68-0135 - S8610U Universal Intermittent Pilot Modulesame as those of standard models except as...

PRODUCT DATA

® U.S. Registered TrademarkCopyright © 1996 Honeywell Inc. • All Rights Reserved 68-0135-2

S8610UUniversal Intermittent Pilot Module

APPLICATIONThe S8610U Universal Replacement Ignition Module isdesigned to provide easy field replacement of a wide range ofintermittent pilot ignition modules manufactured byHoneywell, Robertshaw, Johnson and others. The S8610UModule provides ignition sequence, flame monitoring, andsafety shutoff for intermittent pilot central furnaces, residentialboilers, and other heating appliances.

FEATURES• Provides up to 1.0A pilot and 2.0A main valve current

rating.

• System uses rectification principle for flame sensing.

• For use with separate igniter and sensor orcombination igniter-sensor. Q345, Q348, Q362, Q373or Q381 Igniter-sensor recommended as combinationigniter-sensor; Q179C with igniter and sensormounted on one bracket, or Q354 Sensor with Q345,Q348, Q362, Q373 or Q381 Igniter-sensorrecommended as separate igniter and sensor.

• Q3450/Q3480 Hot Surface Pilot hardware plugsdirectly into system control.

• Can be used on natural or LP gas; provides 100percent shutoff on ignition failure. Waits six minutesnominal following shutoff, then reinitiates the pilotignition sequence. The ignition trial-shutoff-wait cyclerepeats until the pilot lights or the call for heat ends.

• Replaces numerous Honeywell and competitormodules.

• Capacitive discharge spark output.

• Temperature rating is -40°F to 175°F (-40°C to 79°C)when used with 1.0A or less main valve; -40°F to 165°F(-40°C to 74°C) when used with 1.0 to 2.0A main valve.

Contents

Application........................................................................... 1Features .............................................................................. 1Specifications ...................................................................... 2Ordering Information ........................................................... 2Planning the Installation ...................................................... 4Installation ........................................................................... 6Startup and Checkout ......................................................... 15Maintenance........................................................................ 15Operation ............................................................................ 16Troubleshooting .................................................................. 17ANSI Standards .................................................................. 21

S8610U UNIVERSAL INTERMITTENT PILOT MODULE

68-0135—2 2

ORDERING INFORMATION

When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to theTRADELINE® Catalog or price sheets for complete ordering number, or specify:1. SUPER TRADELINE® order number.

If you have additional questions, need further information, or would like to comment on our products or services, please write orphone:1. Your local Home and Building Control Sales Office (check white pages of your phone directory).2. Home and Building Control Customer Logistics

Honeywell Inc., 1885 Douglas Drive NorthMinneapolis, Minnesota 55422-4386

In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9.International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France,Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.

SPECIFICATIONSIMPORTANT

The specifications given in this publication do notinclude normal manufacturing tolerances. Therefore,units may not exactly match the listed specificationsAlso, units are tested and calibrated under closelycontrolled conditions, and some minor differences inperformance can be expected if those conditions arechanged.

SUPER TRADELINE® ModelsSUPER TRADELINE® models are selected and packaged forease of handling, ease of stocking, and maximum replacementvalue. SUPER TRADELINE® model specifications are thesame as those of standard models except as noted.

SUPER TRADELINE® Model Available:S8610U Universal Intermittent Pilot Module.

Electrical Ratings:Voltage: 24V, 60 Hz.Current Draw: 1A pilot valve, 2A main valve.Valve Contact Rating: 0.2A.

Trial for Ignition:90 seconds maximum, then 100% shutoff (pilot and maingas).

Continuous Retry:Five-minute minimum (six-minute nominal) delay if pilot failsto light during trial for ignition. After delay, trial for ignition isrepeated. This sequence (trial, delay, trial, delay) continuesuntil pilot lights or call for heat ends.

Spark Generator Output:13 kV peak at 25 pF load.

Thermostat Anticipator Setting:0.2A plus pilot valve rating plus main valve rating.

Ambient Temperature Rating:-40°F to +175°F (-40°C to +79°C) with main valve rated

1.0A or less.-40°F to +165°F (-40°C to +74°C) with main valve rated

1.0A to 2.0A.

Relative Humidity Rating:5 to 90% RH at 95°F.

Flame Failure Response Time:0.8 sec at 1.0 mA flame current.

Terminals:SENSE: 3/16 in. male quick connect.All Other Terminals Including Ignition: 1/4 in. male quick

connects. Molex plug for connection to HoneywellD80D or D892 Vent Damper.

Flame Current:1 uA minimum.

Mounting:Mounts in any position except with terminals up. However,recommended mounting position is with terminals down toprovide maximum protection from dripping water or dustaccumulation. Fasten with no. 6-32 machine or no. 8sheetmetal screws of appropriate length. See Fig. 1.

Underwriters Laboratories Inc. Component Recognized:File no. MH15564, Guide no. MCCZ2.

IAS Design Certified: C2030011.

Other System ComponentsThese modules provide operating control of an intermittentpilot system. Additional components required to complete thesystem must be ordered separately:• Dual valve combination gas control designed for

intermittent pilot.• Combination pilot burner/igniter-sensor or separate igniter

and sensor on pilot burner bracket.• Ignition cable.• Transformer.• 24V thermostat.• High limit and other auxiliary controls, as required.

Dual Valve Combination Gas Control:Any that meet current ratings listed below. VR8204,

VR8440 or VR8520 are recommended.S8610U: 1.0A pilot, 2.0A main valve.

Pilot Burner/Igniter-Sensor:See Table 1.


68-0135—23

2 (51)

M1123A

3-3/16(81)

2-5/8 (67)1/4(6)

3-15/16(100)

3-3/8(86)

1-1/32(26)

5-7/16 (138)

3-3/8 (86) (2)3/16(5)

(2)

3/16(5)

(2)

Fig. 1. Approximate ignition module dimensions in in. (mm).

Table 1. Pilot Burner/Igniter-Sensors.

Ignition Cable:Use Honeywell preassembled cable, see Table 2, orassemble locally. Use the cable recommended in Table 3 (orequivalent), insulated female 1/4 in. quick connect andinsulated Rajah connector receptacle. Maximumrecommended length is 36 in. (914 mm).

Table 2. Honeywell Preassembled Ignition Cables(UL Style 3257).

Cable Part Module

Number Length End Igniter End

394800-30 30 in. 1/4 in. quickconnect,insulated

Rajah connectorreceptacle, 90degree rubberboot

394801-30 30 in. 1/4 in. quickconnect,insulated

Rajah connectorreceptacle, straightrubber boot

Table 3. Recommended Ignition Cable for Field Assembly.

Voltage Temperature Rating

Cable Type Rating (rms) °C °F

UL Style 3217 10,000 150 302

UL Style 3257 10,000 250 484

Transformer:Add current ratings of module, pilot valve, main valve, ventdamper and any other components of the control system todetermine transformer-size requirement. Use a 30 VA orlarger transformer if a vent damper will be connected to theS8610U Vent Damper Connector.

Thermostat:Use open-close switch type, or independently-poweredelectronic, 24V thermostat capable of switching rated controlsystem load. Before using electronic thermostat poweredthrough the heating/cooling controls, consult thermostatmanufacturer to assure proper control system operation.

High Limit and Other Auxiliary Controls:As specified by the heating appliance manufacturer.

Ignition Modules Replaced

WARNINGCheck Table 4 before replacing an existing intermittentpilot module with the S8610U. If the existing module isnot listed, do not use the S8610U to replace it unlessyou are certain the specifications of the S8610Umatch those of the existing module.

