Honeywell S89C User manual

Honeywell
-
THE S89 AND S890 PROVIDE OPERATING CON-
TROLAND SYSTEM SHUTDOWN ON LOSS OF MAIN
BURNER FLAME IN DIRECT IGNITION CENTRAL
HEAT FURNACES AND HEATING APPLIANCES
WITH HOT SURFACE IGNITER.
0 S89C,G,J and S890C,G,J are for systems with a
combination igniter-sensor.
0 S890D,H and S890D,H are for systems with separate
igniter and sensor.
0 S89C,D,J and S890C,D,J lock out after one try for
ignition.
0 S89G,H and S890G,H provide three tries for ignition
before lockout, with 30 sec. min. purge before second
and third tries.
0 S89J and S89OJ provide 2 or 4 sec. (depending on
model) max. ignition activation periods.
q S890 provides 30 sec. min. prepurge on initial trial for
ignition.
0 Compatible with Norton 201 and 271 or equivalent hot
surface igniters.
0 S89D,H and S890D,H require a separate sensor
mounted on burner (Q354 recommended).
•i Available with leadwires for line voltage connections.
0 Available with Molex plug for connecting D80D Vent
Damper.
Cl Modules can be used on either naturalor LP gas; they
provide 100 percent shutoff of gas on lockout.
0 Modules have relay contacts for use with any direct
ignition gas control with max. 2.0 A, 24 Vat rating.
0 Modules use rectification principle for flame sensing.
0 Minus 40° F to +175” F [minus 40” C to +79” C]
temperature rating.
J.A.
Rev. 9-89 Form Number 68-6070-l 0 Honeywell Inc. 1989
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ELECTRICAL RATINGS:
Voltage and frequency: 20.5 to 28.5 V (24 V nom.), 60
HZ.
Current rating: 0.2 A.
Gas control contact ratings (at 24 Vat): 2.0 A running,
20.0 A inrush.
IGNITER WARM-UP PERIOD: 34 sec., nom.
THERMOSTAT ANTICIPATOR SETTING: 0.2 A plus oas
rating. VR8205, VR845, VR854, VR8450 or VR8540
recommended.
HOT SURFACE IGNITER OR IGNITER-SENSOR: Nor-
ton Model 201 or 271 or equivalent.
NOTE: If igniter other than Norton Model 201 or 271 is
used, the igniter must meet the following minimum
specifications, required over the life of the igniter:
control current rating.
AMBIENT TEMPERATURE RATING: Minus 40° F to
+175“ F [minus 40“ C to +79” C].
RELATIVE HUMIDITY RATING: 5 to 90 percent at 95“ F.
FLAME FAILURE RESPONSE TIME: 2 sec. max. with a
2.5 uA flame signal.
FLAME CURRENT: 0.8 J.LADC, min.
TERMINALS: 114 in. male quick connects for line voltage
and sensor connections; 3/l 6 in. male quick connects
for all low voltage connections. Terminal options (spec-
ify when ordering):
9 Molex plug for connection to D80D Vent Damper.
l 10 in. [250 mm] min. color-coded leadwires for all
line voltage connections.
MOUNTING: Mounts in any position. Fasten with No. 6-32
machine or No. 8 sheetmetal screws, 1 in. long.
DIMENSIONS: See Fig. 1.
UNDERWRITERS LABORATORIES INC. COMPONENT
RECOGNIZED: FILE NO. MP268, Guide No. MCCZ2.
CANADIAN GAS ASSOCIATION CERTIFIED: 1029-ABI-
6218.
AMERICAN GAS ASSOCIATION CERTIFIED: 20-2081.
OTHER SYSTEM CONTROLS
The S89 and S890 provide operating control of a direct
ignition system using a hot surface igniter. Additional
components required to complete the system must be
ordered separately. They include:
DUAL VALVE COMBINATION GAS CONTROL: Any di-
rect ianition aas control with 2.0 A max. main valve
Igniter must reach 1000” C 11832’ Fj within 34
seconds with 102 Vat applied.
Igniter must maintain at least 500M ohms insulation
resistance between the igniter leadwires and the
igniter mounting bracket.
Igniter must not develop an insulating layer on its
surface (over time) which would prevent flame
sensing.
Igniter surface area immersed in flame must not
exceed 1/4of the grounded area immersed in flame.
This would prevent flame sensing.
Igniter current draw at 132 Vat must not exceed 5 A.
SENSOR: Separate sensor required for all S89D,H and
S890D,H. Honeywell 0354 recommended.
IGNITER WIRING: Provide wiring harness to suit applica-
tion.
l Leadwires: No. 18 AWG, stranded copper with
105OC rated l/l 6 in. PVC insulation.
l Terminals: Insulated 114 in. female quick connects
or solderless connectors to module (depending on
module) and suitable connector to igniter.
TRANSFORMER: Add current ratings of module, gas
control, vent damper and any other components of the
control system to determine transformer size require-
ment.
