Honeywell S8600A User manual

2 I511
:
b
2: [671 b
Lh ONLY ON MODELS WITH VENT DAMPER PLUG.
M1123 ._ ____ --.._--.__-__-_-~.- ___. _ _
FIG. l-APPROXIMATE IGNITION MODULE DIMENSIONS IN In. [mm].
ELECTRICAL RATINGS:
Voltage and frequency: 20.5 to 28.5 V (24 V nom.), 60
HZ.
CANADIAN GAS ASSOCIATION CERTIFIED: 1029-ABI-
6269.
Current rating: 0.2 A. AMERICAN GAS ASSOCIATION DESIGN CERTIFIED:
20-l 4D3.
Valve contact ratings (at 24 Vat):
S8600, S8660 S8610, S8670
Run 1 Inrush Run 1 Inrush
Pilot l.OA 1 lO.OA 1.0 A 1 lO.OA
Main 1 l.OA 1 lOoA I 2.0A t 20.0A
SPARKGENERATOROUTPUT: 13 kVpeakat25 pf load.
THERMOSTAT ANTICIPATOR SETTING: 0.2 A plus pilot
valve rating plus main valve rating.
AMBIENT TEMPERATURE RATING:
S8600,58660: -40” F to +175” F [-40° C to +79O C].
S8610, S8670: -40” F to +175” F [-40° C to +79” C] with
main valve rated 1.OA or less; -40” F to +165’ F [-40°
C to +74” C] with main valve rated over 1.OA to 2.0 A.
RELATIVE HUMIDITY RATING: 5 to 90 percent RH at
95” F.
FLAME FAILURE RESPONSE TIME: 0.8 sec. at 1.OuA
flame current.
CONTINUOUS RETRY TIMING (SSSOOMonly): 5 minute
min., 6 minute nom. off time between trials for ignition.
TERMINALS:
SENSE (S8600A,B; S8610A,B only): 3/16 in. male
quick connect.
All otherterminals, including ignition: l/4 in. male quick
connects. Models available with Molex plug forconnec-
tion to Honeywell D80D Vent Damper.
FLAME CURRENT: 1 ).LA,min.
MOUNTING: Mounts in any position except with terminals
up. However, recommended mounting position is with
terminals down to provide maximum protection from
dripping water or dust accumulation. Fasten with No. 6-
32 machine or No. 8 sheetmetal screws of appropriate
length.
UNDERWRITERS LABORATORIES INC. COMPONENT
RECOGNIZED: File No. MH15564, Guide No. MCCZ2.
OTHER SYSTEM COMPONENTS
These modules provide operating control of an intermit-
tent pilot system. Additional components required to
complete the system must be ordered separately. They
include:
Dual valve combination gas control designed for
intermittent pilot
Combination pilot burner/igniter-sensor
(S8600F,H,M; S8610F,H; and S8670D)
Separate igniter and sensor on pilot burner bracket
(S8600A,B)
Ignition cable
Transformer
24V thermostat
High limit and other auxiliary controls as required
DUAL VALVE COMBINATION GAS CONTROL: Any that
meets current ratings listed below. VR8204, VR8440 or
VR8520 recommended.
S8600, S8660: 1.OA pilot, 1.O A main valve.
S8610, S8670: 1.OA pilot, 2.0 A main valve.
PILOT BURNER/IGNITER-SENSOR: See Table 2.
TABLE 2-PILOT BURNER/IGNITER-SENSORS.
PILOT BURNEW FLOW RATE*
MODULE IGNITER-SENSOR cfh 1 m3/hr
S8600F.H.M: Q345 0.8 1 0.02
S8610F;H; Q346 1.0 0.03
S8660D; Q348 1.5 0.04
S8670D Q362 0.5 0.014
Q381 0.5 0.014
S8600A,B Q179C ) 1.8 1 0.05
Q354 with Q345. Q346. Q348. Q362 or
‘With natural gas at 7.0 in. WC[1.7 kPa].
3 68-0085-2

and the 24V terminal on the module. To change out a
module with TH-R, TH-W terminals:
1. Remove the wires from the 25V(2) and TH-R termi-
nals on the old module. Connect these two wires with a
solderless connector.
2.Tag and remove the remaining wires from the old
module.
3. Remove the old module and mount the new one in the
same location.