Pilot Burner/ Flow Rate*Igniter-Sensor cfh m3/hr

Combined Q345 0.8 0.02

Q348 1.5 0.04

Q362 0.5 0.014

Q373 0.8 0.02

Q381 0.5 0.014

Separate Q179C 1.8 0.05

Q354 with Q345, Q348, Q362 or Q381.

*With natural gas at 7.0 in. wc (1.7 kPa).


68-0135—2 4

The S8610U replaces existing flame rectification typeintermittent pilot ignition modules with the followingcharacteristics:• Single rod (local sense) or two rod (remote sense) flame

sensing.• Non-100 percent shutoff, 100 percent shutoff/lockout, or

100 percent shutoff/continuous retry.• Natural or LP gas.• Shutoff/lockout times of 30 seconds or longer.• Prepurge times of four seconds or shorter.• Pilot burners with flow rates of 1500 Btuh or less.• With or without vent dampers.

A complete list of the specific Honeywell and other modulesthat the SUPER TRADELINE® S8610U is designed toreplace is provided in Table 4.

The S8610U SUPER TRADELINE® package containscomplete, easy-to-use instructions, plus the accessoriesrequired to adapt the existing spark cable (Rajah, stud, nail,or other) to the spark terminal on the S8610U. It also provideslabels to help assure proper marking of the wires attached tothe existing module.

The S8610U SUPER TRADELINE® Universal Module is notdesigned to replace controls with the following characteristics:• Flame sensing other than by flame rectification (White

Rodgers Cycle-Pilot®, Robertshaw thermal sensing).• Flame rectification modules with shutoff/lockout times of

less than 30 seconds, prepurge times of more than fourseconds, or pilot burners larger than 1500 Btuh.

• Standing pilot appliances.

Honeywell provides additional control packages toaccomplish these replacements. See the HoneywellElectronic Ignition Service Manual, form 70-6604, or call yourHoneywell wholesaler.

PLANNING THE INSTALLATIONWARNINGFIRE OR EXPLOSION HAZARDCAN CAUSE PROPERTY DAMAGE, SEVEREINJURY OR DEATH.Follow these warnings exactly:1. Plan the installation as outlined below.2. Plan for frequent maintenance as described in

the Maintenance section.

When intermittent pilot systems are used on central heatingequipment in barns, greenhouses, and commercial propertiesand on heating appliances such as commercial cookers,agricultural equipment, industrial heating equipment and poolheaters, heavy demands are made on the controls. Specialsteps may be required to prevent nuisance shutdowns andcontrol failure due to frequent cycling, severe environmentalconditions related to moisture, corrosive chemicals, dust orexcessive heat. These applications require Honeywell Homeand Building Control Engineering review; contact yourHoneywell Sales Representative for assistance.

Review the following conditions that could apply to yourspecific installation and take the precautionary stepssuggested.

Frequent CyclingThese controls are designed for use on appliances thattypically cycle three to four times an hour only during theheating season only. In year-round applications with greatercycling rates, the control can wear out more quickly. Performa monthly checkout.

Water Or Steam CleaningIf a module or gas control gets wet, replace it. If the applianceis likely to be cleaned with water or steam, protect (cover) thecontrols and wiring from water or steam flow. Mount thecontrols high enough above the bottom of the cabinet so theydo not get wet during normal cleaning procedures. Use aNEMA 4 enclosure for the ignition module; see the ElectronicIgnition Service Manual, form 70-6604.

High Humidity or Dripping WaterDripping water can cause the module to fail. Never install anappliance where water can drip on the controls.In addition, high ambient humidity can cause the gas controlto corrode and fail.

If the appliance is in a humid atmosphere, make sure aircirculation around the controls is adequate to preventcondensation. Also, regularly check out the system. A NEMA4 enclosure is recommended for the ignition module; see theElectronic Ignition Service Manual, form 70-6604.

Corrosive ChemicalsCorrosive chemicals can attack the module and gas control,eventually causing a failure. If chemicals are used for routinecleaning, make sure they cannot reach the controls. Wherechemicals are suspended in air, as in some industrial oragricultural applications, use a NEMA 4 enclosure for theignition module; see the Electronic Ignition Service Manual,form 70-6604.

Dust or Grease AccumulationHeavy accumulations of dust or grease can cause controls tomalfunction. Where dust or grease can be a problem, providecovers for the module and the gas control to limitcontamination. A NEMA 4 enclosure is recommended for theignition module; see the Electronic Ignition Service Manual,form 70-6604.

HeatExcessively high temperatures can damage controls. Makesure the maximum ambient temperature at the control doesnot exceed the rating of the control. If the appliance operatesat very high temperatures, use insulation, shielding, and aircirculation, as necessary, to protect the controls. Properinsulation or shielding should be provided by the appliancemanufacturer; verify that proper air circulation is maintainedwhen the appliance is installed.


68-0135—25

Table 4. S8610U Replaces these Ignition Modules.