THERMOSTAT: Compatible with any Honeywell 24 V
thermostat and with competitive 24 V thermostats that
are powered independently of the module.
HIGH LIMIT AND OTHER AUXILIARY CONTROLS: As
specified by the heating appliance manufacturer.
5 IN.O.C.(6)
[I34
i
!!A $IN. Q.C. (5)
A
1 MOLEX PLUG AND TH-W TERMINAL
ON VENT DAMPER MODELS ONLY.
A SENSE TERMINAL ON D AND H
MODELS ONLY.
A
3 LEADWIRE MODELS HAVE 4
LEADWIRES IN PLACE OF LINE
VOLTAGE TERMINALS.
FIG. l-APPROXIMATE S89/S890 DIMENSIONS IN In. [mm IN BRACKETS].
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L
Disconnect power supply before beginning wiring
to prevent electrical shockorequipment damage.
If a new gas control is to be installed, turn off gas
supply before starting installation. Conduct Gas
Leak Test according to gas control manufac-
turer’s instructions after the gas control is in-
stalled.
lf module must be mounted near moisture or
water, provide suitable waterproof enclosure.
PERFORM PREINSTALLATION SAFETY INSPECTION
Ifthis is a replacement installation, check the appliance
and venting system carefully before installing new module.
If a condition which could result in unsafe operation is
detected, the appliance should be shut off and the owner
advised of the unsafe condition. Any potentially unsafe
condition must be corrected before proceeding with the
installation.
MAINTENANCE REQUIREMENTS IN SEVERE ENVI-
RONMENTS
Regular preventive maintenance is important in any ap-
plication, but especially so in agricultural and industrial
applications because
l In many such applications, the equipment operates
1OO,OOO-200,000 cycles per year. Such heavy cy-
cling can wearoutthegascontrolinonetotwoyears.
A normal forced air furnace, for which the controls
were originally intended, typically operates less than
20,000 cycles per year.
l Exposure to water, dirt, chemicals, and heat can
damage the module or the gas control and shut
down the control system. A NEMA 4 enclosure can
reduce exposure to environmental contaminants.
See Electronic Ignition Service Manual, form 70-
6604.
The maintenance program should include regular
checkout of the system as outlined under Checkout, page
11.
FIRE OR EXPLOSION HAZARD
MAY CAUSE PROPERTY DAMAGE, SEVERE
INJURY OR DEATH
Do not attempt to take the module apart or to
clean it. Improper reassembly and cleaning may
cause unreliable operation.
1
Maintenance frequency must be determined individu-
ally for each application. Some considerations are:
l Cycling frequency. Appliances that may cycle more
than 20,000 times annually should be checked
monthly.
l Intermittent use. Appliances that are used season-
ally should be checked before shutdown and again
before the next use.
9 Consequence of unexpected shutdown. Where the
cost of an unexpected shutdown would be high, the
system should be checked more often.
l Dusty, wet, or corrosive environment. Since these
environments can cause the controls to deteriorate
more rapidly, the system should be checked more
often. Protective enclosures, as outlined under
“Planning the Installation”, are recommended re-
gardless of checkout frequency.
Any control should be replaced if it does not perform
properly on checkout or troubleshooting. In addition, re-
place any module if it is wet or looks like it has ever been
wet.
MOUNT IGNITION MODULE
Select a location close enough to the burner to allow a
short, direct cable route to the igniter. Ambient tempera-
ture at the module must be within the range of minus 40”
F to plus 175” F [minus 40” C to plus 79” C]. The module
must be protected from water, moisture, corrosive chemi-
cals and excessive dust and grease.
The module can be mounted in any position. Fasten
securely with four No. 6-32 machine or No. 8 sheetmetal
screws 1 in. [25 mm] long.
MOUNT THE SYSTEM CONTROLS
Mount any required controls, such as the gas control,
hot surface igniter, flame sensor, thermostat, limit and
transformer according to manufacturer’s instructions.
1. Check the wiring diagram furnished by the appli-
ance manufacturer, if available, for circuits differ-
ing from the wiring hookups shown. Carefully
follow any special instructions affecting the gen-
eral procedures outlined below.
2. Disconnect the power supply before making wir-
ing connections to prevent electrical shock or
equipment damage.
I I
IMPORTANT
1. All wiring must comply with applicable electrical
codes and ordinances.
2. When installing the hot surface igniter, the lead-
wires should be kept as short as possible and
should not be allowed to rest against grounded
metal surfaces.
3. A common ground is required for the S89/S890
and the main burner. The 24 V (GND) terminal
internally grounds one side of the transformer.
Any auxiliary controls or limits must not be in the
grounded leg. In addition, the appliance should
be earth-grounded.
4. Make sure thetransformer has adequate VA. The
ignition module requires at least 0.2 A at 24 Vat.