4. Reconnect the remaining wires as shown in Table 5.
5. Increase the thermostat anticipator setting by 0.2 A.
TABLE 5-TERMINAL CROSS REFERENCE.
TERMINAL ON TERMINAL ON
OLD MODULE: NEW MODULE:
25V(l) 24V(GND)
TH-W 24V
MV MV
MVIPV MVIPV
PV PV
GND(Burner) GND(Burner)
r S66CvX.H.M; S8610F.H; S866OD; Sffi70D
1
GND 24V TH-W A VENT
DAMPER
1 - MAIN
DUAL VALVE COMBINATION
GAS CONTROL
FIG. 2-S8600F,H,M; S661 OF,H; S6666D; S8670DCONNECTlONS INA HEATING SYSTEM WITHAN ATMOSPHERIC
BURNER.
0345. 0346,
0346. Q3is. a361
PILOT BURNER/
IGNITER-SENSOR
PILOT BURNER
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
& ALTERNATE LIMIT CONTROLLER LOCATION.
A MAXIMUM CABLE LENGTH 3 fi [0.9 m],
)& CONTROLS IN 24VClRCUlT MUST NOT BE IN GROUND LEG TO
TRANSFORMER.
h FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT
THERMOSTAT TO TH-W. LEAVE 24V OPEN. DD NOT REMOVE VENT
DAMPER PLUG. Ml175A
7 68-0085-2

S8600F.H.M: S6610F.H
I A VENT
GND 24V DAMPER
MV MWPV PV (BURNER) GND 24V TH-W PLUG SPARK
I I I I I
DUAL VALVE COMBINATION
GASCONTROL
I
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
A ALTERNATE LIMIT CONTROLLER LOCATION.
A MAXIMUM CABLE LENGTH 3 ft lo.9 ml.
A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO
TRANSFORMER.
& REMOVE PLUG ONLY IF USING VENT DAMPER. FUSE BLOWS
ON STARTUP WHEN PLUG IS REMOVED; THEN MODULE
WILL OPERATE ONLY WHEN VENT DAMPER IS CONNECTED.
l-lA”NLDD
,b
D60D VENl
DAMPER
Q345. Q346.
D346. Q362. Q361
BURNER
GROUND
FIG. 3--S8600F,H,M; S8610F,H WITH VENT DAMPER PLUG IN A HEATING SYSTEM WITH AN ATMOSPHERIC
BURNER AND A D80D VENT DAMPER.
S86WA.B; S66104B
A VENT
GND 24V TH-W DAMPER
MV MV/PV PV (BURNER) GND 24V (OPT) PLUG (OPT) SENSE SPARK
--1 l---1
I I I
I L__,!
THERMOSTAT
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REOUIRED.
A ALTERNATE LIMIT CONTROLLER LOCATION.
A MAXIMUM CABLE LENGTH 311[0.9 ml.
A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO
TRANSFORMER.
A FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG,
CONNECT THERMOSTAT TO TH-W. LEAVE 24V OPEN. DO NOT
REMOVE VENT DAMPER PLUG.
.^. ..___uw
u PILOTGAS
- SUPPLY
FIG. 4--S8600A,B; S861OA,B CONNECTIONS IN A HEATING SYSTEM.
8

S66OOA.B:S6610AB
DUAL VALVE COMBINATION
GAS CONTROL
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED.
A ALTERNATE LIMIT CONTROLLER LOCATION. LIMIT
GND
Mb’ MV/PV PV (BURNER) 24V DAMPER
GND 24V TH-W PLUG kh SENSE SPARK
/!?J MAXIMUM CABLE LENGTH 3 ft IO.9 m].
A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND
LEG TO TRANSFORMER. I
A REMOVE PLUG ONLY IF USING VENT DAMPER. (HOT) --
A DEOD.ViNT DAbiPER.
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
MAXIMUM CABLE LENGTH 3 11(0.9 m].
CONTROLS IN 24V CIRCUIT MUST NOT BE IN
GROUND LEG TO TRANSFORMER.
FOR MODULE WITH TH-W TERMINAL AND VENT
DAMPER PLUG, CONNECT THERMOSTAT TO TH-W.
LEAVE 24V OPEN. DO NOT REMOVE VENT DAMPER
PLUG.
