Honeywell SUPER TRADELINE S8610U User manual

Honeywell
S8610U
Universal Intermittent Pilot Module
SUPER TRADELINE®
INSTA ATION INSTRUCTIONS
APP ICATION
The SUPER TRADELINE® S8610U Universal Replace
ent Ignition Module is designed to provide easy field
replace ent of a wide range of inter ittent pilot ignition
odules anufactured by Honeywell, Robertshaw,
Penn-Johnson and others. The S8610U odule provides
ignition sequence, fla e onitoring, and safety shutoff
for inter ittent pilot central furnaces, residential boilers,
and other heating appliances. The S8610U replaces
existing fla e rectification type inter ittent pilot ignition
odules with the following characteristics:
• Single rod (local sense) or two rod (re ote sense)
fla e sensing.
• Non-100 percent shutoff, 100 percent shutoff/lockout,
or 100 percent shutoff/continuous retry.
• Natural or LP gas.
• Shutoff/lockout ti es of 30 seconds or longer.
• Prepurge ti es of four seconds or shorter.
• Pilot burners with flow rates of 1500 Btuh or less.
• With or without vent da pers.
A WARNING
Check Table 1 before replacing an existing
inter ittent pilot odule with the S8610U. If the
existing odule is not listed, do not use the
S8610U to replace it unless you are certain the
specifications of the S8610U atch those of the
existing odule.
A co plete list of the specific Honeywell and other
odules that the SUPER TRADELINE® S8610U is
designed to replace is provided in Table 1.
The S8610U SUPER TRADELINE® package contains
co plete, easy-to-use instructions, plus the accessories
required to adapt the existing spark cable (Rajah, stud,
nail, or other) to the spark ter inal on the S8610U. It also
provides labels to help assure proper arking of the wires
attached to the existing odule.
The S8610U SUPER TRADELINE® Universal Module is
not designed to replace controls with the following
characteristics:
• Fla e sensing other than by fla e rectification (White
Rodgers Cycle-Pilot®, or Robertshaw ther al sensing).
• Fla e rectification odules with shutoff/lockout ti es
of less than 30 seconds, prepurge ti es of ore than 4
seconds, or pilot burners larger than 1500 Btuh.
• Standing pilot appliances.
Honeywell provides additional control packages to
acco plish these replace ents. See the Honeywell
Electronic Ignition Service Manual, for 70-6604, or call
your Honeywell wholesaler.
SPECIFICATIONS
Electrical Ratings:
Voltage: 24V, 60 Hz.
Current Draw: 1A pilot valve, 2A ain valve.
Valve Contact Rating: 0.2A.
Trial For Ignition:
90 seconds axi u , then 100 percent shutoff (pilot and
ain gas).
Continuous Retry:
Five- inute ini u (six- inute no inal) delay if pilot
fails to light during trial for ignition. After delay, trial for
ignition is repeated. This sequence (trial, delay, trial, delay)
continues until pilot lights or call for heat ends.
Flame Failure Response Time:
0.8 sec ax at 1.0 uA fla e current.
Ambient Operating Temperature:
-40°F to 165°F (-40°C to 74°C). (If ain valve current is 1A
or less, 175°F (79°C) axi u a bient applies.)
®U.S. Registered Trade ark
Copyright © 1996 Honeywell Inc. • All Rights Reserved 6 9 -0 7 2 9 -3

S8 610U UNIVERSAL INTERM ITTEN T P H O T MODULE
Table 1. S8610U Replaces these Ignition Modules.
Camstat S86H1089 CSA42A-603R G60PAG-5 G60RCG-2 G67AG-8
IPI-24-00 S86H1097 CSA42A-604R G60PAG-6 G60RCJ-1 G67BG-2
S86H1105 CSA43A-600R G60PAJ-1 G60RDG-1 G67BG-3
Fenwal S86H1121 CSA44A-600R G60PAK-1 G60RDK-1 G67BG-4
05-203025-005 S86H1147 CSA45A-601R G60PAK-2 G60RGL-1 G67BG-5
05-203026-005 S90A1005 CSA45A-602R G60PFH-1 G60RHL-1 G67MG-1
S90B1003 CSA46A-600R G60PFH-2 G60RHP-1 G67MG-4
Honeywell S90B1011 CSA48A-600R G60PFL-1 G60RPL-1 G67NG-2
S86A1001 S8600A1001 CSA49A-600R G60PFQ-1 G60RSL-1 G600AX-1
S86A1019 S8600B1009 CSA49A-605R G60PVL-1 G60ZAG-1 G600AY-1
S86A1027 S8600C1015 CSA51A-601R G60QAG-2 G65BBG-1 G600MX-1
S86A1035 S8600F1000 CSA52A-600R G60QAG-3 G65BBG-2 G600NX-1
S86B1009 S8600F1034 G60AAA-1 G60QAK-1 G65BBG-3 G600RX-1
S86B1017 S8600F1042 G60AAG-1 G60QBG-1 G65BBG-4 G670AW-1
S86B1025 S8600H1006 G60AAG-3 G60QBG-2 G65BBG-5 G770MGA-1
S86C1007 S8600H1022 G60AAG-4 G60QBG-3 G65BBG-6 G770MGA-2
S86C1015 S8600H1048 G60AAG-5 G60QBG-4 G65BBG-7 G770MGC-1
S86C1031 S8600H1055 G60AAG-6 G60QBG-5 G65BBG-8 G770MGC-2
S86C1049 S8600H1089 G60CAA-1 G60QBG-6 G65BBM-1 G770MGC-3
S86C1056 S8600H1105 G60CAA-3 G60QBG-7 G65BBM-2 G770MHA-1
S86D1005 S8600M1005 G60CAG-1 G60QBG-8 G65BBM-3 G770NGA-1
S86D1021 S8600M1013 G60CAG-2 G60QBG-9 G65BBM-4 G770NGC-4
S86E1002 S8610A1009 G60CAG-3 G60QBH-1 G65BCG-1 G770NGC-5
S86E1010 S8610B1007 G60CAG-4 G60QBK-1 G65BCM-1 G770NGC-6
S86E1028 S8610B1015 G60CAG-5 G60QBK-3 G65BFG-1 G770NGC-7
S86E1036 S8610C1005 G60CAG-6 G60QBL-1 G65BFM G770RGA-1
S86E1044 S8610F1008 G60CAG-7 G60QBL-2 G65BKG-1 G770RHA-1
S86E1051 S8610F1016 G60CAG-8 G60QCG-1 G65BKG-2 G770MHA-2
S86E1069 S8610F1024 G60CAG-9 G60QCJ-1 G65BKG-3 G770MHC-1
S86E1077 S8610F1032 G60CBA-1 G60QCL-1 G65BKM-1 G770NHA-1
S86E1101 S8610H1012 G60CBA-3 G60QDG-1 G65BKM-2 G770NHC-1
S86E1119 S8610H1038 G60CBG-1 G60QFL-1 G65BKM-3 G770RHA-2
S86E1127 S8610H1046 G60CBG-10 G60QHL-1 G65DBG
S86F1000 S8610H1053 G60CBG-11 G60QJL-1 G65DBM-1
S86F1018 S8610H1079 G60CBG-14 G60QLG-1 G65DBM-3 Robertshaw
S86F1026 S8610M1003 G60CBG-16 G60QPL-1 G65DCM-1 780-715
S86F1042 S8610M1029 G60CBG-17 G60QRH-1 G65DFG 780-735
S86F1059 S8620H1028 G60CBG-3 G60QRL-1 G65DFM-1 780-737
S86F1067 G60CBG-4 G60QRL-2 G65DKG SP715
S86F1075 G60CBG-9 G60QRL-3 G65DKM SP715A
S86F1083 HSC G60CCA-1 G60QSL-1 G65FBG SP735
S86F1091 1003-3 G60CCG-1 G60QTH-1 G65FFG SP735D
S86G1008 1003-300 G60CPG-1 G60QTL-1 G65FKG SP735L
S86G1016 G60DBG-1 G60RAG-1 G66AG-1 USI 715U
S86G1032 Penn- G60DCG-1 G60RAK-1 G66BG-1
S86G1057 Johnson G60DCG-2 G60RBG-1 G66MG-1
S86G1073 CSA35A-617R G60PAG-1 G60RBG-2 G66NG-1
S86H1006 CSA35A-618R G60PAG-2 G60RBG-3 G67AG-3
S86H1022 CSA42A-600R G60PAG-3 G60RBK-1 G67AG-4
S86H1048 CSA42A-601R G60PAG-4 G60RBK-2 G67AG-7
69-0729—3 2