Add the current draws of all other devices in the
control circuit, including the gas control, and
multiply by 24 to determine the total VA require-
ment of these components. Add this total to 4.8
VA (forthe ignition module). The result isthe mini-
mum transformer VA rating. Use a Class IItrans-
former if replacement is required.
5. Check that Ll (hot) and L2 (neutral) are wired to
the proper terminals. If Ll and L2 are inter-
changed, the S89/S890 will not detect the flame,
and will go into safety shutdown.
Connect Igniter
Prepare wiring harness. See Igniter wiring, page 3.
1. On models with quick connects, use insulated 114in.
female quick connects to connect the wiring harness leads
to the HSI terminals on the ignition module.
2. On models with leadwires, use solderlessconnectors
to connect the wiring harness leads to the blue leads from
the module.
3. Connect the wiring harness to the igniter.
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Connect Vent Damper
The D80B Vent Damper can be used with all ignition
modules, although the Molex plug provided on some
modules simplifies wiring connections when used with the
D80D Plug-In Vent Damper. Once a module with vent
damperplug has powered a vent damper circuit, it cannot
be used in a gas system without a vent damper. A non-
replaceable fuse in the module blows on initial power-up.
Oncethisfuse has blownthemodulewon’tworkunlessthe
vent damper is connected.
To connect the plug-in model to D80D:
1. Remove the plug from the terminal strip on the
ignition module case and discard.
2. Using the wiring harness supplied, insert the match-
ing pin plug into receptacle on case and other end to vent
damper.
To connect the D808, follow the wiring diagrams sup
plied with the vent damper or see Fig. 5 for typical connec-
tions.
Connect Ignition Module
1. Connect remaining system components to the igni-
tion module terminals as shown in the appropriate wiring
diagram, Figs. 2 to 10.
l Figs. 2 and 3 are basic circuits for a heating only
atmospheric burner system. Fig. 2 shows the C,G
and J models with combination igniter-sensor; Fig. 3
shows the D,H models with separate igniter and sen-
sor.
l Figs. 4 and 5 show the C,G and J models with a
D80 Vent Damper. Never use a vent damper in an
LP gas system or in a fan-assisted combustion
system.
l Figs. 6-10 show S89C,G,J/S890C,G,J with
combination igniter-sensor in a variety of systems,
with alternate connections for vent damper plug
models. Remember, however, that a vent damper
should not be used in a fan-assisted combustion
system or an LP gas system and that the vent
damper plug must not be removed except to connect
a D80D with the plug-in cable. S89D,H/S890D,H
with separate igniter and sensor can be substituted
inthesehookupsbysimplyconnectingthesensoras
shown in Fig. 3. -
2. Refer to heating appliance manufacturer’s instruc-
tions for wiring auxiliary controls.
3. Adjust thermostat heat anticipator to match system
current draw. The current draw equals the total current
required for the ignition module (0.2 A) plus the gas control
and any other auxiliary equipment in the control circuit.
Connect Gas Control
Use No. 18 gauge solid or stranded wire. Use 3/l 6 in.
femalequickconnectsfor moduleconnections. Connectto
gas control terminals as shown in wiring diagrams, using
terminals appropriate to the gas control.
Ground Control System
The igniter, flame sensor and ignition module must
share acommon ground with the main burner. Use thermo-
plastic insulated wire with a minimum rating of 105O C
[221 o Fj for the ground wire; asbestos insulation is not ac-
ceptable. If necessary, use ashield to protect the wire from
radiant heat generated by the burner. Connect the ground
wire as follows:
1.Fii one end of the ground wire with a female 3/l 6 in.
quick-connect terminal and connect it to the male quick-
connect GND(BURNER) terminal on the ignition 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.
DUALVALVE
COMBINATION S69C.G.J/S89OC.G.JHOT
GASCONTROL SURFACEIGNITIONCONTROL
THERMOSTAT
OR CONTROLLER
A
POWERSUPPLY.PROVIDEDISCONNECTMEANS A CONTROLSIN24V CIRCUITMUSTNOT BE INGROUND LEGTO
ANDOVERLOADPROTECTIONAS REQUIRED. TRANSFORMER.
MAKESURE Ll ANDL2ARE NOT REVERSED; 4 FORMODULEWITHTH-W TERMINALANDVENT DAMPERPLUG.
THISWOULDPREVENTFLAMEDETECTION. A
A JUMPERM-W AND24V TERMINALS.DO NOT REMOVEVENT
ALERNATE LIMITCONTROLLERLOCATION. DAMPERPLUG.
FACTORYTESTTERMINAL.DO NOT USE.
M2190 i LEADWIREMODELISCOLOR-CODEDAS SHOWN.
FIG. 2-S89C, G, J AND S89OC, G, J IN AN ATMOSPHERIC BURNER HEATING SYSTEM.