OPERATOR OPERATOR
DUAL VALVE COMBINATION
GASCONTROL
FIG. 6-S8600F,H,M; S8610F,H; S8660D OR S8670D CONNECTIONS IN A HEATING SYSTEM WITH A FAN-
ASSISTED COMBUSTION BURNER.
0345.0346,
0346, Q362. Q361
PILOT BURNER/
IGNITER-SENSOR
S6600F,H.M; S6610F.H; S6660D; S6670D
GND
MV MVlPV PV (BURNER)
A VENT
24V TH-W DAMPER
GND 24V (OPT) PLUG (OPT) SPARK
IT BURNER L2 Ll
.LER
9 68-0085-2

S66CQF.H.M; S661ff.H; S866QD; S6670D
GND 24V A VENT TH-W DAMPER
COMBINATION GAS CONTROL
MV MVlPV PV (BURNER] GND 24V (OPT) PLUG (OPT) SPARK
CONTROLLER
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
A ALTERNATE LIMIT CONTROLLER LOCATION
A MAXIMUM CABLE LENGTH 3 fi [0.9 m]
0 CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO
TRANSFORMER.
A FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT
THERMOSTAT TO TH-W. LEAVE 24V OPEN. W NOT REMOVE VENT
DAMPER PLUG.
FIG. 7-S8600F,H,M; S8610F,H; S8660D OR S8670D CONNECTIONS IN A HEATING SYSTEM WITH ATWO STAGI
GAS CONTROL AND A FAN-ASSISTED COMBUSTION BURNER.
10

S66CQF.H.M; S861w.~; ~6660~; ~8670~
GND /& VENT 24V M-W DAMPER
MV MV/PV PV (BURNER) GND 24V (OPT) PLUG (OPT) SPARK
“1 r--i
i I I
, !-_A
I I I I l__la D80B
END SWITCH
N.O. N.C.
r-t-t--
I - MAIN
DUAL VALVE COMBINATION
GAS CONTROL
FIG. &S8600F,H,M; S8610F,H; S8660D OR S8670D IN A HEATING SYSTEM WITH A D80B VENT DAMPER.
1THERii?iSTAT 1
0345.0346,
0346.0362.0361
PILOT BURNER/
IGNITER-SENSOR
ER
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS
REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
MAXIMUM CABLE LENGTH 3 Ii [O.Q m].
CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER.
FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT
THERMOSTAT TO TH-W. LEAVE 24V OPEN. 00 NOT REMOVE VENT DAMPER PLUG.
COLORS REFER TO WIRE HARNESS, IF USED.
11 68-0085-2

LIMIT
CON- 1
TROLLEF
S96QOF.H.M; S9610F.H; S966OD; S8670D
A VENT
GND 24V TH-W DAMPER
MV MViPV PV IBURNER) GND 24V (OPT) PLUG (OPT) SPARK
DUAL VALVE COMBINATION
GAS CONTROL
THERMOSTAT (HOT)
dOT) L2
t
R9239
FAN
CENTER
FAN
CONTROL
COMBUSTION
MOTOR
COMBUSTION
AIR BLOWER
RELAY
AIR
PROVING
SWITCH
CONTROLLER
G. 9-S8600F,H,M; S8610F,H; S8660D; OR S8670D CONNECTIONS IN A HEATING-COOLING SYSTEM WITH A
FAN-ASSISTED COMBUSTION BURNER.
SENSOR
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS
REOUIRED.
8 ALTERNATE LIMIT CONTROLLER LOCATION.
A MAXIMUM CABLE LENGTH 3 fl[O.9 m].
A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER
A FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT
Ml1824 THERMOSTAT TO TH-W. LEAVE 24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.
12

CABLE :
P
SS6CQF.H.M; SS610F.H; S966OD; S9670D
GND 24V TH-W /& VENT
DAMPER
MV MWPV PV (BURNER) GND 24V (OPT) PLUG (OPT) SPARK
ll-ri-l --i
F-T!f r--i
I I
! .
I-H-I I
DUAL VALVE COMBINATION
GAS CONTROL
FIG. lO-S86OOF,H,M; S861OF,H; S8660D; OR S8670D CONNECTIONS IN A HYDRONIC HEATING SYSTEM WITI
A D80D VENT DAMPER.