S8 610 U UNIVERSAL INTERM ITTEN T PILO T MODULE
P ANNING THE INSTA ATION
A WARNING
FIRE OR EXPLOSION HAZARD
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY, OR DEATH.
Follow these warnings exactly:
1. Plan the installation as outlined below.
2. Plan for frequent aintenance as described in
the Maintenance section.
When inter ittent pilot syste s are used on central
heating equip ent in barns, greenhouses, and co er
cial properties and on heating appliances such as
co ercial cookers, agricultural equip ent, industrial
heating equip ent and pool heaters, heavy de ands are
ade on the controls. Special steps can be required to
prevent nuisance shutdowns and control failure due to
frequent cycling, severe environ ental conditions related
to oisture, corrosive che icals, dust or excessive heat.
These applications require Honeywell Ho e and
Building Control Engineering review; contact your
Honeywell Sales Representative for assistance.
Review the following conditions that can apply to your
specific installation and take the precautionary steps
suggested.
Frequent Cycling
These controls are designed for use on appliances that
typically cycle three to four ti es an hour only during the
heating season. In year-round applications with greater
cycling rates, the control can wear out ore quickly;
perfor a onthly checkout.
Water or Steam Cleaning
If a odule or gas control gets wet, replace it. If the
appliance is likely to be cleaned with water or stea ,
protect (cover) the controls and wiring fro water or
stea flow. Mount the controls high enough above the
botto of the cabinet so they do not get wet during
nor al cleaning procedures. Use a NEMA 4 enclosure
for the ignition odule; see the Electronic Ignition
Service Manual, for 70-6604.
High Humidity or Dripping Water
Dripping water can cause the odule to fail. Never install
an appliance where water can drip on the controls.
In addition, high a bient hu idity can cause the gas
control to corrode and fail.
If the appliance is in a hu id at osphere, ake sure air
circulation around the controls is adequate to prevent
condensation. Also, regularly check out the syste . A
NEMA 4 enclosure is reco ended for the ignition
odule; see the Electronic Ignition Service Manual,
for 70-6604.
Corrosive Chemicals
Corrosive che icals can attack the odule and gas
control, eventually causing a failure. If che icals are
used for routine cleaning, ake sure they do not reach
the controls. Where che icals are suspended in air, as
in so e industrial or agricultural applications, use a
NEMA 4 enclosure for the ignition odule; see the
Electronic Ignition Service Manual, for 70-6604.
Dust or Grease Accumulation
Heavy accu ulations of dust or grease can cause
controls to alfunction. Where dust or grease can be a
proble , provide covers for the odule and the gas
control to li it conta ination. A NEMA 4 enclosure is
reco ended for the ignition odule; see the Electronic
Ignition Service Manual, for 70-6604.
Heat
Excessively high te peratures can da age controls.
Make sure the axi u a bient te perature at the
control does not exceed the rating of the control. If the
appliance operates at very high te peratures, use
insulation, shielding, and air circulation, as necessary, to
protect the controls. Proper insulation or shielding should
be provided by the appliance anufacturer; verify proper
air circulation is aintained when the appliance is
installed.
INSTA ATION
When Installing this Ignition System...
1. Read these instructions carefully. Failure to follow
the could da age the co ponents or cause a
hazardous condition.
2. Check the ratings given in the instructions and on
the co ponents to ake sure they are suitable for
your application.
3. Installer ust be a trained, experienced service
technician.
4. After installation is co plete, check out co ponent
operation as provided in these instructions.
A WARNING
FIRE OR EXPLOSION HAZARD
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY, OR DEATH.
1. If the ignition odule gets wet, it can
alfunction, leading to the accu ulation of
explosive gas.
• Never install where water can flood, drip or
condense on the odule.
• Never use a odule that has been wet.
Replace it.
2. Liquefied petroleu (LP) gas is heavier than
air and will not vent upward naturally.
• Do not light the pilot or operate electric
switches, lights or appliances until you are
sure the appliance area is free of gas.
3. Do not atte pt to disasse ble or clean the
odule. I proper reasse bly and cleaning
can cause unreliable operation.
A CAUTION
1. Disconnect power supply before beginning
wiring to prevent electrical shock or equip
ent da age.
2. If a new gas control is to be installed, turn off
the gas supply before starting installation.
Conduct a Gas Leak Test according to the
gas control anufacturer instructions after
the gas control is installed.
3. If the odule ust be ounted near
oisture or water, provide a suitable
waterproof enclosure.
4. Using the wire labels provided, label all wires
before they are disconnected. Wiring errors
can cause i proper appliance operation and
dangerous conditions such as bypassing
safety features.
369-0729—3