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DUAL VALVE
COMBINATION SBW.HIS89OD.H HOT SURFACE
GAS CONTROL IGNITION CONTROL
DAMPER PLUG
THERMOSTAT
OR CONTROLLER
A
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS A
4 FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG,
AND OVERLOAD PROTECTION AS REQUIRED. JUMPER M-W AND 24V TERMINALS. DO NOT REMOVE VENT DAMPER PLUG.
MAKE SURE Ll AND L2ARE NOT REVERSED;
THIS WOULD PREVENT FLAME DETECTION. A
FACTORY TEST TERMINAL. DO NOT USE.
it
ALTERNATE LIMIT CONTROLLER LOCATION. A
LEADWIRE MODEL IS COLOR-CODED AS SHOWN.
CONTROLS IN 24V CIRCUIT MUST NOT BE IN
GROUND LEG TO TRANSFORMER. M2200
FIG. 3-S89D,H AND S890D,H IN AN ATMOSPHERIC BURNER HEATING SYSTEM.
DUAL VALVE
COMBINATION S99C.G,JiS89OC.G.J HOT SURFACE
DSOD VENT
DAMPER
CONTROLLER
OR CONTROLLER
A
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS A
REMOVE PLUG ONLY IF USING VENT DAMPER. FUSE SLOWS ON
AND PROTECTION AS REQUIRED.
A STARTUP WHEN PLUG IS REMOVED; THEN MODULE WILL
ALTERNATE LIMIT CONTROLLER LOCATION. OPERATE ONLY WHEN VENT DAMPER IS CONNECTED.
Q A
FACTORY TEST TERMINAL. Do NOT USE.
CONTROLS IN 24V CIRCUIT MUST NOT SE IN
GROUND LEG TO TRANSFORMER. A LEADWIRE MODEL IS COLOR-CODED AS SHOWN. M2191
FIG. 4-S89C, G, J AND S89OC, G, J IN AN ATMOSPHERIC BURNER HEATING SYSTEM WITH THE D80D VENT
DAMPER.
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THERMOSTAT DUAL VALVE
OR COMBINATION SS9C.G.JlS89OC.G.J HOT
CONTROLLER GAS CONTROL SURFACE IGNITION CONTROL
IGNITER-
SENSOR
I I
I
I IP \ J J
BURNER
=GROUNIJ LIMIT C-ZZNTRnlI FR II
LIMIT A
CONTROLLER
I
TRANSFORMER
n
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS A FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG.
AND OVERLOAD PROTECTION AS RECUIRED. JUMPER TH-W AND 24V TERMINALS. DO NOT REMOVE VENT DAMPER PLUG.
A ALTERNATE LIMIT CONTROLLER LOCATION. A FACTORY TEST TERMINAL. DO NOT USE.
A CONTROLS IN 24V CIRCUIT MUST NOT BE IN A LEADWIRE MODEL IS COLOR-CODED AS SHOWN.
GROUND LEG TO TRANSFORMER. A CONNECT COLORS OF WIRE AS SHOWN. M2192
FIG. S-S89C, G, J AND S89OC, G, J IN AN ATMOSPHERIC BURNER HEATlNG SYSTEM WITH D80B VENT DAMPER.
N--L1 1 . .
A I Ls
*; A !‘* Ll
(HOT) r---7 (HOT)
4-L2 I”
b- ma . . L2
b
COMSUSTlON COMBUSTION
AIR BLOWER AIR SLOWER THERMOSTAT x
RELAY OR CONTROLLER
MOTOR
DUAL VALVE
COMBINATION SS9C.G.JlS89OC.G.J HOT
GAS CONTROL SURFACE IGNITION CONTROL
I HOT
AIR _I
PROVING _t
SWITCH T
I_
DAMPER PLUG
OA 0
IILIMIT
CONTROLLER
n
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND
AND OVERLOAD PROTECTION AS REQUIRED. LEG TO TRANSFORMER.
MAKE SURE Ll AND L2 ARE NOT REVERSED:
THIS WOULD PREVENT FLAME DETECTION. A FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG,
JUMPER M-W AND 24V TERMINALS. DO NOT REMOVE VENT DAMPER PLUG.
A ALTERNATE LIMIT CONTROLLER LOCATION. Ih FACTORY TEST TERMINAL. DO NOT USE.
A POWER SUPPLY. PROVIDE DISCONNECT MEANS A LEADWIRE MODEL IS COLOR-CODED AS SHOWN.
AND OVERLOAD PROTECTION AS REQUIRED. M2193
-
FIG. 6-S89C,G,J AND S890C,G,J IN A FAN-ASSISTED COMBUSTION HEATING SYSTEM.