CAMSTATIPI-24-00

FENWAL05-203025-00505-203026-005

S86H1089S86H1097S86H1105S86H1121S86H1147S90A100

CSA42A-604RCSA43A-600RCSA44A-600RCSA45A-601RCSA45A-602RCSA46A-600R

G60PAG-6G60PAJ-1G60PAK-1G60PAK-2G60PFH-1G60PFH-2

G60RCG-2G60RCJ-1G60RDG-1G60RDK-1G60RGL-1G60RHL-1

G67AG-7G67AG-8G67BG-2G67BG-3G67BG-4G67BG-5

HONEYWELLS86A1001S86A1019S86A1027S86A1035

S90B1003S90B1011S8600A1001S8600B1009S8600C1015S8600F1000

CSA48A-600RCSA49A-600RCSA49A-605RCSA51A-601RCSA52A-600RG60AAA-1

G60PFL-1G60PFQ-1G60PVL-1G60QAG-2G60QAG-3G60QAK-1

G60RHP-1G60RPL-1G60RSL-1G60ZAG-1G65BBG-1G65BBG-2

G67MG-1G67MG-4G67NG-2G600AX-1G600AY-1G600MX-1

S86B1009S86B1017S86B1025S86C1007S86C1015S86C1031

S8600F1034S8600F1042S8600H1006S8600H1022S8600H1048S8600H1055

G60AAG-1G60AAG-3G60AAG-4G60AAG-5G60AAG-6G60CAA-1

G60QBG-1G60QBG-2G60QBG-3G60QBG-4G60QBG-5G60QBG-6

G65BBG-3G65BBG-4G65BBG-5G65BBG-6G65BBG-7G65BBG-8

G600NX-1G600RX-1G670AW-1G770MGA-1G770MGA-2G770MGC-1

S86C1049S86C1056S86D1005S86D1021S86E1002S86E1010

S8600H1089S8600H1105S8600M1005S8600M1013S8610A1009S8610B1007

G60CAA-3G60CAG-1G60CAG-2G60CAG-3G60CAG-4G60CAG-5

G60QBG-7G60QBG-8G60QBG-9G60QBH-1G60QBK-1G60QBK-3

G65BBM-1G65BBM-2G65BBM-3G65BBM-4G65BCG-1G65BCM-1

G770MGC-2G770MGC-3G770MHA-1G770NGA-1G770NGC-4G770NGC-5

S86E1028S86E1036S86E1044S86E1051S86E1069S86E1077

S8610B1015S8610C1005S8610F1008S8610F1016S8610F1024S8610F1032

G60CAG-6G60CAG-7G60CAG-8G60CAG-9G60CBA-1G60CBA-3

G60QBL-1G60QBL-2G60QCG-1G60QCJ-1G60QCL-1G60QDG-1

G65BFG-1G65BFMG65BKG-1G65BKG-2G65BKG-3G65BKM-1

G770NGC-6G770NGC-7G770RGA-1G770RHA-1G770MHA-2G770MHC-1

S86E1101S86E1119S86E1127S86F1000S86F1018S86F1026

S8610H1012S8610H1038S8610H1046S8610H1053S8610H1079S8610M1003

G60CBG-1G60CBG-10G60CBG-11G60CBG-14G60CBG-16G60CBG-17

G60QFL-1G60QHL-1G60QJL-1G60QLG-1G60QPL-1G60QRH-1

G65BKM-2G65BKM-3G65DBGG65DBM-1G65DBM-3G65DCM-1

G770NHA-1G770NHC-1G770RHA-2

S86F1042S86F1059S86F1067S86F1075S86F1083S86F1091S86G1008

S8610M1029S8620H1028

HSC1003-31003-300

G60CBG-3G60CBG-4G60CBG-9G60CCA-1G60CCG-1G60CPG-1G60DBG-1

G60QRL-1G60QRL-2G60QRL-3G60QSL-1G60QTH-1G60QTL-1G60RAG-1

G65DFGG65DFM-1G65DKGG65DKMG65FBGG65FFGG65FKG

ROBERTSHAW780-715780-735780-737SP715SP715ASP735

S86G1016S86G1032S86G1057S86G1073S86H1006S86H1022S86H1048

PENN-JOHNSONCSA35A-617RCSA35A-618RCSA42A-600RCSA42A-601RCSA42A-603R

G60DCG-1G60DCG-2G60PAG-1G60PAG-2G60PAG-3G60PAG-4G60PAG-5

G60RAK-1G60RBG-1G60RBG-2G60RBG-3G60RBK-1G60RBK-2

G66AG-1G66BG-1G66MG-1G66NG-1G67AG-3G67AG-4

SP735DSP735LUSI 715U


68-0135—2 6

INSTALLATION1. Read these instructions carefully. Failure to follow them

could damage the components or cause a hazardouscondition.

2. Check the ratings given in the instructions and on thecomponents to make sure they are suitable for yourapplication.

3. Installer must be a trained, experienced servicetechnician.

4. After installation is complete, check out componentoperation as provided in these instructions.

WARNINGFIRE OR EXPLOSION HAZARD CAN CAUSEPROPERTY DAMAGE, SEVERE INJURY, ORDEATH.1. If it gets wet, the ignition module can malfunction,

leading to accumulation of explosive gas.• Never install where water can flood, drip or

condense on the module.• Never use a module that has been wet.

Replace it.2. Liquefied petroleum (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 aresure the appliance area is free of gas.

3. Do not attempt to disassemble or clean themodule. Improper reassembly and cleaning cancause unreliable operation.

CAUTION1. Disconnect the power supply before beginning

the wiring to prevent electrical shock orequipment damage.

2. If a new gas control is to be installed, turn off thegas supply before starting the installation.Conduct a Gas Leak Test according to the gascontrol manufacturer instructions after the gascontrol is installed.

3. If the module must be mounted near moisture orwater, provide a suitable waterproof enclosure.

4. Using the wire labels provided, label all wiresbefore they are disconnected. Wiring errors cancause improper appliance operation anddangerous conditions such as bypassing safetyfeatures.

Perform Preinstallation Safety InspectionThe preinstallation checks described in ANSI StandardZ21.71 in Exhibit A must be done before the replacementmodule is installed. If a condition is detected that could resultin unsafe operation, the appliance should be shut off and theowner advised of the unsafe condition. Correct any potentiallyunsafe condition before proceeding with the installation.

Remove Old ModuleDisconnect power supply before doing any work on the unit.Disconnect and tag the wires from the old module using thewire labels provided. Remove the old module from itsmounting location.

Mount New Ignition ModuleWe recommend mounting the S8610U Module in the samelocation as the old module, if possible. Otherwise, select alocation close enough to the burner to allow a short (3 ft(0.9m) maximum) direct cable route to the igniter. Ambienttemperature at the module must be within the range listed inthe Specifications section.

Mount the module with the terminals pointing down to protectthem from dripping water and dust. The module can also bemounted with the terminals on either side. Do not mount withterminals pointing up. Refer to Fig. 2 for mountingrecommendations. When it is necessary to drill new mountingholes, use the S8610U as a template to mark the mountinghole pattern. Drill new holes as required. Fasten securely withfour no. 6-32 machine or no. 8 sheetmetal screws.

Wire the Module

CAUTION1. Check the wiring diagram furnished by the

appliance manufacturer, if available, andcompare with Tables 5 through 8. Carefully followany special instructions affecting the generalprocedures outlined below.

2. Disconnect the power supply before makingwiring connections to prevent electrical shock orequipment damage.

IMPORTANT1. A common ground is required on:

a. The pilot burner mounting bracket, andb. The GND (BURNER) terminal on the ignition

module. Failure to use the GND (BURNER)terminal can result in intermittent loss of sparkand/or loss of flame current sensitivity.

2. Make sure the transformer has adequate VA. Theignition module requires at least 0.2A at 24 Vac. Addthe current draws of all other devices in the controlcircuit, including the pilot and main valves in the gascontrol, and multiply by 24 to determine the total VArequirement of these components. Add this total to4.8 VA (for the ignition module). The result is theminimum transformer VA rating. Use a Class IItransformer when replacement is required.

3. When a vent damper is connected to the S8610Uvent damper connector, be sure the systemtransformer delivers at least 30 VA. The S8610U hasan internal fuse that is intended to prevent appliancelightoff if the vent damper is not in place or wiredproperly. Using a small transformer can interfere withthe proper operation of the fuse and bypass theintended safety feature.

� Connect the wires to the S8610U Ignition Module asshown in Tables 5 through 8. Make sure that adequatesystem ground is provided as indicated in the wiringtables.

� Verify the thermostat anticipator setting as explained inthe IMPORTANT above.


68-0135—27

Fig. 2. Module mounting recommendations.

TERMINALS FACING DOWN

TERMINALS FACING LEFT TERMINALS FACING RIGHT

MOUNT IN ONE OF THESE POSITIONS

DO NOT MOUNT WITH TERMINALS FACING UP

M2647

NOTE: The wiring diagrams in Fig. 5 through 8 show typicalhookups for the S8610U Ignition Module and shouldbe used for reference only.

Modify Ignition Cable, If NecessaryUse existing ignition cable if it is in good condition. If theexisting ignition cable does not have a 1/4 in. quick-connecton the module end, either use the Rajah adapter or strip thewire and replace with the 1/4 in. insulated quick-connectsupplied. If the cable must be replaced, order a Honeywellignition cable, see Table 2. It may be necessary to replace theconnector at the pilot burner end to match the pilot burnerspark termination.

NOTE: When using an S8610U to replace an S86, use theenclosed adapter to convert the S86 Ignition Cableto an S8610U Ignition Cable. Then, install theadapter and cable to the S8610U Ignition Module.

NOTE: The cable must not run in continuous contact with ametal surface or spark voltage is greatly reduced.Use ceramic or plastic standoff insulators asrequired.


68-0135—2 8

Tab

le 5

. Co

nver

sio

n f

rom

Ho

ney

wel

l S86

, S90

, S86

00 a

nd

S86

10 t

o S

8610

U10

03.