ER
ND
ISLACK 1
ORANGE LB148J
THERMOSTAT
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS
REQUIRED.
A CUT PLUG OFF MODULE END OF DSOD WIRE HARNESS, CONNECT LEADWIRE
COLORS AS SHOWN.
A MAXIMUM CABLE LENGTH 3 It IO.9 m].
A FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT
THERMOSTAT TO TH-W. LEAVE 24V OPEN. DO NOT REMOVE VENT DAMPER PLUG
/& LEAVE TP-Z AND Z-W JUMPERS IN PLACE M118lA
13 68-0085-2

DUAL VALVE COMBINATION
GASCONTROL
FIG. ll-S8600F,H,M; S8610F,H; S8660D OR S8670D CONNECTIONS IN A COMMERCIAL WATER HEATER
CONTROL SYSTEM.
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
A ALTERNATE LIMIT CONTROLLER LOCATION.
A MAXIMUM CABLE LENGTH 3 11IO.9 ml.
A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO
TRANSFORMER.
&& FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT
THERMOSTAT TO TH-W. LEAVE 24V OPEN. Do NOT REMOVE VENT
DAMPER PLUG.
CHECKOUT
Check out the gas control system:
l At initial installation of the appliance.
l As part of regular maintenance procedures. Mainte-
nance intervals are determined by the application.
See PLANNING THE INSTALLATION, page 4, for
more information.
l As the first step in troubleshooting.
l Any time work is done on the system.
::::::::.,:.::::::.....................
....i
.:::::
‘.‘.‘.‘.‘... ... ......../ . ..... . ...........‘.‘.. .. ....>. .: :. ::::::: .,.........:.:.:.:.:...............‘.............~.pi::.:.:,
:,:. .::::.. ,:i:;:““’ ‘:,:’ j.;;.; ,+;. .::::.. ..:.:.:,; .:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.):.,:,~,~ ,:,:,:,, :,,,I
~~~~~~/N~~~
.,.......................,.,.,.,,,.,.,.,.,.,.,.,.....,..~.~.~......:.
. . . . . . . . . :.: :.. :... . . . . . . . . . . . .._.. ..:,:.:.:.:. :: :.:.,.,.,.,.,.,.,.,.,.,., ;;:, ,jj::., “”
.“=.=.=.....::.‘.:.:.:::.:.:::.:.: ...................i. ):‘.:.:.‘.::: :,.,:,:::::::::::::
.I... ,, ~ :.:.,.,. .:.. . .
FAILURE TO HEED THESE WARNINGS MAY
CAUSE FIRE OR EXPLOSION WITH PROPERTY
DAMAGE, INJURY, OR LOSS OF LIFE.
Ifyou smell gasor suspect a gas leak, turn off
gas at manual service valve and evacuate the
building. Do not try to light any appliance, do
not touch any electrical switch or telephone
In the building until you are sure no spilled
gas remains.
Gas leak test must be done as described In
Steps 1 and 5 below on initial installation and
any time work is done Involving the gas pip-
ing.
STEP 1: Perform Visual Inspection.
0 With power off, make sure all wiring connections are
clean and tight.
0 Turn on power to appliance and ignition module.
q Open manual shutoff valves in the gas line to the
appliance.
0 Do gas leak test ahead of gas control if piping has been
disturbed.
A L
$
.l L2
(1
HO’ r)
0345.Cl346.0246.
Q362,0361
PILOT BURNEW
IGNITER-SENSOR 1
S6600F.H.M; S6610F.H; S66iXD; S6670D
24V M-W A VENT
GND DAMPER
MV MWPV PV (BURNER) GND 24V (OPT) PLUG (OPT) SPARK
CONTROLLER
GAS LEAK TEST: Paint pipe joints with rich soap and
water solution. Bubbles indicate gas leak. Tighten joints to
stop leak. Recheck with soap and water.
STEP 2: Review Normal Operating Sequence and Module
Specifications.
0 See OPERATION, page 15, and SPECIFICATIONS,
page 2.
STEP 3: Reset the Module.
0 Turn the thermostat to its lowest setting.
q Wait one minute.
As you do Steps 4 and 5, watch forpoints where operation
deviates from normal. Refer to Troubleshooting Chart to
correct problem.