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DUAL VALVE
COMBINATION
GAS CONTROL
DAMPER PLUG
THERMOSTAT
CONTROLLER
Ih
e-L’ (HOT)
f-L2
COMBUSTION
AIR BLOWER AIR BLOWER
MOTOR RELAY
A POWER SUPPLY. PROVIDE DISCONNECT MEANS A FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER
AND OVERLOAD PROTECTION AS REQUIRED. PLUG, JUMPER M-W AND 24V TERMINALS. DO NOT
A ALTERNATE LIMITCONTROLLER LOCATION. REMOVE VENT DAMPER PLUG.
A A
CONTROLS IN 24V CIRCUIT MUST NOT SE IN FACTORY TEST TERMINAL. DO NOT USE.
GROUND LEG TO TRANSFORMER. A LEADWIRE MODEL IS COLOR-CODED AS SHOWN. M2194
FIG. 7-S89C,G,J AND S890C,G,J IN A TWO STAGE FAN-ASSISTED COMBUSTION HEATlNG SYSTEM.
MEUSTION AIR
HOT
SURFACE
IGNITER-
SENSOR
A POWER SUPPLY. PROVIDE DISCONNECT MEANS A FOR MODULE WITH TH-W TERMINAL AND VENT
AND OVERLOAD PROTECTION AS REOUIRED. DAMPER PLUG, JUMPER TH-W AND 24V TERMINALS.
A OPTIONAL LIMITCONTROLLER LOCATION. Do NOT REMOVE VENT DAMPER PLUG.
A A
CONTROLS IN 24V CIRCUIT MUST NOT BE IN FACTORY TEST TERMINAL. DO NOT USE.
GORUND LEG TO TRANSFORMER. A LEADWIRE MODEL IS COLOR-CODED AS SHOWN. M2195
FIG. 8-!389C,G,H AND S890C,G,H IN A FAN-ASSISTED COMBUSTION HEATING-CENTRAL COOLING SYSTEM.
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’ b-&K’ 1 DUALVALVE
CIRCULATOR,-
A
I-
BURNER
= GROUND II
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
MAKE SURE Ll AND L2ARE NOT REVERSED;
THIS WOULD PREVENT FLAME DETECTION.
Ll’
(HOT) A
CONNECT COLORS OF WIRE AS SHOWN.
A
FOR MOOULE WlTH TH-W ERMINAL AND VENT
DAMPER PLUG, JUMPER TH-W AND 24V TERMINAL.
DO NOT REMOVE VENT DAMPER PLUG.
A
FACTORY TEST TERMINAL. DO NOT USE.
A LEADWIRE MODEL IS COLORCOOEO AS SHOWN.
A
LEAVE TP-i! AND Z-W JUMPERS IN PLACE.
HOT
SURFACE
IGNITER-
SENSOR
M2196
FIG. 9-S89C,J AND S89OC,J IN A HYDRONIC HEATING SYSTEM WITH ATMOSPHERIC BURNER.
10
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DUAL VALVE
COMBINATION S8SC.G,.l!S89tZG.J HOT
GAS CONTROL SURFACE IGNITION CONTROL
HOT
SURFACE
IGNITER-
SENSOR
EC0 l’ y CONTROLLER
A
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS A
FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG,
AND OVERLOAD PROTECTION AS REQUIRED. JUMPER TH-W AND 24V TERMINALS. DO NOT REMOVE VENT
MAKE SURE Ll AND L2 ARE NOT REVERSED: DAMPER PLUG.
THIS WOULD PREVENT FLAME DETECTION.
A A-
FACTORY TEST TERMINAL. DO NOT USE.
EC0 SWITCH SHUTS DOWN SYSTEM IF TANK
I TEMPERATURE EXCEEDS 21w F [99 C] A
LEADWIRE MODEL IS COLOR-CODED AS SHOWN.
,&, CONTROLS IN 24VClRCUlT MUST NOT SE IN
GROUND LEG TO TRANSFORMER. M2197
FIG. lmC,G,J AND S990C,G,J IN A COMMERCIAL WATER HEATING SYSTEM.
CHECKOUT
Check out the 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.
FIRE OR EXPLOSION HAZARD.
CAN CAUSE PROPERTY DAMAGE, SEVERE
INJURY OR DEATH.
I. If you smell gas or suspect agas leak, turn off
gas at manual service valve and evacuate the
house. Do not try to light any appliance, do
not touch any electrical switch or telephone
in the bullding until you are sure no spilled
gas remains.
2. 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 plp-
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.
0 Open manual shutoff valves in the gas line to the
appliance.
0 Do gas leak test upstream of gas control if piping has
been disturbed.
GAS LEAK TEST: Paint pipe joints with rich soap and
watersolution. Bubbles indicategas leak. Tighten joints
to stop leak.
STEP 2: Review Normal Operating Sequence (Fig. 12)
and Module Specifications.
0 See OPERATION, page 12, and SPECIFICATIONS,
page 2.
STEP 3: Reset the Module.
0 Turn the thermostatto its lowestsetting.
0 Wait one minute.
As you do Steps 4 and 5, watch for points where
operation deviates from normal. Refer to Troubleshooting
Chart (Fig. 13) to correct problem.
