42)
1-2/3
(42)
5/16
(8) 5/16
(8)
5/16
(8)
3/8
(10)
3/8
(10)
3/8
(10)
3/4 (19) 3/4 (19)
3/4 (19)
1/5
(5)
1/5
(5)
1/5
(5)
1/5
(5)
5/8
(16)
5/8
(16)
1/4
(8)
1/4
(8)
2-1/5 (56)
2-1/5 (56)
Fig. 3. Mounting bracket dimensions for Q3450E,F,G.

Q3450A,B,C,D,E,F,G AND Q3480B,C, SmartValve
™
SYSTEM PILOT BURNERS
68-0125—2
5
BC
7/8
29/32
15/16
31/32
1
2
22.2
23.0
23.8
24.6
25.4
50.8
19/32
5/8
21/32
11/16
23/32
3/4
25/32
13/16
27/32
15.1
15.9
16.7
17.5
18.3
19.1
19.8
20.6
21.4
5/16
11/32
3/8
13/32
7/16
15/32
1/2
17/32
9/16
7.9
8.7
9.5
10.3
11.1
11.9
12.7
13.5
14.3
1/32
1/16
3/32
1/8
5/32
3/16
7/32
1/4
9/32
0.8
1.6
2.4
3.2
4.0
4.8
5.6
6.4
7.1
IN. MM IN. MM IN. MM IN. MM
1
2
MOUNTING HOLE, TAPPED FOR 10-32 SCREW.
1/4 IN. COMPRESSION FITTING.
M9588A
1
(25)
12
1
(25)
12
1/2 (13)
1/2
(13) 1/2
(13)
1/2 (13)
1/3
(9) 1/3
(9)
1/3
(9)
1/3
(9)
1-5/6 (46) 1-5/6 (46)
1-4/5
(45) 1-4/5
(45)
2-1/10
(53) 2-1/10
(53)
3/16 (5)
DOWEL 3/16 (5)
DOWEL
3/16 (5) DOWEL
3/16 (5) 3/16 (5)
7/16
(11)
7/16
(11)
Fig. 4. Mounting bracket dimensions for Q3480B,C.

Q3450A,B,C,D,E,F,G AND Q3480B,C, SmartValve
™
SYSTEM PILOT BURNERS
68-0125—2 6
INSTALLATION
When Installing this Product…
쐃Read these instructions carefully. Failure to follow
instructions can damage product or cause a hazardous
condition.
쐇Check ratings given in instructions and on product to
make sure product is suitable for your application.
쐋Make sure installer is a trained, experienced service
technician.
쐏After completing installation, use these instructions to
check out product operation.
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY,
OR DEATH.
Follow these warnings exactly:
1. Disconnect power supply before wiring to prevent
electrical shock or equipment damage.
2. To avoid dangerous accumulation of fuel gas,
turn off gas supply at appliance service valve
before starting installation and perform Gas Leak
Test after completion of installation.
3. Do not bend pilot tubing at the control or pilot
after compression nut is tightened. Gas leakage
at the connection may result.
Follow appliance manufacturer instructions if available;
otherwise, use instructions provided below.
Location
쐃Position the pilot burner for easy access and
observation. In replacement applications, replace the
pilot burner with an identical unit and position the new
pilot burner in the same location and orientation as the
original pilot burner.
쐇Mount the pilot burner on the main burner. Mounting
surfaces other than the main burner can shift, bend, or
warp as the furnace expands and contracts while
operating. See Fig. 5.
PILOT BURNER MUST
BE RIGIDLY POSITIONED
RELATIVE TO MAIN BURNER M2688A
Fig. 5. Mount pilot burner on main burner.
쐋Mount the pilot burner so the pilot flame remains
properly positioned with respect to the main burner
flame. See Fig. 6.
쐏Supply pilot flame with ample air which is free of
combustion products.
쐄Do not impinge pilot flame on adjacent parts. Do not
impinge main burner flame on pilot burner.
쐂Do not expose the pilot flame to falling scale that could
impair the main burner ignition.
PILOT BURNER
JUST RIGHT
PILOT BURNER
TOO LOW
PILOT BURNER
TOO HIGH
MAIN BURNER
FLAME WILL
IMPINGE ON
IGNITION-
SENSOR
IGNITION
FLAME WILL
IMPINGE ON
MAIN BURNER
IGNITION FLAME
JUST MISSES
MAIN BURNER
M9537
Fig. 6. Location of pilot burner.
쐆Do not expose the pilot burner to main burner rollout
while igniting or extinguishing.
쐊Do not expose the pilot flame to drafts that push or pull
the pilot flame away from the igniter-flame rod.
Connect Pilot Gas Tubing
쐃Cut tubing to the desired length and bend as necessary
for routing to the pilot burner. Do not make sharp bends
or deform tubing. Do not bend tubing at control after
compression nut is tightened because this can result in
gas leakage at connection.
쐇Square off and remove burrs from the end of the tubing.
쐋Push tubing into compression nut clearance hole until
tubing bottoms.
NOTE: When replacing SmartValve™ System control,
cut off the old compression fitting and replace
it with a new compression fitting provided with
the new pilot burner. Never use the old
compression fitting because it might not
provide a gas-tight seal. See Fig. 7.
쐏While holding the tubing all the way in, engage threads
and turn until finger tight.
쐄Using a wrench, turn compression nut one turn beyond
finger tight.
Do not overtighten.
쐂Connect the other end of the tubing to the ignition
system control according to the ignition system control
manufacturer instructions.
Wire Pilot Burner to Ignition System Control
쐃Mount the igniter-flame rod assembly on the pilot
burner.
쐇Connect the igniter-flame rod assembly keyed plug
connector to its mating terminal block labeled IGNITER
on the SV9500/SV9600.
쐋Use ceramic or plastic standoff insulators as necessary
to prevent cable from contacting metal surfaces.