STEP 4: Check Safety Shutoff Operation.
This step applies to lockout and continuous retry mod-
ules on/y.
0 Turn gas supply off.
0 Set thermostat or controller above room temperature to
call for heat.
Cl Watch for spark at pilot burner either immediately or
following prepurge. See SPECIFICATIONS, page 2.
0 Time spark from start to shutoff. See SPECIFICA-
TIONS, page 2.
On continuous retry models, wait 6 min. nom. Ignition
sequence should start again followed by shutdown after 90
sec.max.
0 Open manual gas cock and make sure no gas is flowing
to pilot or main burner.
Cl Set thermostat below room temperature and wait one
minute before continuing.
14

STEP 5: Check Normal Operation.
0 Set thermostat or controller above room temperature to
call for heat.
0 Make sure pilot lights smoothly when gas reaches the
pilot burner.
0 Make sure main burner lights smoothly without flash-
back.
0 Make sure burner operates smoothly without floating,
lifting, or flame rollout to the furnace vestibule or heat
buildup in the vestibule.
0 tf gas line has been disturbed, complete gas leak test.
GAS LEAK TEST: Paint gas control gasket edges and all
pipe connections downstream of gas control, including
pilot tubing connections, with rich soap and water solution.
Bubbles indicate gas leaks. Tighten joints and screws or
replace component to stop gas leak. Recheck with soap
and water.
q Turn thermostat or controller below room temperature.
Make sure main burner and pilot flames go out.
Module operation can be conveniently divided into two
phases for S8600, S8610 and three for S8660, S8670. The
phases are
l Prepurge (S8660, S8670 only)
l Trial for ignition (all models)
l Main burner operation (all models)
Figs. 12 and 13 summarize the normal operating se-
quences of the modules.
PREPURGE (S8660, S8670 ONLY)
When the S8660 is used in a fan-assisted combustion
system, the combustion air blower starts on a call for heat.
On proof of airflow, the air proving switch closes and
energizes the S8660, S8670. When the module is used in
an atmospheric system, the call for heat energizes the
module.
In either case, the module first initiates a 45 sec. delay
to allow system prepurge. After prepurge, the module
starts the pilot ignition sequence.
START
STAGE 1
TRIAL FOR
IGNIITION
STAGE 2
MAIN BURNER
OPERATION
END
THERMOSTAT (CONTROLLER)
CALLS FOR HEAT
First valve (pibt) operator opens
Pilot burner lights.
Module sense*
lhnw current.
PILOT BURNER OPERATION
Pilot burned does not light.
OR Module R.X$lO”Se
SBGOOA,F Ignition spark continues, p~ld
S6610A.F valve remains open until system
is reset
S86WB.H After 15 or 90 se@ syslem
S66lOB.H locks out; must be
“lanually reset.
S66OOM After 90 %%.a system shuts 011;
after 5 minutes min. (6 minutes
nom.). module restarts trial for
ignition; ignition trial, shutoff, wait
sequence repeats until pilot lights
or call for he;d ends.
aShutoff/lcckout timing is stamped on module
-Spark generator off.
-Second valve operator (main)
opens.
Module moniiors pilot flame
current.
Systemshuts off. restarts when power
PILOT FLAME FAILURE
Main valve cbses.
V&es cbse. pibt and main
burners are off.
FIG. 12-S8600, S8610 NORMAL OPERATING SEQUENCE.
15 68-0085-2

TRIAL FOR IGNITION temperature for one minute or by turning off power to the
Pilot Ignition module for one minute.
Following prepurge timing (S8660, S8670), or on the
callfor heat (SSSOO,SSSlO), the moduleenergizesthefirst
main valve operator. The first main valve opens, which
allows gas to flow to the pilot burner. At the same time, the
electronic spark generator in the module produces a high
voltage spark pulse output. The voltage generates a spark
at the igniter (S8600A,B; S8610A,B) or igniter-sensor
(S8600F,H,M; S8610F,H; S8660; S8670) that lights the
pilot.
Safety Shutoff with Continuous Retry (SSSOOM)
If the pilot does not light, or the pilot flame current is not
at least 1.Ofl and steady, the module will not energize the
second (main) valve and the main burner will not light.
S8600A,F; S861 OA,F will continue to spark as long as the
thermostat calls for heat, or until the pilot lights.