STEP 4: Check Safety Lockout Operation.
0 Turn gas supplyoff.
Cl Setthermostatorcontrollerabove roomtemperatureto
call for heat.
0 Watchfor igniter warmup either immediately or follow-
ing prepurge. See SPECIFICATIONS, page 2.
0 Time the length of time gascontrol stays open. The time
should not exceed the following:
4 sec. modelA. sec.
6 sec. model-7.5 sec.
11 sec. model-l 5.0 sec.
15 sec. model-22.0 sec.
El Threetryforignitionmodu/eson/y(S89G,H; S890G,H):
Watch for start of 30 sec. min. purge, followed by 34 sec.
nom. igniter warmup and second try for ignition. After a
third purge, warmup and trial for ignition sequence, these
modules lock out.
Cl Open manual gas control knob and make sure no gas
is flowing to burner.
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q Set thermostat below room temperature and wait one
minute before continuing.
STEP 5: Check Normal Operation.
q
Set thermostat or controller above room temperature to
call for heat. BURNER
cl Make sure burner lights smoothly without flashback.
q Make sure burner operates smoothly without floating,
liftina. or flame rollout to the furnace vestibule or heat
buildup in the vestibule.
q If 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 with rich
soap and water solution. Bubbles indicate gas leaks.
Tighten joints and screws or replace component to stop
gas leak.
0 Turn thermostat or controller below room temperature.
Make sure flame goes out.
STEP 6: Check Burner Flame Condition.
The igniter-sensor or sensor must be constantly im-
mersed in flame. Check burner flame condition as shown
in Fig. 11. If necessary, improve the flame condition or
relocate the sensor to a place on the main burner where
condition is better. Do not relocate igniteror igniter-sensor.
.H,GH GAS PRESSURE
.EXCESS PRIMARY AIR OR DRAFl
CHECK FOR
.POOR DRAFT
*EXCESS DRAFT
.“,GH VELOCITY OR
SECONDARY AIR
,NSTALL SHIELD IF NECESSARY
SMALL
BLUE FLAME CHECK FOR:
1 .;mGG$D PORTS OR ORIFICE
.WRONG SIZE ORIFICE
LAZY CHECK FOR:
LACK OF AIR FROM
. ;~~N~NP?IMARY AIR
. LARGE PORTS OR
ORIFICES
GOOD
RECTIFYING
FLAME
,,,55*B
FIG. 1l-CHECK BURNER FLAME CONDITION.
The S89 and S890 are direct ignition controls used with
a hot surface igniter. They provide operating control and
100 percent shutdown on ignition failure or loss of main
burner flame in central heat furnaces and heating appli-
ances.
Module operation is in four phases-prepurge (S890
only), igniter warmup, trial for ignition and burner opera-
tion. Modules offer either one or three trials for ignition. Fig.
12 shows the normal operating sequence.
PREPURGE
When the S890 is used in a fan-assisted combustion
system, the combustion air blower starts on a call for heat
from the thermostat. On proof of airflow, the air proving
switch closes and energizes the S890. When the S890 is
used in an atmospheric system, the call for heat energizes
the module.
In either case, the S890first initiates a30 sec. minimum
delay to allow system prepurge. After prepurge, the S890
energizes the igniter to start the igniter warmup.
IGNITER WARMUP
Following prepurge timing (S890) or call for heat from
the thermostat (S89), the module energizes the hot sur-
face igniter for a 34 sec. nominal warmup period, during
which the gas control is closed.
TRIAL FOR IGNITION
Following the warmup period, the gas control opens for
a timed trial for ignition, allowing gas flow to the main
burner. Nearthe end of thetrialfor ignition period the igniter
shutsoff to allowthe rectification sensorto sense presence
of flame. On modules with specified Ignition Activation
Period (IAP) timing the igniter is on for 2 or 4 sec. maxi-
mum, depending on model. On other modules, the igniter
shuts off about 1 sec. prior to lockout. On all modules, the
flame sense time, which is the time that the gas control is
still open between igniter shutoff and lockout is at least
0.75 sec. If lightoff is successful, the burner operation
phase begins.
BURNER OPERATION
When flame is detected, a flame rectification circuit is
completed between the sensor and burner ground. The
flame sensing circuit in the module detects the flame
current and holds the safety lockout timer in the reset
(normal) operation condition.
When the call for heat ends, the module and gas control
are de-energized. The gas control closes, stopping gas
flow to the burner.
SAFETY SHUTDOWN
The S89 and S890 provide 100 percent shutoff, or
safety lockout on ignition failure or loss of established
flame. C,D and J models of the S89 and S890 lockout after
one trial for ignition. G and H models lock out after three
trials for ignition.
One Trial for Ignition Modules
If no flame is sensed by the end of the timed trial for
ignition, the gas control closes and the module locks out.