S8 610U UNIVERSAL INTERM ITTEN T PILO T M ODULE
Perform Preinstallation Safety Inspection
The preinstallation checks described in ANSI Standard
Z21.71 in Exhibit A ust be done before the replace ent
odule 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.
Remove Old Module
Disconnect power supply before doing any work on the
unit. Disconnect and tag the wires fro the old odule
using the wire labels provided. Re ove the old odule
fro its ounting location.
Mount New Ignition Module
We reco end ounting the S8610U Module in the
sa e location as the old odule, if possible. Otherwise,
select a location close enough to the burner to allow a
short (3 ft. (0.9 ) axi u ), direct cable route to the
igniter. A bient te perature at the odule ust be within
the range listed in the Application section.
Mount the odule with the ter inals down to protect
the fro dripping water and dust. The odule can also
be ounted with the ter inals on either side. Do not
ount with the ter inals pointing up. Refer to Fig. 1 for
ounting reco endations. When it is necessary to drill
new ounting holes, use the S8610U as a te plate to
ark ounting hole pattern. Drill new holes, as required.
Fasten securely with four No. 6-32 achine or No. 8
sheet etal screws.
Wire the Module
A CAUTION
1. Check the wiring diagra furnished by the
appliance anufacturer, if available, and
co pare with Tables 3 through 6. Carefully
follow any special instructions affecting the
general wiring procedures outlined below.
2. Disconnect the power supply before aking
wiring connections to prevent electrical shock
or equip ent da age.
IMPORTANT
1. A common ground is required on:
a. The pilot burner mounting bracket, and
b. The GND BURNER) terminal on the ignition
module. Failure to use the GND BURNER)
terminal can result in intermittent loss of spark
and/or loss of flame current sensitivity.
2. Make sure the transformer has adequate VA.
The ignition module requires at least 0.2A 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 4.8 VA for the
ignition module). The result is the minimum
transformer VA rating. Use a Class II transformer
when replacement is required.
3. When a vent damper is connected to the S8610U
vent damper connector, be sure the system
transformer delivers at least 30 VA. The S8610U
has an internal fuse that is intended to prevent
appliance lightoff if the vent damper is not in
place or wired properly. Using a small trans
former can interfere with the proper operation of
the fuse and bypass the intended safety feature.
O Connect the wires to the S8610U Ignition Module as
shown in Tables 3 through 6. Make sure that
adequate syste ground is provided as indicated in
the wiring tables.
0 Verify the ther ostat anticipator setting as explained
in the I portant.
NOTE: The wiring diagra s in Fig. 2 through 4 show
typical hookups with the S8610U Ignition Module
and should be used for reference only.
MOUNT IN ONE OF THESE POSITIONS
DO NOT MOUNT
WITH TERMINA S FACING UP
M2647
Fig. 1. Module mounting recommendations.
Modify Ignition Cable, If Necessary
Use existing ignition cable if it is in good condition. If the
existing ignition cable does not have a 1/4 in. quick-
connect on the odule end, either use the Rajah adapter
or strip the wire and replace with the 1/4 in. insulated
quick-connect supplied. If the cable ust be replaced,
order a Honeywell ignition cable, see Table 2. It ight be
necessary to replace the connector at the pilot burner end
to atch the pilot burner spark ter ination.
NOTE: When using an S8610U to replace an S86, use
the enclosed adapter to convert the S86 Ignition
Cable to an S8610U Ignition Cable. Then,
install the adapter and cable to the S8610U
Ignition Module.
69-0729—3 4

S8 610 U UNIVERSAL INTERM ITTEN T P H O T MODULE
Table 2. Honeywell Preassembled Ignition
Cables (U Style 3257).
Cable Part
Number ength Module End Igniter End
394800-30 30 in. 1/4 in.
quick
connect,
insulated
Rajah connector
receptacle, 90
degree rubber
boot
394801-30 30 in. 1/4 in.
quick
connect,
insulated
Rajah connector
receptacle,
straight rubber
boot
NOTE: The cable ust not run in continuous contact
with a etal surface or spark voltage is greatly
reduced. Use cera ic or plastic standoff
insulators, as required.
Arc Table
Arc ength Action
No arc or arc
less than 1/8 in.
(3 )
Check external fuse, if provided.
Verify power at odule input
ter inal. Replace odule if fuse
and power are okay.
Arc 1/8 in. (3 )
or longer. Voltage output is okay.
Table 3. Conversion from Honeywell S86, S90, S8600 and S8610 to S8610U1003.
Replace ent
Control Old Control
Ter inal
Function S8610U1003 S86A,C S86B,D S86E,F,G,H
S8600A,B,C
S8610A,B,C
S90A,B S8600F,H,M
S8610F,H,M Procedural Notes
Main valve
operator MV MV MV MV MV MV
Main valve
and pilot
co on
MV/PV MV/PV MV/PV MV/PV MV/PV MV/PV
Pilot valve
operator PV PV PV PV PV PV
Burner
ground
connection
GND
(BURNER) GND GND GND (BURNER) GND (BURNER) GND (BURNER)
Transfor er
secondary
(unswitched
leg)
24V GND 25V (1) 25V (GND) 25V (1)e 24V GND 24V GND
Transfor er
secondary
(switched
leg)
24V* 25V (2) 25V 25V (2)e* 24V* 24V* * Im p orta nt: If the old odule had a vent
da per plug but a vent da per was not
installed, or if it did not have a vent
da per plug: leave the vent da per plug
in position on the S8610 and connect the
25V (2) or 24V wire fro the old odule
to the Th-W ter inal on the S8610U. Do
n ot use the 24V te rm in al on the
S8610U.
25V (2) or 24V used only in syste s where
plug-in cable connects da per to odule. If the old odule had a vent da per with a plug connection to a Molex connector,
wire the ter inals as indicated in the
table.
TH-W TH-Ra TH-Ra TH-Ra TH-W (This
ter inal
not included on
S90.)
TH-W
TH-Wb TH-W TH-Wb
Fla e
sensor SENSEf d d d SENSEf d
Igniter/
sensor SPARK IGN COILc IGN COILc IGN COILc SPARK SPARK
a If 25V (2) and TH-R have wires connected, disconnect and splice together with solderless connector.
b If TH-R and TH-W are ju pered together, connect 25V (2) lead fro S86 to TH-W on S8610U1003.
c Use Rajah to quick connector adapter (supplied) or cut Rajah connector off ignition cable at odule end; attach insulated quick
connect for connection to S8610.
d Leave black ju per connected.
e Ter inals ay be arked 25V on so e odels and 24V on later odels. These are functionally equivalent.
f On dual igniter and sensor odels, re ove ju per quick connect fro S8610U1003 Sense ter inal, cut ju per wire at circuit board,
and discard.
569-0729—3