The S8600M provides 100 percent gas shutoff, fol-
lowed by retry for ignition. Operation on ignition failure is
the same as lockout modules, except that a timer starts
timing immediately following shutoff. Six minutes nom.
(five minutes min.) after shutoff, the module restarts the ig-
nition sequence. The ignition trial, shutoff, wait sequence
continues until eitherthe pilot lights or the thermostat is set
below room temperature to end the call for heat. The
module can also be reset by setting down the thermostat
for one minute.
MAIN BURNER OPERATION
Safety Lockout (S8600B,H; S8610B,H; S8660D;
S8670D)
These modules provide 100 percent shutoff and safety
lockout. A timer in these models starts timing the moment
the trial for ignition starts. Ignition sparkcontinuesonly until
the timed trial for ignition period ends. Then the module
goes into safety lockout. Lockout de-energizes the first
main valve operator and closes the first main (pilot) valve
in the oas control, stopping pilot gas flow. The control
system-must be reset bj set&i the thermostat below room
When the pilot flame is established, aflame rectification
circuit is completed between the sensor and burner
ground.Theflamesensingcircuitinthemoduledetectsthe
flame current, shuts off the spark generator and energizes
the second main valve operator. The second main valve
opens and gas flows to the main burner, where it is ignited
by the pilot burner. On lockout models, the flame current
also holds the safety lockout timer in the reset (normal)
operating condition.
When the call for heat ends. both valve operators are
de-energized, and both valves in the gas coritrol close.
START
J
STAGE 1
PREPURGE
STAGE 2
TRIAL FOR fGNITION
STAGE 3
MAIN BURNER
OPERATION
END
CALLS FOR HEAT I
I Combustion air bbwer starts. I
+, First valve (pilot) operator cpens.
2J PILOT BURNER OPERATION
Pilot burner lights. Pild burner does not light.
sa660. se670 senses flame OR After 15 or 90 set=,system
current. locks out; must be manually reset.
aLockoti liming is
stamped on module.
*Spark generator off.
.Seoond valve operator (main)
open*.
System shuts off. restarts when power IS
Module monitors pilot flame
current. PILOT FLAME FAILURE
Main valve closes.
V&es dose. pilot and main
burners are off. MI 171*
FIG. 13-S8660, S8670 NORMAL OPERATING SEQUENCE.
16

1.
2.
3.
4.
5.
IMPORTANT
The following service procedures are provided
as a general guide. Follow appliance manufac-
turer’s service instructions if available.
On lockout and retry models, meter readings be-
tween gas control and ignition module must be
taken within the trial for ignition period. Once the
ignition module shuts off, lockout models must
be reset by setting the thermostat down for at
least one minute before continuing. On retry
models, wait for retry or reset at the thermostat.
lf any component does not function properly,
make sure it is correctly installed and wired
before replacing it.
The ignition module cannot be repaired. If it
malfunctions, it must be replaced.
Only trained, experienced service technicians
should service intermittent pilot systems.
Perform the checkout on page 14 as the first step in
troubleshooting. Then check the appropriate trou-
bleshooting guide (Fig. 15 or 16) and the schematic
diagram (Figs. 17-22) to pinpoint the cause of the prob-
lem. If troubleshooting indicates an ignition problem, see
Ignition System Checks below to isolate and correct the
problem.
Following troubleshooting, perform the checkout pro-
cedure (page 14) again to be sure system is operating
normally.
IGNITION SYSTEM CHECKS
STEP 1: Check ignition cable.
Make sure:
0 Ignition cable does not run in contact with any metal
surfaces.
0 Ignition cable is no more than 36 in. [0.9 m] long.
0 Connections to the ignition module and to the igniter or
igniter-sensor are clean and tight.
0 Ignition cable provides good electrical continuity.
STEP 2: Check ignition system grounding. Nuisance
shutdowns are often caused by a poor or erratic
ground.
0 A common ground, usually supplied by the pilot burner
bracket, is required for the module and the pilot burner/
igniter sensor.
l Check for good metal-to-metal contact between
the pilot burner bracket and the main burner.
l Checkthe ground lead from the GND(SURNER)
terminal on the module to the pilot burner. Make
sure connections are clean and tight. If the wire is
damaged or deteriorated, replace it with No. 14-l 8
gauge, moisture-resistant, thermoplastic insulated
wire with 105O C [221” F] minimum rating.