Rep

lace

men

tC

on

tro

lO

ld C

on

tro

l

Ter

min

al F

un

ctio

nS

8610

U10

03S

86A

,CS

86B

,DS

86E

,F,G

,H

S86

00A

,B,C

S86

10A

,B,C

S90

A,B

S86

00F

,H,M

S86

10F

,H,M

Pro

ced

ura

l No

tes

Mai

n va

lve

oper

ator

MV

MV

MV

MV

MV

MV

Mai

n va

lve

and

pilo

tco

mm

onM

V/P

VM

V/P

VM

V/P

VM

V/P

VM

V/P

VM

V/P

V

Pilo

t val

ve o

pera

tor

PV

PV

PV

PV

PV

PV

Bur

ner

grou

ndco

nnec

tion

GN

D(B

UR

NE

R)

GN

D

GN

D

GN

D(B

UR

NE

R)

GN

D(B

UR

NE

R)

GN

D(B

UR

NE

R)

Tra

nsfo

rmer

seco

ndar

y(u

nsw

itche

d le

g)

24V

GN

D25

V (

1)25

V (

GN

D)

25V

(1)

e24

V G

ND

24V

GN

D

Tra

nsfo

rmer

seco

ndar

y

(sw

itche

d le

g)

24V

*25

V (

2)25

V25

V (

2)e*

24V

*24

V*

*Im

po

rtan

t: If

the

old

mod

ule

had

a ve

nt d

ampe

rpl

ug b

ut a

ven

t dam

per

was

not

inst

alle

d, o

r if

itdi

d no

t hav

e a

vent

dam

per

plug

: lea

ve th

e ve

ntda

mpe

r pl

ug in

pos

ition

on

the

S86

10 a

ndco

nnec

t the

25V

(2)

or

24V

wire

from

the

old

mod

ule

to th

e T

H-W

term

inal

on

the

S86

10U

.D

o n

ot

use

th

e 24

V t

erm

inal

on

th

e S

8610

U.

25V

(2)

or

24V

use

d on

ly in

sys

tem

s w

here

plug

-in c

able

con

nect

s da

mpe

r to

mod

ule.

If th

e ol

d m

odul

e ha

d a

vent

dam

per

with

a p

lug

con

ne

ctio

n

to

a

Mo

lex

con

ne

cto

r,

wir

e

the

term

inal

s as

indi

cate

d in

the

tabl

e.

TH

-WT

H-R

aT

H-R

aT

H-R

aT

H-W

(Thi

s te

rmin

alno

t inc

lude

don

S90

.)

TH

-W

TH

-Wb

TH

-WT

H-W

b

Fla

me

sens

orS

EN

SE

fd

dd

SE

NS

Ef

d

Igni

ter/

sens

orS

PA

RK

IGN

CO

ILc

IGN

CO

ILc

IGN

CO

ILc

S

PA

RK

SP

AR

Ka

If 25

V (

2) a

nd T

H-R

hav

e w

ires

conn

ecte

d, d

isco

nnec

t and

spl

ice

toge

ther

with

sol

derle

ss c

onne

ctor

.b

If T

H-R

and

TH

-W a

re ju

mpe

red

toge

ther

, con

nect

25V

(2)

lead

from

S86

to T

H-W

on

S86

10U

1003

.c

Use

Raj

ah to

qui

ck c

onne

ctor

ada

pter

(su

pplie

d) o

r cu

t Raj

ah c

onne

ctor

off

igni

tion

cabl

e at

mod

ule

end;

atta

ch in

sula

ted

quic

k co

nnec

t for

con

nect

ion

to S

8610

.d

Leav

e bl

ack

jum

per

conn

ecte

d.e

Ter

min

als

may

be

mar

ked

25V

on

som

e m

odel

s an

d 24

V o

n la

ter

mod

els.

The

se a

re fu

nctio

nally

equ

ival

ent.

fO

n du

al ig

nite

r an

d se

nsor

mod

els,

rem

ove

jum

per

quic

k co

nnec

t fro

m S

8610

U10

03 S

ense

term

inal

, cut

jum

per

wire

at c

ircui

t boa

rd, a

nd d

isca

rd.


68-0135—29

Tab

le 6

. Co

nver

sio

n f

rom

Ro

ber

tsh

aw S

P71

5 an

d S

P73

5 to

S86

10U

1003

(in

c lu

des

780

-XX

X a

nd

US

1715

U).

Rep

lace

men

tC

on

tro

lO

ld C

on

tro

l SP

715

and

SP

735

(in

clu

des

780

-XX

X a

nd

US

I 715

U)c

,d

Ter

min

al F

un

ctio

nH

on

eyw

ell

S86

10U

1003

7000

D V

alve

7100

D V

alve

7100

K V

alve

Pro

ced

ura

l No

tes

Mai

n va

lve

oper

ator

MV

MV

(to

: Val

ve T

H)

MV

(to

: Val

ve M

)M

V (

to: V

alve

TR

)—

Mai

n va

lve

and

pilo

t com

mon

M

V/P

VM

V/P

V (

to: V

alve

TR

)M

V/P

V (

to: V

alve

C)

P

V (

to: V

alve

C a

nd T

H)

—

Pilo

t val

ve o

pera

tor

PV

PV

(to

: Val

ve P

ILO

T)*

PV

(to

: Val

ve P

)P

V (

to: V

alve

PIC

K &

HO

LD)

*Thi

s is

the

term

inal

not

jum

pere

dto

TR

.

Bur

ner

grou

nd c

onne

ctio

nG

ND

(B

UR

NE

R)

GN

DG

ND

GN

D—

Tra

nsfo

rmer

sec

onda

ry

24V

GN

DT

RT

RT

R—

(uns

witc

hed

leg)

24V

No

conn

ectio

nN

o co

nnec

tion

No

conn

ectio

n—

E3a

E3a

E3a

Whe

n su

pplie

d, E

3 pr

ovid

esco

nnec

tion

to L

ocko

ut T

imer

.

Tra

nsfo

mer

sec

onda

ry

(sw

itche

d le

g)

TH

-WT

HT

HT

HIf

LO-1

5 is

par

t of t

he in

stal

latio

n,us

e th

e w

ire d

isco

nnec

ted

from

E1

tagg

ed T

herm

osta

t.

Fla

me

sens

orS

EN

SE

bS

EN

SE

eS

EN

SE

eS

EN

SE

e—

Pilo

t ign

iter

SP

AR

KIG

NIG

NIG

N—

1.U

se e

xist

ing

wiri

ng h

arne

ss to

mak

e co

nnec

tions

to S

8610

per

tabl

e. I

MP

OR

TA

NT

If in

stal

latio

n in

clud

es L

O-1

5 Lo

ckou

t Tim

er, d

isca

rd w

ires

to E

3 an

d T

H.

Dis

conn

ect a

nd r

etai

n w

ire to

LO

-15

term

inal

E1.

Tag

wire

,The

rmos

tat.

Dis

card

LO

-15.