S8 610U UNIVERSAL INTERM ITTEN T P H O T MODULE
Table 4. Conversion from Robertshaw SP715 and SP735C to S8610U1003 (Includes 780-XXX and USI715U).
Terminal Function
Replacement
Control Old Control SP715 and SP735
(includes 780-XXX and USI 715U)c>d
Procedural Notes
Honeywell
S8610U1003 7000D Valve 7100D Valve 7100K Valve
Main valve operator MV MV
(to: Valve TH) MV (to: Valve M) MV (to: Valve TR) —
Main valve and pilot
co on MV/PV MV/PV (to: Valve TR) MV/PV (to: Valve C) PV
(to: Valve C and TH) —
Pilot valve operator PV PV
(to: Valve
PILOT)*
PV
(to: Valve P) PV (to: Valve PICK &
HOLD)
*This is the ter inal not
ju pered to TR.
Burner ground
connection GND (BURNER) GND GND GND —
Transfor er
secondary
(unswitched leg)
24V GND TR TR TR —
24V No connection No
connection No connection —
Transfo er
secondary
(switched leg)
E3a E3a E3a When supplied, E3
provides connection to
Lockout Ti er.
TH-W TH TH TH If LO-15 is part of the
installation, use the
wire disconnected fro
E1 tagged Thermostat.
Fla e sensor SENSEb SENSEe SENSEe SENSEe —
Pilot igniter SPARK IGN IGN IGN —
1. Use existing wiring harness to ake connections to S8610 per table. IMPORTANT: If installation includes LO-15
Lockout Ti er, discard wires to E3 and TH. Disconnect and retain wire to LO-15 ter inal E1. Tag wire,Ther ostat.
Discard LO-15.
2. On 7000D series valve, retain (or install) white ju per between valve TR and pilot solenoid.
a If LO-15 Lockout ti er is not installed, E3 connector provided on SP715 is not used.
b I portant: If the USI 715U with co bination igniter sensor is not used, re ove black ju per quick connect fro
Sense ter inal of S8610U1003. Cut ju per wire at circuit board and discard.
c For replace ent of Robertshaw Fla e Switch syste s (SP710, 720, 730, 750, 780-700, 780-701,780-710, 780-711,
780-712 and 780-713), see Honeywell Ignition Control Handbook.
d 780-715 and USI 715U are equivalent to SP715; 780-735 and 780-737 are equivalent to SP735. For other 780-XXX
odels, see notec.
e OPT. SENSOR on USI 715U. No external connection if co bination igniter sensor is used.
69-0729—3 6

S8 610 U UNIVERSAL INTERM ITTEN T P H O T MODULE
T a ble 5. C o n v ersio n fro P e n n -Jo h nso n C SA — (A ll), G 60, G 65, G 66, G 67, G 600, G 67 0 O r G 770 to S 8610U 1003.
T e r in a l
F u n ctio n
R e p la c e e n t
C o n tro l O ld C o n tro l
P ro c e d u ra l N o te s
H o n e yw e ll
S 86 1U 1 00 3
C S A 45 A -60 0 R d , G 60, G 65, G 66, G 67,
G 600 O R G 670 In s ta lla tio n w ith
L o ck o u t M o d ule s a s fo llo w s :*
G 770N o n e (Y 79) Y 79 A
o d u le d Y 79 B
o d u le c
M a in v a lv e
o p e ra to r
M V 3 3 Y 7 9 B M V M V (3)
M a in v a lv e a n d
p ilo t c o o n
M V /P V G R G R G R G R O U N D (5 )
P ilo t v a lv e
o p e ra to r
P V 1 1 Y 7 9 B P V P V (1)
B u rn e r g ro u n d
c o n n e ctio n
G N D
(B U R N E R )
G R G R G R G R O U N D
T ra n s fo r e r
s e c o n d a ry
(u n s w itc h e d le g)
2 4 V G N D G R G R G R G R O U N D
T ra n s fo r e r
s e c o n d a ry
(s w itc h e d leg )
T H -W * 2 a Y 7 9 T H S b 2 T H -S (2)
2 4 V * N o
c o n n e ctio n *
N o
c o n n e ctio n *
N o
c o n n e ctio n *
N o
c o n n e ctio n *
F la e s e n s o r S E N S E * 4 e 4 e 4 e S E N S E (4 )e
P ilo t ig n ite r S P A R K IG N C O IL IG N C O IL IG N C O IL IG N C O IL It ig h t b e
n e c e s s a ry to c u t o ff
R a ja h c o n n e c to r
a n d /o r a tta c h
in s u la te d q u ic k
c o n n e c t.
a D is c a rd w ire b etw e e n tra n sfo r e r a n d te r in al 5 (G 6 0) o r 6 (G 6 00 ); o th e rw is e, u se e x is tin g h arn e s s fo r w irin g.
b D is ca rd w ire s b e tw e e n Y 7 9 A a nd o d u le a s fo llo w s: R ed to 3 , B la c k to 2, W h ite to G R . D is c a rd w ire be tw e e n
tra n s fo r e r a n d 6.
c D is c a rd w ire s b e tw e e n Y 7 9 B a nd o d ule a s fo llo w s : W h ite to 3, B la ck to 1, B ro w n to G R . D isc a rd w ire b etw e e n
tra n s fo r e r a n d 6.
d C S A c o d e n u b e rs (fo r e x a p le , C S A 4 5 A -6 0 0 R ) are e q u iv a le n t to G 6 00 a n d use th e s a e w irin g in fo r a tio n ta ble s.
e Important: Remove black jumper quick connect from Sense terminal of S8610U1003; cut jumper wire at circuit board
and discard.
*IF IN S T A LLA T IO N DO ES N O T IN C LU D E V EN T DA M P E R W ITH P LU G C O N N EC TIO N TO M O DU LE :
1. L e a ve v e n t d a p e r p lu g o n S 8 6 1 0 U M o d ule in p ositio n.
2. U se T H -W te r in al.
*IF IN S T A LLA T IO N IN C LU DE S V EN T D AM P E R W ITH P LU G C O N NE C TIO N TO M O DU LE :
1. R e p la ce S 8 6 1 0 U M o d ule v e n t d a p e r p lu g w ith d a p e r M o le x c on n e c to r.
2. W ire th e r o s ta t W w ire to T H -W .
3. R un w ire fro s w itc h e d le g o f tra n s fo r e r s e c o n d a ry to b oth th e r o s ta t R a n d S 86 1 0 M o d u le 2 4 V te r in als .
769-0729—3

S8 610U UNIVERSAL INTERM ITTEN T P H O T MODULE
Table 6. Conversion from Camstat, Fenwal or HSC to S8610U1003.
Terminal
Function
Replacement
Control Old Control
Procedural Notes
Honeywell
S8610U1003 CAMSTAT
IPI-24-00aFENWA 05-20XbHSC 1003-3
and 1003-3003
M ain valve
operator M V MV M AIN V A LV E M V —
M ain va lve and
pilot co on M V/P V G N D G RO UN D G N D/C O M F enw al only: run separate lead to S8610 valve
co on ter inal.
Pilot valve
operator PV PV PILO T VA L V E PV —
B urner ground
connection G N D (B U R N E R ) G ND To a ssure good ground, run se para te w ire fro pilot
burner to S8610 GND
(B U R N E R ).
Tran sfo r er
se condary
(unsw itched leg)
24V GN D T2 G R O UN D G N D/C O M
24V No co nnection No connectio n No conn ection —
Tran sfo r er
se condary
(sw itched leg)
TH -W T1 PO W ER 24 V AC
Fla e sensor S EN SE Sc —S E N S O R c —
Pilot igniter S P AR K IGN H.V. IGN C O IL S trip odule end of ignition
cable as necessary and
attach insulated q uick
co nnect fo r connection to
S8610.
a Use existing w iring harness to ake connections to S8610.
b Tag all w ires at odule co nnector w ith ter inal designations. Cut w ires at connector, attach quick connects and
connect to S8610; per table.
c I m p o r t a n t : Remove black jumper quick connect from Sense terminal of S8610U1003; cut jumper wire at circuit board
and discard.
69-0729—3 8