- Check the ceramic flame rod insulator for
cracks or evidence of exposure to extreme heat,
which can permit leakage to ground. Replace
pilot burner/igniter-sensor and provide shield if
necessary.
-lf flame rod or bracket are bent out of posi-
tion, restore to correct position.
STEP 3: Check spark ignition circuit. You will need a
short jumper wire made from ignition cable or other
heavily insulated wire.
0 Close the manual gas valve.
0 Disconnect the ignition cable at the SPARK terminal
on the module.
When performing the following steps, do not
touch stripped end of jumper or SPARK terml-
nal. The ignitlon circuit generates over 10,000
volts and electrlcal shock can result.
0 Energize the module and immediately touch one end
of the jumper firmly to the GND terminal on the module.
Move the free end of the jumper slowly toward the
SPARK terminal until a spark is established.
0 Pull the jumper slowly away from the terminal and note
the length of the gap when sparking stops. Check table
below.
ARC LENGTH
No arc or arc less
than l/8 in. [3 mm]
ACTION
Check external fuse, if
provided.
Verify power at module
input terminal.
Arc l/8 in. [3 mm]
or longer.
Replace module if fuse
and power okay.
Voltage output is okay
STEP 4: Check pilot and main burner lightoff.
0 Set the thermostat to call for heat.
0 Watch the pilot burner during the ignition sequence.
See if:
l Ignition spark continues after the pilot is lit.
l The pilot lights and the spark stops, but main
burner does not light.
l S86OOB,H,M;S8610B,H;S8660D;S8670Donly:
The pilot lights, the spark stops and main burner
lights, but the system locks out.
0 lf so, ensure adequate flame current as follows.
l Turn off furnace at circuit breaker or fuse box.
l Clean the flame rod with emery cloth.
l Make sure electrical connections are clean and
tight. Replace damaged wire with moisture-resistant
No. 18 wire rated for continuous duty up to 105” C
[221” q.
l Check for cracked ceramic insulator, which can
cause short to ground, and replace igniter-sensor if
necessary.
l At the gas control, disconnect main valve wire
from the TH or MV terminal.
17 68-0085-2

l Turn on power and set thermostat to callfor heat.
The pilot should light but the main burner will remain
off because the main valve actuator isdisconnected.
l Check the pilot flame. Make sure it is blue, steady
and envelops3/8to l/2 in. [lOto 13 mm]of theflame
rod. See Fig. 14 for possible flame problems and
their causes.
l lf necessary, adjust pilotflame by turning the pilot
adjustment screw on the gas control clockwise
r‘\ to decrease or counterclockwise n
to increase pilot flame. Following adjustment, al-
ways replace pilot adjustment cover screw and
tighten firmly to assure proper gas control operation.
l Set thermostat below room temperature to end
call for heat.
1 Recheck ignition sequence as follows.
l Reconnect main valve wire.
l Set thermostat to call for heat.
l Watch ignition sequence at burner.
l if spark still doesn’t stop after pilot lights, replace
ignition module.
l Ifmain burner doesn’t light or if main burner lights
but system locks out, check module, ground wire
and gas control as described in appropriate trou-
bleshooting chart, Fig. 15 or 16.
APPEARANCE I CAUSE
SMALL BLUE FLAME CHECK FOR LACK OF GAS FROM:
. CLOGGED ORIFICE FILTER
. CLOGGED PILOT FILTER
. LOW GAS SUPPLY PRESSURE
. PILOT ADJUSTMENT AT
MINIMUM
LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM:
,I
P
. LARGEORIFICE
. DIRTY LINT SCREEN, IF USED
. DIRTY PRIMARY AIR
OPENING, IF THERE IS ONE
. PILOT ADJUSTMENT AT
MINIMUM
WAVING BLUE FLAME CHECK FOR:
. EKCESSIVE DRAFT AT PILOT
LOCATION
. RECIRCULATING PRODUCTS
OF COMBUSTION
I
NOISY LIFTING BLOWING FLAME CHECK FOR:
. HIGH GAS PRESSURE
FIG. 14-EXAMPLES OF UNSATISFACTORY PILOT
FLAMES.
18