2.O

n 70

00D

ser

ies

valv

e, r

etai

n (o

r in

stal

l) w

hite

jum

per

betw

een

valv

e T

R a

nd p

ilot s

olen

oid.

aIf

LO-1

5 Lo

ckou

t tim

er is

not

inst

alle

d, E

3 co

nnec

tor

prov

ided

on

SP

715

is n

ot u

sed.

bIm

po

rtan

tIf

the

US

I 715

U w

ith c

ombi

natio

n ig

nite

r se

nsor

is n

ot u

sed,

rem

ove

blac

k ju

mpe

r qu

ick

conn

ect f

rom

Sen

se te

rmin

al o

f S86

10U

1003

. Cut

jum

per

wire

at

circ

uit b

oard

and

dis

card

.

cF

or r

epla

cem

ent o

f Rob

erts

haw

Fla

me

Sw

itch

syst

ems

(SP

710,

720

, 730

, 750

, 780

-700

, 780

-701

, 780

-710

, 780

-711

, 780

-712

and

780

-713

), s

ee H

oney

wel

l Ign

ition

Con

trol

Han

dboo

k.d

780-

715

and

US

I 715

U a

re e

quiv

alen

t to

SP

715;

780

-735

and

780

-737

are

equ

ival

ent t

o S

P73

5. F

or o

ther

780

-XX

X m

odel

s, s

ee n

otec

.e

OP

T. S

EN

SO

R o

n U

SI 7

15U

. No

exte

rnal

con

nect

ion

if co

mbi

natio

n ig

nite

r se

nsor

is u

sed.


68-0135—2 10

Tab

le 7

. Co

nver

sio

n f

rom

Pen

n-J

oh

nso

n C

SA

(A

ll), G

60, G

66, G

67, G

600,

G67

0 o

r G

770

to S

8610

U10

03.

Rep

lace

men

t

Co

ntr

ol

Old

Co

ntr

ol

Ho

ney

wel

l

CS

A45

A-6

00R

d, G

60, G

65, G

66, G

67, G

600

or

G67

0 In

stal

lati

on

wit

h L

ock

ou

t M

od

ule

s as

follo

ws:

*

Ter

min

al F

un

ctio

nS

861U

1003

No

ne

(Y79

)Y

79A

mo

du

led

Y79

B m

od

ule

cG

770

Pro

ced

ura

l No

tes

Mai

n va

lve

oper

ator

MV

33

Y79

B M

VM

V (

3)

Mai

n va

lve

and

pilo

t com

mon

MV

/PV

GR

GR

GR

GR

OU

ND

(5)

Pilo

t val

ve o

pera

tor

PV

11

Y79

B P

VP

V (

1)

Bur

ner

grou

nd c

onne

ctio

nG

ND

(BU

RN

ER

)G

RG

RG

RG

RO

UN

D

Tra

nsfo

rmer

sec

onda

ry(u

nsw

itche

d le

g)24

V G

ND

GR

GR

GR

GR

OU

ND

Tra

nsfo

rmer

sec

onda

ry(s

witc

hed

leg)

TH

-W*

2aY

79 T

HS

b2

TH

-S (

2)

24V

*N

o co

nnec

tion*

No

conn

ectio

n*N

o co

nnec

tion*

No

conn

ectio

n*

Fla

me

sens

orS

EN

SE

*4e

4e4e

SE

NS

E (

4)e

Pilo

t ign

iter

SP

AR

KIG

N C

OIL

IGN

CO

ILIG

N C

OIL

IGN

CO

ILIt

mig

ht b

e ne

cess

ary

to c

ut o

ff R

ajah

conn

ecto

r an

d/or

atta

ch in

sula

ted

quic

kco

nnec

t.a

Dis

card

wire

bet

wee

n tr

ansf

orm

er a

nd te

rmin

al 5

(G

60)

or 6

(G

600)

; oth

erw

ise,

use

exi

stin

g ha

rnes

s fo

r w

iring

.b

Dis

card

wire

s be

twee

n Y

79A

and

mod

ule

as fo

llow

s: R

ed to

3, B

lack

to 2

, Whi

te to

GR

. Dis

card

wire

bet

wee

n tr

ansf

orm

er a

nd 6

.c

Dis

card

wire

s be

twee

n Y

79B

and

mod

ule

as fo

llow

s: W

hite

to 3

, Bla

ck to

1, B

row

n to

GR

. Dis

card

wire

bet

wee

n tr

ansf

orm

er a

nd 6

.d

CS

A c

ode

num

bers

(fo

r ex

ampl

e, C

SA

45A

-600

R)

are

equi

vale

nt to

G60

0 an

d us

e th

e sa

me

wiri

ng in

form

atio

n ta

bles

.e

Imp

ort

ant

Rem

ove

blac

k ju

mpe

r qu

ick

conn

ect f

rom

Sen

se te

rmin

al o

f S86

10U

1003

; cut

jum

per

wire

at c

ircui

t boa

rd a

nd d

isca

rd.

*IF

INS

TA

LLA

TIO

N D

OE

S N

OT

INC

LUD

E V

EN

T D

AM

PE

R W

ITH

PLU

G C

ON

NE

CT

ION

TO

MO

DU

LE:

1.Le

ave

vent

dam

per

plug

on

S86

10U

Mod

ule

in p

ositi

on.

2.U

se T

H-W

term

inal

.*I

F IN

ST

ALL

AT

ION

INC

LUD

ES

VE

NT

DA

MP

ER

WIT

H P

LUG

CO

NN

EC

TIO

N T

O M

OD

ULE

:1.

Rep

lace

S86

10U

Mod

ule

vent

dam

per

plug

with

dam

per

Mol

ex c

onne

ctor

.2.

Wire

ther

mos

tat W

wire

to T

H-W

.3.

Run

wire

from

sw

itche

d le

g of

tran

sfor

mer

sec

onda

ry to

bot

h th

erm

osta

t R a

nd S

8610

Mod

ule

24V

term

inal

s.


68-0135—211

Tab

le 8

. Co

nver

sio

n f

rom

CA

MS

TAT,

FE

NW

AL

or

HS

C t

o S

8610

U10

03.

Rep

lace

men

tC

on

tro

lO

ld C

on

tro

l

Ter

min

al F

un

ctio

nH

on

eyw

ell

S86

10U

1003

CA

MS

TA

T

IPI-

24-0

0aF

EN

WA

L05

-20X

bH

SC

100

3-3

and

10

03-3

00a

Pro

ced

ura

l No

tes

Mai

n va

lve

oper

ator

MV

MV

MA

IN V

ALV

EM

V—

Mai

n va

lve

and

pilo

t com

mon

MV

/PV

GN

DG

RO

UN

DG

ND

/CO

MF

enw

al o

nly:

run

sep

arat

e le

ad to

S86

10 v

alve

com

mon

term

inal

.

Pilo

t val

ve o

pera

tor

PV

PV

PIL

OT

VA

LVE

PV

—

Bur

ner

grou

nd c

onne

ctio

nG

ND

(B

UR

NE

R)

GN

D—

—T

o as

sure

goo

d gr

ound

, run

sep

arat

e w

ire fr

ompi

lot b

urne

r to

S86

10 G

ND

(B

UR

NE

R).

Tra

nsfo

rmer

sec

onda

ry(u

nsw

itche

d le

g)24

V G

ND

T2

GR

OU

ND

GN

D/C

OM

—

24V

No

conn

ectio

nN

o co

nnec

tion

No

conn

ectio

n—

Tra

nsfo

rmer

sec

onda

ry

(sw

itche

d le

g)T

H-W

T

1P

OW

ER

24 V

AC

—

Fla

me

sens

orS

EN

SE

Sc

—S

EN

SO

Rc

—

Pilo

t ign

iter

SP

AR

KIG

NH

.V.