> [ » [ > [ »
S8 610 U UNIVERSAL INTERM ITTEN T PILO T MODULE
S8610U
/ \ POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
fk ALTERNATE LIMIT CONTROLLER LOCATION.
^ MAXIMUM CABLE LENGTH 3 ft (0.9 ).
/ \ CONTROLS IN 24V CIRCUIT MUST NOT BE GROUND LEG TO TRANSFORMER.
5 REMOVE PLUG ONLY IF USING VENT DAMPER. FUSE BLOWS ON STARTUP WHEN PLUG IS
REMOVED AND VENT DAMPER WIRING HARNESS IS INSTALLED, THEN MODULE OPERATES
ONLY WHEN VENT DAMPER IS CONNECTED.
/k, REMOVE JUMPER AND CONNECT SENSE TERMINAL ON TWO ROD APPLICATION ONLY.
7 IF THE VENT DAMPER IS CONNECTED, WIRE 24V TERMINAL, AS SHOWN. CONNECT VENT
DAMPER CABLE IN PLACE OF PLUG SHIPPED WITH THE S8610U. IF NO VENT DAMPER IS
CONNECTED, DO NOT WIRE 24V TERMINAL.
30 VA MINIMUM WHEN VENT DAMPER IS CONNECTED TO DAMPER PLUG. M2641
Fig. 2. S8610U in heating system with atmospheric burner.
S8610U
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
MAXIMUM CABLE LENGTH 3 ft (0.9 ).
CONTROLS IN 24V CIRCUIT MUST NOT BE GROUND LEG TO TRANSFORMER.
LEAVE VENT DAMPER PLUG CONNECTED.
REMOVE JUMPER AND CONNECT SENSE TERMINAL ON TWO ROD APPLICATION ONLY. M2642B
Fig. 3. S8610U in heating system with power-assisted combustion.
969-0729—3

S8 610U UNIVERSAL INTERM ITTEN T PILO T M ODULE
START
]
STAGE 1
TRIA FOR
IGNITION
STAGE 2
MAIN BURNER
OPERATION
END
Fig. 4. S8610U in typical ST9120 application.
STARTUP AND CHECKOUT
Check out the gas control syste :
• At initial installation of the appliance.
• As part of regular aintenance procedures.
• At aintenance intervals deter ined by the application.
• As the first step in troubleshooting.
• Any ti e work is done on the syste .
Maintenance frequency ust be deter ined individually
for each application; see Maintenance section.
A WARNING
FIRE OR EXPLOSION HAZARD
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY, OR DEATH.
1. If you s ell gas or suspect a gas leak, turn off
the gas at the anual service valve and
evacuate the building. Do not try to light any
appliance; do not touch any electrical switch
or telephone in the building until you are sure
no spilled gas re ains.
2. Gas leak test ust be done as described in
Steps 1 and 6 below during initial installation
and anyti e work is done involving the gas
piping.
Step 1: Perform visual inspection.
a. With power off, ake sure all wiring connections are
clean and tight.
b. Turn on the power to the appliance.
c. Open the anual shutoff valves in the gas line to the
appliance.
d. Test for gas leak before gas control if piping has been
disturbed.
Gas eak Test:
Paint the gas control gasket edges and all pipe connec
tions downstrea 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 co ponent to stop gas leak. Recheck with soap
and water solution.
Step 2: Verify control system ground.
The igniter, fla e sensor, and ignition odule ust share
a co on ground with the ain burner. Use ther oplastic
insulated wire with a ini u rating of 105°C (221°F) for
the ground wire; asbestos insulation is not acceptable. If
the te perature at the wire could exceed 105°C (221°F),
use a shield to protect the wire fro radiant heat gener
ated by the burner. Connect the ground wire as follows:
a. Fit one end of the ground wire with a fe ale 1/4 in.
quick-connect ter inal and connect it to the ale
quick-connect GND (BURNER) ter inal on the
ignition odule.
b. Strip the other end of the wire and fasten it under the
igniter bracket ounting screw. If necessary, use a
shield to protect the ground wire fro radiant heat.
c. The burner serves as the co on grounding area. If
there is not good etal-to- etal contact between the
burner and ground, run a lead fro the burner to
ground.
NOTE: Earth ground is not required.
69-0729—3 10

S8 610 U UNIVERSAL INTERM ITTEN T P L O T M ODULE
Step 3: Review normal operating sequence
and module specifications.
a. See Operation and Application sections.
Step 4: Reset the module.
a. Turn the ther ostat to its lowest setting.
b. Wait one inute.
As you do Steps 4 and 5, watch for points where operation
deviates from normal. Refer to Troubleshooting Guide, Fig.
7, to correct problem.
Step 5: Check safety shutoff operation.
a. Turn off the gas supply.
b. Set the ther ostat or controller above the roo
te perature to call for heat.
c. Watch for spark at pilot burner.
d. Ti e spark fro start to shutoff. Spark should shut
off after 90 seconds axi u . Ignition sequence
repeats after five inutes ini u .
e. Open anual gas control knob and ake sure no
gas is flowing to pilot or ain burner.
f. Set the ther ostat below the roo te perature and
wait one inute before continuing.
Step 6: Check normal operation.
a. Set the ther ostat or controller above the roo
te perature to call for heat.
b. Make sure the pilot lights s oothly when the gas
reaches the pilot burner.
c. Make sure the ain burner lights s oothly without
flashback.
d. Make sure the burner operates s oothly without
floating, lifting, or fla e rollout to the furnace
vestibule or heat buildup in the vestibule.
e. If the gas line has been disturbed, co plete the gas
leak test.
Gas eak Test:
Paint the gas control gasket edges and all pipe connec
tions downstrea of the gas control, including pilot
tubing connections, with a rich soap and water solution.
Bubbles indicate gas leaks. Tighten the joints and
screws or replace co ponent to stop gas leak. Recheck
with soap and water solution.
f. Turn the ther ostat or controller below the roo
te perature. Make sure the ain burner and pilot
fla es go out.
MAINTENANCE
A WARNING
FIRE OR EXPLOSION HAZARD
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY, OR DEATH.
Do not atte pt to take the odule apart or to clean
it. I proper asse bly and cleaning can cause
unreliable operation.
Regular preventive aintenance is i portant in applica
tions that place a heavy load on syste controls, such as
in the co ercial cooking and agricultural and industrial
industries because:
• In any applications, particularly co ercial cooking,
the equip ent operates 100,000 to 200,000 cycles
per year. Such heavy cycling can wear out the gas
control in one to two years.
• Exposure to water, dirt, che icals and heat can
da age the gas control and shut down the control
syste . A NEMA 4 enclosure can reduce exposure to
environ ental conta inants. See electronic Ignition
Service Manual, for 70-6604.
The aintenance progra should include regular syste
checkout as outlined in the Startup and Checkout
section, and the control syste as described in the
appliance anufacturer literature.
Maintenance frequency ust be deter ined individually
for each application. So e considerations are:
• Cycling frequency. Appliances that can cycle 20,000
ti es annually should be checked onthly.
• Inter ittent use. Appliances that are used seasonally
should be checked before shutdown and again before
the next use.
• Consequence of unexpected shutdown. Where the
cost of an unexpected shutdown would be high, the
syste should be checked ore often.
• Dusty, wet, or corrosive environ ent. Because these
environ ents can cause the gas control to deteriorate
ore rapidly, the syste should be checked ore
often.
Any control should be replaced if it does not perfor
properly on checkout or troubleshooting. In addition,
replace any odule if it is wet or looks like it has ever
been wet. Protective enclosures, as described in
Planning the Installation section, are reco ended
regardless of checkout frequency.
11 69-0729—3