It must be manually reset by removing power or setting the
thermostat below room temperature for at least 46 sec-
onds.
12
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lf the burner lights normally but goes out during the run
cycle, the gas control closes and the module initiates a
warmup period followed by one trial for ignition. lf flame is
not established, the gas control closes and the module
locks out, requiring manual reset.
Three Trial for Ignition Modules
If no flame is sensed by the end of the first timed trial for
ignition, the gas control closes and the module initiates a
second 30 sec. minimum purge cycle, followed by warmup
and a second trial for ignition. Ifflame is not established the
purge, warmup, trial for ignition cycle is repeated a third
time. Ifflame is still not established following the third trial,
the gas control closes and the module locks out. It must be
manually reset by removing power or setting the thermo-
stat below room temperature for at least 45 sec.
If the burner goes out during the run cycle, the gas
control closes and the module checks for the number of
ignition trials performed during the current call for heat. If
the number is less than three, the module initiates a purge,
warmup and trial for ignition. After the third trial during a
singlecallfor heat, the module locksout. The module must
be manually reset following lockout.
I THERMOSTAT CALLS
KKIl4EA.T I
NOFLAME
SIMUUTING
FAILURE
PURGE
(S&u MODELSONLY)
iGNITEI WARMS UP 4
GASCCMROCDPENS
FOFITMED TRIAL
FOR IGNITION.
IGNITER
WARMUP
1
SINGLE-TFIY
MDDELs
I
LESS
THAN
THREE
CALL FO&AT
Is SATISIFED.
FIG. 12-S89/S890 NORMAL OPERATING SEQUENCE.
13 68-0070-l
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IMPORTANT 1
The following service procedures are provided as
a general guide. Follow appliance manufac-
turer’s service instructions if available.
All meter readings must be taken within the trial
for ignition period. Once the ignition period ends,
the system must be reset by setting the thermo-
stat down for at least 45 sec. before continuing.
If any component does not function properly,
make sure it is correctly installed and wired
before replacing it.
1.
2.
3.
4.
5.
The ignition module cannot be repaired. lf it mal-
functions, it must be replaced.
Only trained, experienced service technicians
should service direct ignition systems.
Perform the checkout steps on page 11 as the first step
in troubleshooting. Then check the troubleshooting guide
(Fig. 13) and the schematic diagram (Fig. 14) to pinpoint
the cause of the problem.
Following troubleshooting, perform the checkout pro-
cedure (page 11) again to be sure system is operating
normally.
IGNITION SYSTEM CHECKS
STEP 1: Check Igniter wire harness.
Make sure:
0 Ignition wire does not touch any metal surface.
•1 Connections to the module and the igniter-sensor are
clean and tight.
0 Ignition wire 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 is required for the module, igniter,
flame sensor and main burner.
- Check for good metal-to-metal contact between
the igniter bracket and the main burner.
- Checkthe ground lead from the GND (BURNER)
terminal on the module to the igniter bracket. 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 105“ C [221” F] minimum rating. Use a
shield if necessary to protect the ground wire from
radiant heat.
- Check temperature at the igniter ceramic or
flame sensor insulator. Excessive temperature will
permit leakage to ground. Provide shield if tempera-
ture exceeds rating of igniter or sensor.
- lf flame sensor or bracket is bent out of position,
restore to correct position.
- Replace igniter and sensor or igniter-sensor with
identical unit if insulator is cracked.
STEP 3: Check flame sensing circuit.
q Make sure burner flame is capable of providing a good
rectification signal. See Fig. 11.
q Make sure about 3/4 to 1 in. of the flame sensor or
igniter-sensor is continuously immersed in the flame for
best flame signal. See Fig. 11. Bend the bracket or flame
sensor, or relocate the sensor as necessary. Do not
relocate an igniter or combination igniter-sensor.
0 Check for excessive (over 1000“ F [538O C]) tempera-
ture at ceramic insulator on flame sensor. Excessive
temperature can cause short to ground; move sensor to
cooler location or shield insulator. Do not relocate an
igniter or combination igniter-sensor.
0 Check for cracked igniter-sensor or sensor ceramic
insulator, which can cause short to ground, and replace
unit if necessary.
. Make sure electrical connections are clean and
tight. Replace damaged wire with moisture-resistant
No. 18 wire rated for continuous duty up to 105O C
[221 o q.
0 lf the igniter is other than a Norton 201 or 271, make
sure it meets the following specifications.
l Igniter must reach 1000” C [1832” F’j within 36
seconds with 102 Vat applied.
l igniter must maintain at least 500 Mohms insula-
tion resistance between the igniter leadwires and the
igniter mounting bracket.
l Igniter must not develop an insulating layer on its
surface (overtime) which would preventflamesens-
ing.
l Igniter surface area immersed in flame must not
exceed 1/4of the grounded area immersed in flame.