IGN

CO

ILS

trip

mod

ule

end

of ig

nitio

n ca

ble

as n

eces

sary

and

atta

ch in

sula

ted

quic

k co

nnec

t for

con

nect

ion

to S

8610

.a

Use

exi

stin

g w

iring

har

ness

to m

ake

conn

ectio

ns to

S86

10.

bT

ag a

ll w

ires

at m

odul

e co

nnec

tor

with

term

inal

des

igna

tions

. Cut

wire

s at

con

nect

or, a

ttach

qui

ck c

onne

cts

and

conn

ect t

o S

8610

; per

tabl

e.

cIm

po

rtan

tR

emov

e bl

ack

jum

per

quic

k co

nnec

t fro

m S

ense

term

inal

of S

8610

U10

03; c

ut ju

mpe

r w

ire a

t circ

uit b

oard

and

dis

card

.


68-0135—2 12

Fig. 3. S8610U in heating system with atmospheric burner.

L1 (HOT)

L2

1

4

8

1

2

3

4

5

6

7

8

2

7

5

63

M2641D

S8610U

MV MV/PV PVGND(BURNER)

24VGND 24V TH-W

VENTDAMPERPLUG SENSE SPARK

WIRINGHARNESS

THERMOSTAT

D892 VENTDAMPER

LIMITCONTROLLER

GROUND

SENSOR

IGNITER

MAINVALVECOMPILOT

1STOPERATOR

2NDOPERATOR

DUAL VALVE COMBINATIONGAS CONTROL

PILOT GASSUPPLY

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

ALTERNATE LIMIT CONTROLLER LOCATION.

MAXIMUM CABLE LENGTH 3 ft (0.9m).

CONTROLS IN 24V CIRCUIT MUST NOT BE GROUND LEG TO TRANSFORMER.

REMOVE PLUG ONLY IF USING VENT DAMPER. FUSE BLOWS ON STARTUP WHEN PLUG ISREMOVED AND VENT DAMPER WIRING HARNESS IS INSTALLED; THEN MODULE OPERATES ONLY WHEN VENT DAMPER IS CONNECTED.

REMOVE JUMPER AND CONNECT SENSE TERMINAL ON TWO ROD APPLICATION ONLY.

IF THE VENT DAMPER IS CONNECTED, WIRE 24V TERMINAL, AS SHOWN. CONNECT VENTDAMPER 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.


68-0135—213

Fig. 4. S8610U in heating system with power-assisted combustion.

L1 (HOT)

L2

L2

1

L1 (HOT)

1

4

1

2

3

4

5

6

2

5

6 3

M2642B

S8610U


24VGND 24V TH-W


THERMOSTAT

LIMITCONTROLLER

PILOT BURNERGROUND

SENSOR

IGNITER

MAINVALVECOMPILOT

1STOPERATOR

2NDOPERATOR

DUAL VALVE COMBINATIONGAS CONTROL

PILOT GASSUPPLY



MAXIMUM CABLE LENGTH 3 ft (0.9m).

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.

CONTROLLER

COMBUSTIONAIR BLOWERMOTOR

COMBUSTIONAIR BLOWERRELAY

AIRPROVINGSWITCH


68-0135—2 14

Fig. 5. S8610U in a typical ST9120 application.

1

1

S8610U


24VGND 24V TH-W


L2 (N)

L1 (N)

TO 120 OR240 VACPOWER SUPPLY

120 OR240 VAC

TRANSFORMER

24 VAC

COMBUSTIONBLOWER

STARTINGCAP

CIRCULATINGFAN

COMPRESSORAND OUTDOORFAN NETWORK

UNUSEDMOTOR LEDS

M1

M3

M2 H

1 2 3 4 5

1 2 3 4 CR

L2

L1

C

C C

X X YHEAT

COOL

ST9120ELECTRONICFAN TIMER

ROLLOUTFUSE

LIMIT

PILOT GASSUPPLY

PILOT BURNERGROUND

Q345, Q348, Q362, Q381PILOT BURNER/IGNITER-SENSOR

PV

MV/PV

MVC

COMBINATIONGAS CONTROL

COM.

PRESSURESWITCH

N.O.

AUXILIARYLIMIT

5-WIRECABLE

COMPRESSORCONTACTOR

= STANDARD TERMINAL = OPTIONAL TERMINAL

REMOVE JUMPER AND CONNECT SENSE TERMINALON TWO ROD APPLICATION ONLY.

M2644B

THERMOSTAT

G

GW

W C

Y

Y

R

R

LOMLMHHI

FUSE


68-0135—215

STARTUP AND CHECKOUTCheck out the gas control system:• At initial appliance installation.• As part of regular maintenance procedures.• At maintenance intervals determined by the application.• As the first step in troubleshooting.• Any time work is done on the system.

Maintenance frequency must be determined individually foreach application. See Maintenance section.

WARNINGFIRE OR EXPLOSION HAZARDCAN CAUSE PROPERTY DAMAGE, SEVEREINJURY, OR DEATH.1. If you smell gas or suspect a gas leak, turn off the

gas at the manual service valve and evacuate thebuilding. Do not try to light any appliance; do nottouch any electrical switch or telephone in thebuilding until you are sure no spilled gas remains.

2. Gas leak test must be done as described in steps1 and 6 below on initial installation and anytimework is done involving the gas piping.

Step 1: Perform visual inspection.a. With power off, make sure all wiring connections are

clean and tight.b. Turn on the power to the appliance.c. Open the manual shutoff valves in the gas line to the

appliance.d. Test for gas leak before gas control if piping has been

disturbed.

Gas Leak Test:Paint the gas control gasket edges and all pipe connectionsdownstream of the gas control, including pilot tubingconnections, with a rich soap and water solution. Bubblesindicate gas leaks. Tighten the joints and screws or replacethe component to stop the gas leak. Recheck with soap andwater solution.

Step 2: Verify control system ground.The igniter, flame sensor, and ignition module must share acommon ground with the main burner. Use thermoplasticinsulated wire with a minimum rating of 105°C (221°F) for theground wire; asbestos insulation is not acceptable. If thetemperature at the wire could exceed 105°C (221°F), use ashield to protect the wire from radiant heat generated by theburner. Connect the ground wire as follows:a. Fit one end of the ground wire with a female 1/4 in.

quick-connect terminal and connect it to the male quick-connect GND (BURNER) terminal on the ignition module.

b. Strip the other end of the wire and fasten it under theigniter bracket mounting screw. If necessary, use a shieldto protect the ground wire from radiant heat.

c. The burner serves as the common grounding area. Ifthere is not good metal-to-metal contact between theburner and ground, run a lead from the burner to ground.

NOTE: Earth ground is not required.

Step 3: Review normal operating sequence and modulespecifications.a. See Operation and Specifications sections.

Step 4: Reset the module.a. Turn the thermostat to its lowest setting.b. Wait one minute.

As you do Steps 5 and 6, watch for points where operationdeviates from normal. Refer to Troubleshooting Guide, Fig. 8,to correct the problem.

Step 5: Check safety shutoff operation.a. Turn off the gas supply.b. Set thermostat or controller above the room temperature

to call for heat.c. Watch for spark at pilot burner.d. Time spark from start to shutoff. Spark should shut off

after 90 seconds maximum. Ignition sequence repeatsafter five minutes minimum.

e. Open the manual gas control knob and make sure nogas is flowing to the pilot or main burner.

f. Set the thermostat below the room temperature and waitone minute before continuing.