S8 610U UNIVERSAL INTERM ITTEN T PILO T M ODULE
1
TURN OFF GAS SUPPLY.
TURN THERMOSTAT
(CONTROLLER) TO CALL
FOR HEAT.
POWER TO MODULE.
(24V NOMINAL)
CHECK AT TH-W TERMINAL,
AND ALSO AT 24V TERMINAL
IF A VENT DAMPER IS
CONNECTED TO THE
DAMPER CONNECTOR.
YES ^
SPARK ACROSS
IGNITER/SENSOR GAP?
YES
TURN ON GAS SUPPLY.
PILOT BURNER LIGHTS?
YES
SPARK STOPS WHEN
PILOT IS LIT?
YES
MAIN BURNER LIGHTS?
YES
SYSTEM RUNS UNTIL
CALL FOR HEAT ENDS?
YES
CALL FOR HEAT ENDS.
SYSTEM SHUTS OFF?
TROUBLESHOOTING
ENDS.
NOTE: Before troubleshooting, fa iliarize yourself with the startup and checkout procedure.
Check line voltage power, low voltage transfor er, li it controller, ther ostat (controller) and wiring. Also,
check air proving switch on co bustion air blower syste (if used) and verify that vent da per (if used) is open
and end switch is ade.
Pull ignition lead and
check spark at odule. On odels with vent da per plug, ake sure vent da per
was not installed, then re oved. Replace vent da per,
if necessary.
On other odels, replace odule.
Check ignition cable, ground wiring, cera ic insulator and gap, and correct.
Check boot of the ignition cable for signs of elting or buckling. Replace cable and take protective action
to shield cable and boot fro excessive te peratures.
Check that all anual gas valves are open, supply tubing and pressures are good, and pilot burner orifice
is not blocked.
Check electrical connections between odule and pilot operator on gas control.
Check for 24 Vac across PV-MV/PV ter inals on odule. If voltage is okay, replace gas control; if not,
replace odule
Check continuity of ignition cable and ground wire.
Clean fla e rod.
Check electrical connections between fla e rod and odule.
Check for cracked cera ic fla e rod insulator.
Check that pilot fla e covers fla e rod and is steady and blue.
Adjust pilot fla e.
If proble persists, replace odule.
Check for 24 Vac across MV-MV/PV ter inals. If no voltage, replace odule.
Check electrical connections between odule and gas control. If okay, replace gas control or gas
control operator.
Check continuity of ignition cable and ground wire.
NOTE: If ground is poor or erratic, shutdowns can occur occasionally even though operation is nor al
at the ti e of checkout.
Check te perature at igniter-sensor insulator. High te peratures can cause a short.
Check that pilot fla e covers fla e rod and is steady and blue.
If checks are okay, replace odule.
Check for proper ther ostat (controller) operation.
Re ove MV lead at odule; if valve closes, recheck te perature controller and wiring; if not, replace
gas control.
Repeat procedure until troublefree operation is obtained.
START
Spark okay?
YES
YES
M2643B
Fig. 5. S8610U normal operating sequence.
69-0729—3 12

S8 610 U UNIVERSAL INTERM ITTEN T P H O T MODULE
OPERATION
Module operation can be conveniently divided into two
phases for the S8610:
• Trial for ignition.
• Main burner operation.
Fig. 5 su arizes the nor al odule operating se
quence.
TROUB ESHOOTING
IMPORTANT
1. The following service procedures are provided as
a general guide. Follow appliance manufacturer
service instructions if available.
2. Meter readings between gas control and ignition
module must be taken within the trial for ignition
period. Once the ignition module shuts off, wait
for retry or reset at the thermostat
3. If any component does not function properly,
make sure it is correctly installed and wired
before replacing it.
4. The ignition module cannot be repaired. If it
malfunctions, replace it
5. Only trained, experienced service technicians
should service intermittent pilot systems.
6. After servicing, verify proper system operation.
Perfor the checkout step in the Startup and Checkout
section as the first step in troubleshooting. Then check the
Troubleshooting Guide (Fig. 7) and the sche atic diagra
(Fig. 8) to deter ine the exact cause of the proble . If
troubleshooting indicates an ignition proble , see Ignition
Syste Checks section to isolate and correct the proble .
After troubleshooting, perfor the checkout procedures
again to be sure syste is operating nor ally.
Ignition System Checks
Step 1: Check ignition cable.
Make sure:
a. Ignition cable does not run in contact with any etal
surfaces.
b. Ignition cable is no ore than 36 in. (0.9 ) long.
c. Connections to the ignition odule and to the igniter
or igniter-sensor are clean and tight.
d. Ignition cable provides good electrical continuity.
Step 2: Check ignition system grounding. Nui
sance shutdowns are often caused by a poor or
erratic ground.
a. A co on ground, usually supplied by the pilot
burner bracket, is required for the odule and the
pilot burner/igniter-sensor.
• Check for good etal-to- etal contact between
the pilot burner bracket and the ain burner.
• Check the ground lead fro the GND (BURNER)
ter inal on the odule to the pilot burner. Make
sure connections are clean and tight. If the wire is
da aged or deteriorated, replace it with No. 14
through 18 gauge, oisture-resistant, ther o
plastic insulated wire with 105°C (221°F) ini
u rating.
— Check the cera ic fla e rod insulator for
cracks or evidence of exposure to extre e
heat, which can per it leakage to ground.
Replace pilot burner/igniter-sensor and
provide shield, if necessary.
— If fla e rod or bracket are 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.
a. Close the anual gas valve.
b. Disconnect the ignition cable at the SPARK ter inal
on the odule.
A WARNING
ELECTROCUTION HAZARD
CAN CAUSE SERIOUS INJURY
OR DEATH.
When perfor ing the following steps, do not touch
stripped end of ju per or SPARK ter inal. The
ignition circuit generates over 10,000 volts and
electrical shock can result.
c. Energize the odule and i ediately touch one
end of the ju per fir ly to the GND ter inal on the
odule. Move the free end of the ju per slowly
toward the SPARK ter inal until a spark is estab
lished.
d. Pull the ju per slowly away fro the ter inal and
note the length of the gap when sparking stops, check
as follows:
13 69-0729—3