Q3450A,B,C,D,E,F,G AND Q3480B,C, SmartValve
™
SYSTEM PILOT BURNERS
68-0125—2
7
PILOT BURNER BODY ON
BRACKET OF PILOT BURNER
TIGHTEN NUT ONE TURN
BEYOND FINGER TIGHT
COMPRESSION FITTING
BREAKS OFF AND CLINCHES
TUBING AS NUT IS TIGHTENED
TO IGNITION
SYSTEM CONTROL M2687A
Fig. 7. Always use the new compression fitting.
STARTUP AND CHECKOUT
Perform Gas Leak Test
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY,
OR DEATH.
Check for gas leaks with soap and water solution any
time work is done on a gas system.
Gas Leak Test:
쐃Make sure the gas supply is turned on at the appliance
service valve.
쐇Paint pipe connections upstream of pilot burner with
rich soap and water solution. Bubbles indicate a gas
leak.
쐋If a leak is detected, tighten the pipe connections.
쐏Set the thermostat to call for heat to light the main
burner.
쐄With the main burner in operation, paint pipe joints
(including adapters) and SV9500/SV9600 control inlet
and outlet with rich soap and water solution.
쐂If another gas leak is detected, tighten adapter screws,
joints, and pipe connections.
쐆Replace part if leak cannot be stopped.
Adjust Pilot Flame
The pilot flame should envelop approximately 3/8 in. (10 mm)
of the sensor tip. See Fig. 8.
To adjust pilot flame:
쐃Turn off system by setting thermostat below the
temperature to call for heat.
쐇Disconnect lead to MV terminal on SV9500/SV9600.
쐋Light pilot by setting the thermostat to call for heat.
쐏Remove pilot adjustment cover screw from gas control.
쐄Turn inner pilot adjustment screw clockwise to
decrease or counterclockwise to increase pilot flame.
쐂Always replace pilot adjustment cover screw and
tighten firmly after completing adjustment to assure
proper operation.
3/8 INCH
(10 mm)
PROPER FLAME
ADJUSTMENT
IGNITER
M9049
SENSOR
Fig. 8. Sensor tip must be in pilot flame.
SERVICE
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY,
OR DEATH
Perform Gas Leak Test any time work is done to the
system.
Pilot Outage
쐃If pilot flame goes out during ignition, but is properly
adjusted, recheck mounting and location instructions in
Location section.
쐇If all mounting and location instructions are followed but
the pilot continues to go out, construct a shield to
protect the pilot flame from the main burner ignition,
extinction and drafts. See Fig. 9
TYPICAL
SHIELD M2686
Fig. 9. Proper shielding of pilot flame.
쐋Check pilot and main burner lightoff.
❑Set the thermostat to call for heat.
❑Watch the pilot burner during the ignition sequence
to determine if:
•Igniter continues to glow red after the pilot is lit.
•The pilot lights and the igniter stops glowing red,
but main burner does not light.

Q3450A,B,C,D,E,F,G AND Q3480B,C, SmartValve
™
SYSTEM PILOT BURNERS
68-0125—2 8
Helping You Control Your World
Home and Building Control
Honeywell Limited
155 Gordon Baker Road
North York, Ontario
M2H 2C9
68-0125—2 J.S. Rev. 12-95 Printed in U.S.A.
QUALITY IS KEY
❑If pilot burner is functioning correctly, ensure
adequate flame current as follows:
•Turn off the furnace at the circuit breaker or fuse
box.
•Clean the flame rod with an emery cloth.
•Make sure electrical connections are clean and
tight.
•Check for cracked ceramic insulator, which can
cause short to ground, and replace igniter-flame
rod assembly if necessary.
•Turn on power and set thermostat to call for heat.
The pilot should light and then the main burner
should light.
Replace Igniter-Flame Rod Assembly
쐃Turn off the furnace at the circuit breaker or fuse box.
쐇Remove the spring clip, then the igniter-flame rod
assembly from the pilot burner.
쐋Disconnect the igniter-flame rod assembly keyed plug
from the igniter connection on the SV9500/SV9600.
쐏Remove the igniter-flame rod assembly from the
furnace.
쐄Install replacement igniter-flame rod assembly in the
pilot burner and secure it with the spring clip.
쐂Connect igniter-flame rod assembly keyed plug to
igniter connection on the SV9500/SV9600.
쐆Turn on power and set the thermostat to call for heat.
The pilot should light and then the main burner should
light.
Check Ignition Cable
쐃Make sure that ignition cable is not in contact with
metal surfaces.
쐇Make sure that ignition cable is not more than
3 ft (1m) long.
쐋Check electrical continuity of ignition cable.
Check Grounding
쐃If ground is poor or erratic, safety shutdown will occur.
Therefore, if frequent shutdowns are reported, check
that ground is made through the pilot tubing.
쐇Excessive temperature at the ceramic flame rod
insulator will permit electrical leakage to ground.
a. If bracket is bent, bend it back to correct position.
b. If insulator is cracked, replace igniter-flame rod
assembly (Q3400A).
Home and Building Control
Honeywell Inc.
1985 Douglas Drive North
Golden Valley, MN 55422
customer.honeywell.com