Step 6: Check normal operation.a. Set the thermostat or controller above the room

temperature to call for heat.b. Make sure the pilot lights smoothly when the gas

reaches the pilot burner.c. Make sure the main burner lights smoothly without

flashback.d. Make sure the burner operates smoothly without floating,

lifting, or flame rollout to the furnace vestibule or heatbuildup in the vestibule.

e. If the gas line was disturbed, complete the gas leak test.

Gas Leak Test:Paint the gas control gasket edges and all the pipeconnections downstream of the gas control, including pilottubing connections, with a rich soap and water solution.Bubbles indicate gas leaks. Tighten the joints and screws orreplace the component to stop the gas leak. Recheck withsoap and water solution.

f. Turn the thermostat or controller below the roomtemperature. Make sure the main burner and pilot flamesgo out.

MAINTENANCE

WARNINGFIRE OR EXPLOSION HAZARD CAN CAUSEPROPERTY DAMAGE, SEVERE INJURY, ORDEATH.Do not attempt to take the module apart or to clean it.Improper assembly and cleaning can cause unreliableoperation.


68-0135—2 16

Regular preventive maintenance is important in commercialcooking, agricultural and industrial industries applications thatplace a heavy load on system controls, because:• In many such applications, particularly commercial

cooking, the equipment operates 100,000 to 200,000cycles per year. Such heavy cycling can wear out the gascontrol in one to two years.

• Exposure to water, dirt, chemicals and heat can damagethe gas control and shut down the control system. ANEMA 4 enclosure can reduce exposure to environmentalcontaminants. See Electronic Ignition Service Manual,form 70-6604.

The maintenance program should include regular systemcheckout as outlined in the Startup and Checkout section,and control system checkout as described in appliancemanufacturer literature.

Maintenance frequency must be determined individually foreach application. Some considerations are:• Cycling frequency. Appliances that can cycle 20,000 times

annually should be checked monthly.• Intermittent use. Appliances that are used seasonally

should be checked before shutdown and again before thenext use.

• Consequence of unexpected shutdown. Where the cost ofan unexpected shutdown would be high, the systemshould be checked more often.

• Dusty, wet, or corrosive environment. Because theseenvironments can cause the gas control to deterioratemore rapidly, the system should be checked more often.

Any control should be replaced if it does not perform properlyon checkout or troubleshooting. In addition, replace anymodule if it is wet or looks like it has ever been wet.Protective enclosures as described in the Planning theInstallation section are recommended, regardless of checkoutfrequency.

OPERATIONModule operation can be conveniently divided into twophases for the S8610:• Trial for ignition.• Main burner operation.

Fig. 6 summarizes the normal operating sequence of themodule.

Fig. 6. S8610U normal operating sequence.

THERMOSTAT (CONTROLLER)SATISFIEDValves close, pilot and mainburners are off.

MAIN BURNER OPERATIONModule monitors pilot flame current.

FLAME CURRENT SENSED• Spark generator off.• Second valve operator (main) opens.

POWER INTERRUPTIONSystem shuts off, restarts when poweris restored.

PILOT FLAME FAILUREMain valve closes.Module starts trial for ignition.

M2640A

PILOT BURNER OPERATION

ORPilot burner lights.Module sensesflame current.

After 90 seconds maximum, system shuts off; trial forignition restarts after minimum of 5 minutes (6 minutesnominal). Ignition, shutoff, wait sequence repeats until pilot lights or call for heat ends.

SPARK GENERATOR POWERED

First valve (pilot) operator opens

THERMOSTAT (CONTROLLER)CALL FOR HEAT

START

STAGE 1TRIAL FORIGNITION

STAGE 2MAIN BURNER

OPERATION

END

�

�

�

�

�

�


68-0135—217

TROUBLESHOOTINGIMPORTANT

1. The following service procedures are provided as ageneral guide. Follow appliance manufacturerservice instructions if available.

2. Meter readings between gas control and ignitionmodule must be taken within the trial for ignitionperiod. Once the ignition module shuts off, wait forretry or reset at the thermostat.

3. If any component does not function properly, makesure it is correctly installed and wired beforereplacing it.

4. The ignition module cannot be repaired. If itmalfunctions, replace it.

5. Only trained, experienced service technicians shouldservice intermittent pilot systems.

6. After servicing, verify proper system operation.

Perform the checkout steps in the Startup and Checkoutsection as the first step in troubleshooting. Then check theappropriate troubleshooting guide (Fig. 8) and the schematicdiagram (Fig. 9) to determine the cause of the problem. Iftroubleshooting indicates an ignition problem, see IgnitionSystem Checks section to isolate and correct the problem.

After troubleshooting, perform the checkout procedures againto be sure the system is operating normally.

Ignition System ChecksStep 1: Check ignition cable.Make sure:a. Ignition cable does not run in contact with any metal

surfaces.b. Ignition cable is no more than 36 in. (0.9m) long.c. Connections to the ignition module and to the igniter or

igniter-sensor are clean and tight.d. Ignition cable provides good electrical continuity.

Step 2: Check ignition system grounding. Nuisance shutdowns areoften caused by a poor or erratic ground.a. A common ground, usually supplied by the pilot burner

bracket, is required for the module and the pilot burner/igniter-sensor.• Check for good metal-to-metal contact between the

pilot burner bracket and the main burner.• Check the ground lead from the GND (BURNER)

terminal on the module to the pilot burner. Make sureconnections are clean and tight. If the wire isdamaged or deteriorated, replace it with No. 14through 18 gauge, moisture-resistant, thermoplasticinsulated wire with 105°C (221°F) minimum rating.— Check the ceramic flame rod insulator for cracks

or evidence of exposure to extreme heat, whichcan permit leakage to ground. Replace pilotburner/igniter-sensor and provide a shield, ifnecessary.

— If flame rod or bracket are bent out of position,restore to the correct position.

Step 3: Check spark ignition circuit. You will need a short jumper wiremade from ignition cable or other heavily insulated wire.a. Close the manual gas valve.b. Disconnect the ignition cable at the SPARK terminal on

the module.

WARNINGELECTROCUTION HAZARD, CAN CAUSESERIOUS INJURY OR DEATH.When performing the following steps, do not touchstripped end of jumper or SPARK terminal. Theignition circuit generates over 10,000 volts andelectrical shock can result.

c. Energize the module and immediately touch one end ofthe jumper firmly to the GND terminal on the module.Move the free end of the jumper slowly toward theSPARK terminal until a spark is established.

d. Pull the jumper slowly away from the terminal and notethe length of the gap; when sparking stops, refer to thetable as follows:

Arc Length Action

No arc or arc lessthan 1/8 in. (3 mm).

Check external fuse, if provided.Verify power at module inputterminal. Replace module if fuseand power are okay.

Arc 1/8 in. (3 mm) orlonger.

Voltage output is okay.

STEP 4: Check pilot and main burner lightoff.a. Set the thermostat to call for heat.b. Watch the pilot burner during the ignition sequence to be

sure:• Ignition spark continues after the pilot is lit.• The pilot lights and the spark stops, but the main

burner does not light.• The pilot lights, the spark stops and the main burner

lights, but the system shuts down.c. If so, verify adequate flame current as follows:

• Turn off the furnace at the circuit breaker or fuse box.• Clean the flame rod with an emery cloth.• Make sure the electrical connections are clean and

tight. Replace the damaged wire with moisture-resistant No. 18 wire rated for continuous duty up to105°C (221° F).

• Check for a cracked ceramic insulator, which cancause short to ground, and replace igniter-sensor orsensor, if necessary.

• At the gas control, disconnect the main valve wirefrom the TH or MV terminal.