S8 610U UNIVERSAL INTERM ITTEN T PILO T M ODULE
Step 4: Check pilot and main burner lightoff.
a. Set the ther ostat to call for heat.
b. Watch the pilot burner during the ignition sequence to
be sure:
• Ignition spark continues after the pilot is lit.
• Pilot lights and the spark stops, but the ain
burner does not light.
• Pilot lights, the spark stops and the ain burner
lights, but the syste shuts down.
c. If so, verify adequate fla e current as follows:
• Turn off the furnace at the circuit breaker or fuse
box.
• Clean the fla e rod with an e ery cloth.
• Make sure the electrical connections are clean and
tight. Replace the da aged wire with oisture-
resistant No. 18 wire rated for continuous duty up
to 105°C (221° F).
• Check for a cracked cera ic insulator, which can
cause short to ground, and replace the igniter
sensor or sensor, if necessary.
• At the gas control, disconnect the ain valve wire
fro the TH or MV ter inal.
• Turn on the power and set the ther ostat to call
for heat. The pilot should light but the ain burner
re ains off because the ain valve actuator is
disconnected.
• Check the pilot fla e. Make sure it is blue, steady
and envelops 3/8 to 1/2 in. (10 to 13 ) of the
fla e rod. See Fig. 6 for possible fla e proble s
and the causes.
• If necessary, adjust the pilot fla e by turning the
pilot adjust ent screw on the gas control
clockwise to decrease or counterclockwise to
increase the pilot fla e. Following adjust ent,
always replace the pilot adjust ent cover screw
and tighten fir ly to assure proper gas control
operation.
• Set the ther ostat below the roo te perature to
end the call for heat.
d. Recheck ignition sequence as follows:
• Reconnect the ain valve wire.
• Set the ther ostat to call for heat.
• Watch the ignition sequence at the burner.
• If spark continues after the pilot lights, replace the
ignition odule.
• If the ain burner does not light or if the ain
burner lights but the syste locks out, check the
odule, ground wire, and gas control, as de
scribed in the Troubleshooting Guide, see Fig. 7.
APPEARANCE CAUSE
SMALL BLUE FL
ii
AME CHECK FOR LACK OF GAS FROM:
• CLOGGED ORIFICE FILTER
• CLOGGED PILOT FILTER
• LOW GAS SUPPLY PRESSURE
• PILOT ADJUSTMENT AT MINIMUM
LAZY YELLOW FLAME
A
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
WAVING BLUE FLAME
A
CHECK FOR:
• EXCESSIVE DRAFT AT PILOT
LOCATION
• RECIRCULATING PRODUCTS
OF COMBUSTION
NOISY LIFTING BLOWING FLAME
&
CHECK FOR:
• HIGH GAS PRESSURE
HARD SHARP FLAME
(i
THIS FLAME IS CHARACTERISTIC
OF MANUFACTURED GAS
CHECK FOR:
• HIGH GAS PRESSURE
• ORIFICE TOO SMALL
M2233A
Fig. 6. Examples of unsatisfactory pilot flames.
69-0729—3 14

S8 610 U UNIVERSAL INTERM ITTEN T PILO T MODULE
I
TURN OFF GAS SUPPLY.
TURN THERMOSTAT
(CONTROLLER) TO CALL
FOR HEAT.
POWER TO MODULE.
(24V NOMINAL)
CHECK AT TH-W TERMINAL,
AND ALSO AT 24V TERMINAL
IF A VENT DAMPER IS
CONNECTED TO THE
DAMPER CONNECTOR.
YES ^
SPARK ACROSS
IGNITER/SENSOR GAP?
YES
'
TURN ON GAS SUPPLY.
PILOT BURNER LIGHTS?
YES
SPARK STOPS WHEN
PILOT IS LIT?
YES
MAIN BURNER LIGHTS?
YES
SYSTEM RUNS UNTIL
CALL FOR HEAT ENDS?
YES
r
CALL FOR HEAT ENDS.
SYSTEM SHUTS OFF?
TROUBLESHOOTING
ENDS.
NOTE: Before troubleshooting, fa iliarize yourself with the startup and checkout procedure.
Check line voltage power, low voltage transfor er, li it controller, ther ostat (controller) and wiring. Also,
check air proving switch on co bustion air blower syste (if used) and verify that vent da per (if used) is open
and end switch is ade.
Pull ignition lead and
check spark at odule. On odels with vent da per plug, ake sure vent da per
was not installed, then re oved. Replace vent da per,
if necessary.
On other odels, replace odule.
Check ignition cable, ground wiring, cera ic insulator and gap, and correct.
Check boot of the ignition cable for signs of elting or buckling. Replace cable and take protective action
to shield cable and boot fro excessive te peratures.
Check that all anual gas valves are open, supply tubing and pressures are good, and pilot burner orifice
is not blocked.
Check electrical connections between odule and pilot operator on gas control.
Check for 24 Vac across PV-MV/PV ter inals on odule. If voltage is okay, replace gas control; if not,
replace odule
Check continuity of ignition cable and ground wire.
Clean fla e rod.
Check electrical connections between fla e rod and odule.
Check for cracked cera ic fla e rod insulator.
Check that pilot fla e covers fla e rod and is steady and blue.
Adjust pilot fla e.
If proble persists, replace odule.
Check for 24 Vac across MV-MV/PV ter inals. If no voltage, replace odule.
Check electrical connections between odule and gas control. If okay, replace gas control or gas
control operator.
Check continuity of ignition cable and ground wire.
NOTE: If ground is poor or erratic, shutdowns can occur occasionally even though operation is nor al
at the ti e of checkout.
Check te perature at igniter-sensor insulator. High te peratures can cause a short.
Check that pilot fla e covers fla e rod and is steady and blue.
If checks are okay, replace odule.
Check for proper ther ostat (controller) operation.
Re ove MV lead at odule; if valve closes, recheck te perature controller and wiring; if not, replace
gas control.
Repeat procedure until troublefree operation is obtained.
START
Spark okay?
YES
YES
M2643B
Fig. 7. S8610U Troubleshooting Guide.
15 69-0729—3

S8 610U UNIVERSAL INTERM ITTEN T P H O T MODULE
ALTERNATE LIMIT CONTROLLER LOCATION.
3 AMP NONREPLACEABLE FUSE. FUSE BLOWS WHEN VENT DAMPER IS PLUGGED IN AND POWER IS APPLIED.
SEPARATE SENSOR IS USED ON TWO-ROD SYSTEMS ONLY. DISCONNECT BLACK JUMPER WIRE FROM SENSE
TERMINAL, CUT AT CIRCUIT BOARD AND DISCARD.
INTERNAL WIRING
EXTERNAL WIRING
SINGLE ROD SYSTEM HAS IGNITER-SENSOR.
L1
M2646B
Fig. 8. Schematic for S8610U.
69-0729—3 16