This would prevent flame sensing.
l Igniter current draw at 132 Vat must not exceed
5 A.
14
fire-parts.com

START
TURN THERMOSTAT
TO CALL FOR HEAT I
NOTE: BEFOFIETROUBLESHOOTING. FAMIUARIZE YOURSELF WITH
START-UP AND CHECKOUT PiOCEOURE. I
I
POWER (24 VAC NOMINAL)? * CHECK UNE VOLTAGE P(IVYER.
* CHECK LCWVOLTAGE TRANSFORMER.
* CHECK UMITCONTROLLER.
- CHECK AIR PROVING SklTCH (IF USED).
* CHECK THERMOSTAT.
. CHECK WIRING.
CHECK THAT CONTROL IS SBQOTYPE.
SBW MODELS ONLY - CHECK AIR PROVING SWITCH.
- REPLACESOW.
CHECK FOA lx) VAC CHECK AND CORRECT WIRING.
AND GLOWS RED AT Ll .L2 ON S8o\s(100. FUSE OR CIRCUIT BREAKER.
YES
NO 1 * CHECK FOR 24 VAC ACROSS VALVE TERMINALS ON SBQiSBQ.3DURING TRlU
FOR IGNITION TIMING. IF NO VOLTAGE, REPLACE SB8,S890.
- CHECK IGNITER POSITICN.
YES * CHECK ELECTRICAL CONNECnONS BETWEEN SBQ/sBQQAND GAS CONTROL
IF OKAY, REPLACE GAB CONTROL
POWERED AND UT 1
YES
NO= IF SBQ/SBoOGOES INTO LOCKOUT, RESET SYSTEM.
* CHECK CONTlNWTY OF GROUND WIRE.
* MAKESURE Ll AND U ARE NOT REVERSED: THIS WOULD PREVENT FLAME
DETECTION.
* CHECK THAT BURNER FLAME COVERS IGNITEWSENSOR OR SENSOR.
* CHECK INSULATION ON lGNlTEWSENSC43 LEADS (C. G AND J MCOELS)
* CHECK INSULATION ON SENSOR LEADB AND CHECK SENSOR POSlnON (D
AND H MODELS).
* IF CHECKS ARE OKAY, REPUCE S8Q,SBQOMODULE
NOTE: IF SBQlsaW GOES INTO LOCKOUT, RESET SYSTEM.
* CHECK CONTINUITY OF GROUND WIRE.
NOTEz IF GRWNO IS POOR OR ERATIC. SHUTDOWNS MAY OCCUR
YES OCCASIONALLY EVEN THOUGH OPERAnON IS NORMAL AT THE TIME OF
CHECKOUT.
1
* CHECK FOR EXCESSNE HEAT AT IGNITER CERAMIC BASE (TEMPERATURE
ABOVE (QUO-F [Ucr C] CAUSES SHORTS TO GROUND).
* IF CHECKS ARE OKAY, REPlACE SBQr58QQMODULE.
- CHECK FOR PROPER TEMPERATURE CONTROLLER 0PERATK)N.
SYSTEMSHUTBOFF * REMOVE VALVE LEAD AT SBQRBQQ:IF VALVE CLOSES, RECHECK
TEMPEFtATURE CONTROLLER AND WIRING: IF NOT, REPLACE GAS
CONTROL
ENDS I REPEAT PROCEDURE UNTIL TROUBLEFREE OPERATION IS OBTAINED. M21Qa
FIG. 134589, S890 TROUBLESHOOTING SEQUENCE.
15 68-0070-l
fire-parts.com

A A
A L!
Lh
IMIT ON-OFF T
CONTROLLER SWITCH L, (HOT)
r”““““““““‘~~~~~~~~~*~~~~~~~~~~
I
“““““““““““““‘I , HOT SIJRCAPC
3d” I Ic?.IITCD I
I ALTERNATE
I LIMIT
I THERMOSTAT /
I OR CONTROLLER
I
t__________
- INERNAL
WIRING 0
ON0 A POWER SUPPLY. PROVIDE DISCONNECT
(BURNER) MEANS AND OVERLOAD PROTECTION AS
EXTERNAL REQUIRED.
--__
2K2
VALVE
RELAY
ANY
DUAL
VALVE
GAS
CONTROL
(2 AMP
MAX.)
A SEN TERMINAL REPLACES CONNECTION
BEMlEEN HSI TERMINAL AND SENSOR CIRCUIT
ON MODELS WITH SEPARATE IGNITER AND
SENSOR. M2199
FIG. 1”89/S890 SIMPLIFIED SCHEMATIC.
Honeywell Inc.
1885 Douglas Drive N.
Golden Valley, MN 55422-4386
International Sales Offices in all principal cities of the world. Manufacturing in
Australia, Canada, Finland, France, Germany, Japan, Mexico, Nethetiands,
Spain, Taiwan, United Kingdom, U.S.A. m
e
PRINTED IN U.S.A. QUALITY IS KEY
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