S8 610 U UNIVERSAL INTERM ITTEN T PILO T MODULE
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 deter ining 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 at ospheric gas burner(s) and
not of the direct vent type. It should be recognized that generalized test procedures cannot anticipate all situations.
Accordingly, in so e cases, deviation fro this procedure ay be necessary to deter ine safe operation of the
equip ent.
a. This procedure should be perfor ed prior to any atte pt at odification of the appliance or the installation.
b. If it is deter ined 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 aking the safety inspection:
O Conduct a Gas Leakage Test of the appliance piping and control syste downstrea of the shutoff valve in the
supply line to the appliance.
0 Visually inspect the venting syste for proper size and horizontal pitch and deter ine there is no blockage or
restrictions, leakage or corrosion or other deficiencies that could cause an unsafe condition.
e Shut off all gas to the appliance and shut off any other fuel-burning appliance within the sa e roo . Use the
shutoff valve in the shutoff valve in the supply line to each appliance.
Q Inspect burners and crossovers for blockage and corrosion.
0 Applicable only to war air heating appliances. Inspect heat exchangers for cracks, openings or excessive
corrosion.
0 Applicable only to boilers. Inspect for evidence of water or co bustion product leaks.
0 Insofar as is practical, close all building doors and windows 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 bathroo exhausts, so they will operate at axi u speed. Do not operate a su er exhaust fan.
Close fireplace da pers. If, after co pleting steps 7 through 12, it is believed sufficient co bustion air is not
available, refer to 1.3.4 of the National Fuel Gas Code (Z223.1) for guidance.
0 Place in operation the appliance being inspected. Follow the lighting instructions. Adjust ther ostat so appliance
will operate continuously.
O a. Deter ine that the pilot is burning properly and that ain burner ignition is satisfactory by interrupting and re
establishing the electrical supply to the appliance in any convenient anner.
b. Deter ine anifold pressure in order to atch input after the new control is installed.
0 a. Visually deter ine that ain burner gas is burning properly; i.e., no floating, lifting or flashback. Adjust the
pri ary air shutter(s) as required.
b. If appliance is equipped with high and low fla e control or fla e odulation, check for proper ain burner
operation at low fla e.
© Test for spillage at the draft hood relief opening after five inutes of ain burner operation. Use a draft gauge, the
fla e of a atch or candle, or s oke fro a cigarette, cigar or pipe.
0 Return doors, windows, exhaust fans, fireplace da pers and all other fuel-burning appliances to their previous
conditions of use.
0 Applicable only to war air heating appliances. Check both li it controller and fan controller for proper operation.
Li it controller operation can be checked by te porarily disconnecting the electrical supply to the blower otor
and deter ining that the li it control acts to shut off the ain burner gas.
0 Applicable only to boilers:
a. Deter ine that the circulating water pu ps are in operating condition.
b. Test low water cutoffs, auto atic feed controls, pressure and te perature li it controls and relief valves in
accordance with the anufacturer's re-co endations and instructions to deter ine they are in operating
condition.
EXHIBIT A OF ANSI STANDARD Z21.71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD INSTALLATION.
17 69-0729—3

S8 610U UNIVERSAL INTERM ITTEN T PILO T M ODULE
Exhibit B
Procedure for Installing Automatic Intermittent Pilot Systems
Prior to beginning this procedure, a preli inary exa ination of the appliance and the auto atic inter ittent pilot syste
should be ade to deter ine that the auto atic inter ittent pilot syste can be properly applied to the appliance.
This procedure is intended as a guide to aid in safely installing a listed auto atic inter ittent pilot syste on an existing
listed appliance equipped with an at ospheric gas burner(s) and not of the direct vent type.
This procedure is based on the assu ption that the history of the specific installation has been one of safe and satisfac
tory 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 so e cases, deviation fro this procedure ay be necessary
to deter ine safe operation of the equip ent.
The following steps should be followed in aking the odifications:
O Perfor a safety inspection of the existing appliance installation. See Exhibit A for a reco ended procedure for
such a safety inspection.
0 Shut off all gas and electricity to the appliance. To shut off gas, use the shutoff valve in the supply line to the
appliance. Do not use the shut-off valve which is provided as part of a co bination control.
e Install the auto atic inter ittent pilot syste in strict accordance with the anufacturer's installation instructions.
Q Turn on all gas and electricity to the appliance.
0 Deter ine that the appliance transfor er has adequate capacity by following the steps outlined below:
a. Co pute the approxi ate current draw by adding the current draw of the auto atic inter it-tent pilot
syste to (1) the current draw of the associated valving, and (2) the current draw of any relays or other
devices operated by the transfor er.
b. Multiply the total current draw as co puted above by 24V to deter ine the total volt-a pere (VA) required.
c. The total VA required should be equal to or less than the VA rating of the transfor er.
d. If the total VA required is greater than the VA rating of the transfor er, the transfor er ust be replaced
with a Class 2 transfor er of adequate rating.
0 Check the heat anticipator in the co fort ther ostat to deter ine if it is properly adjusted to the current draw of
the control syste . Follow the ther ostat anufacturer's instructions.
0 Make certain wiring connections are tight and wires are positioned and secured so they will not be able to contact
high te perature locations.
0 Conduct a Gas Leakage Test of the appliance piping and control syste downstrea of the shutoff valve in the
supply line to the appliance.
0 a. Adjust the ther ostat to its highest te perature setting, and test anifold pressure and adjust the pressure
regulator to atch original input as required (refer to Exhibit A, step 9b).
b. Visually deter ine that ain burner is burning properly; i.e., no floating, lifting or flashback. Adjust the pri ary
air shutter(s) as required.
© If the appliance is equipped with high and low fla e control or fla e odulation, check for proper ain burner
operation at both high and low fla e.
© Deter ine that the pilot is igniting and burning properly and that ain burner ignition is satisfactory by interrupting
and reestablishing the electrical supply to the appliance in any convenient anner. Make this deter ination with
the appliance burner both cold and hot. Perfor this step as any ti es as is necessary to satisfy yourself that
the auto atic inter ittent pilot syste is operating properly.
0 Test the pilot safety device (1) to deter ine if it is operating properly, and (2) for turndown characteristics accord
ing to the anufacturer's installation instructions. No adjust ents should be ade other than those reco ended
by the syste anufacturer.
0 Sequence the appliance through at least three operating cycles.
0 Applicable only to furnaces. Check both the li it controller and the fan controller for proper operation. Li it control
operation can be checked by blocking the circulating air inlet or te porarily disconnecting the electrical supply to
the blower otor and deter ining that the li it controller acts to shut off the ain burner gas.
0 Applicable only to boilers:
a. Deter ine that the circulating water pu ps are in operating condition.
b. Test low water cutoffs, auto atic feed water controls, pressure and te perature li it controllers and relief
valves in accordance with the anufacturer's reco endation to deter ine 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.
69-0729—3 18

19 69-0729—3

Honeywell
Home and Building Con rol
Honeywell In erna ional, Inc.
1985 Douglas Drive Nor h
Golden Valley, MN 55422
Home and Building Con rol
Honeywell Limi ed-Honeywell Limi ée
35 Dynamic Drive S T \ Printed in U SA. on recycled
, , _ , . paper containing at least 10%
Scarborough, On ario post-consu er paper fibers.
M1V 4Z9
69-0729—3 J.S. Rev. 8-96