• Turn on the power and set the thermostat to call forheat. The pilot should light but the main burnerremains off because the main valve actuator isdisconnected.

• Check the pilot flame. Make sure it is blue, steady,and envelops 3/8 to 1/2 in. (10 to 13 mm) of the flamerod. See Fig. 7 for possible flame problems and thecauses.


68-0135—2 18

• If necessary, adjust the pilot flame by turning the pilotadjustment screw on the gas control clockwise todecrease or counterclockwise to increase the pilotflame. Following adjustment, always replace the pilotadjustment cover screw and tighten firmly to assureproper gas control operation.

• Set the thermostat below the room temperature to endthe call for heat.

d. Recheck ignition sequence as follows:• Reconnect the main valve wire.• Set the thermostat to call for heat.• Watch the ignition sequence at the burner.• If spark still does not stop after pilot lights, replace the

ignition module.• If the main burner does not light or if the main burner

lights but system locks out, check module, groundwire, and gas control, as described in theTroubleshooting Guide, Fig. 8.

LAZY YELLOW FLAME

WAVING BLUE FLAME

NOISY LIFTING BLOWING FLAME

HARD SHARP FLAME

SMALL BLUE FLAME CHECK FOR LACK OF GAS FROM:

• CLOGGED ORIFICE FILTER

• CLOGGED PILOT FILTER

• LOW GAS SUPPLY PRESSURE

• PILOT ADJUSTMENT AT MINIMUM

CHECK FOR LACK OF AIR FROM:

• DIRTY ORIFICE

• DIRTY LINT SCREEN, IF USED

• DIRTY PRIMARY AIR OPENING, IF THERE IS ONE

• PILOT ADJUSTMENT AT MINIMUM

CHECK FOR:

• EXCESSIVE DRAFT AT PILOT LOCATION

• RECIRCULATING PRODUCTS OF COMBUSTION

CHECK FOR:

• HIGH GAS PRESSURE

THIS FLAME IS CHARACTERISTIC OF MANUFACTURED GAS

CHECK FOR:

• HIGH GAS PRESSURE

• ORIFICE TOO SMALL

M2233A

APPEARANCE CAUSE

Fig. 7. Examples of unsatisfactory pilot flames.


68-0135—219

NOTE: Before troubleshooting, familiarize yourself with the startup and checkout procedure.

Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring. Also, check air proving switch on combustion air blower system (if used) and verify that vent damper (if used) is open and end switch is made.

On models with vent damper plug, make sure vent damper was not installed, then removed. Replace vent damper, if necessary.On other models, replace module.

Pull ignition lead and check spark at module.

Check ignition cable, ground wiring, ceramic insulator and gap, and correct.Check boot of the ignition cable for signs of melting or buckling. Replace cable and take protective action to shield cable and boot from excessive temperatures.

Check that all manual gas valves are open, supply tubing and pressures are good, and pilot burner orifice is not blocked.Check electrical connections between module and pilot operator on gas control.Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay, replace gas control; if not, replace module

Check continuity of ignition cable and ground wire.Clean flame rod.Check electrical connections between flame rod and module.Check for cracked ceramic flame rod insulator.Check that pilot flame covers flame rod and is steady and blue.Adjust pilot flame.If problem persists, replace module.

Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.Check electrical connections between module 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 normal at the time of checkout.Check temperature at igniter-sensor insulator. High temperatures can cause a short.Check that pilot flame covers flame rod and is steady and blue.If checks are okay, replace module.

Check for proper thermostat (controller) operation.Remove MV lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas control.

TURN OFF GAS SUPPLY.TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT.

POWER TO MODULE.(24V NOMINAL)

SPARK ACROSSIGNITER/SENSOR GAP?

TURN ON GAS SUPPLY.

PILOT BURNER LIGHTS?

SPARK STOPS WHEN PILOT IS LIT?

MAIN BURNER LIGHTS?

SYSTEM RUNS UNTIL CALL FOR HEAT ENDS?

CALL FOR HEAT ENDS.

SYSTEM SHUTS OFF?

TROUBLESHOOTING ENDS.

NO

NO

NO

NO

NO

NO

NO

NO

START

YES

YES

YES

YES

YES

YES

YES

YES

••

•

•

•

••

•••••••

••

•

•••

••

Repeat procedure until troublefree operation is obtained.M2643B

Spark okay?

CHECK AT TH-W TERMINAL, AND ALSO AT 24V TERMINALIF A VENT DAMPER IS CONNECTED TO THE DAMPER CONNECTOR.

Fig. 8. S8610U Troubleshooting Guide.


68-0135—2 20

Fig. 9. Schematic for S8610U.

FLAMEDETECTORCIRCUIT

SPARKDRIVECIRCUIT

RELAYDRIVERS

TIMINGCIRCUITS

LOWVOLTAGEPOWERSUPPLY

1 5 3 6 2 4

1 5 3 6 2 4

VENTDAMPERPLUG

YELLOW

FUSE

1K1 1K2 3K2

2K2 3K1

1K

2K

3K

24V(GND)

SENSE

SPARKGND(BUR-NER)

SENSOR

IGNITER

ARCGAP

ON-OFFSWITCH

LIMITCONTROLLER

24VTRANSFORMER

THERMOSTAT

TH-W

24V

MV/PV

MV

PV

MAINVALVE

PILOTVALVE

HYBRID CIRCUITS

2K1

BURNERGROUND

L1(HOT) L2



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.

SINGLE ROD SYSTEM HAS IGNITER–SENSOR.

1

2

3

4

5

INTERNAL WIRINGEXTERNAL WIRING

1

3

2

2

5

4

M2646B


68-0135—221

ANSI STANDARDS

Exhibit ARecommended 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 indetermining that an appliance is properly installed and is in asafe condition for continuing use.

This procedure is predicated on central furnace and boilerinstallations equipped with an atmospheric gas burner(s) andnot of the direct vent type. It should be recognized thatgeneralized test procedures cannot anticipate all situations.Accordingly, in some cases, deviation from this proceduremay be necessary to determine safe operation of theequipment.a. This procedure should be performed prior to any attempt

at modification of the appliance or the installation.b. If it is determined there is a condition which could result

in unsafe operation, the appliance should be shut off andthe owner advised of the unsafe condition.

The following steps should be followed in making the safetyinspection:

� Conduct a Gas Leakage Test of the appliance pipingand control system downstream of the shutoff valve inthe supply line to the appliance.

� Visually inspect the venting system for proper size andhorizontal pitch and determine there is no blockage orrestrictions, leakage or corrosion or other deficienciesthat could cause an unsafe condition.

� Shut off all gas to the appliance and shut off any otherfuel-burning appliance within the same room. Use theshutoff valve in the shutoff valve in the supply line toeach appliance.

� Inspect burners and crossovers for blockage andcorrosion.

� Applicable only to warm air heating appliances. Inspectheat exchangers for cracks, openings or excessivecorrosion.

� Applicable only to boilers. Inspect for evidence of wateror combustion product leaks.

� Insofar as is practical, close all building doors andwindows and all doors between the space in which theappliance is located and other spaces of the building.Turn on clothes dryers. Turn on any exhaust fans, suchas range hoods and bathroom exhausts, so they willoperate at maximum speed. Do not operate a summerexhaust fan. Close fireplace dampers. If, aftercompleting steps 7 through 12, it is believed sufficientcombustion air is not available, refer to 1.3.4 of theNational Fuel Gas Code (Z223.1) for guidance.

� Place in operation the appliance being inspected.Follow the lighting instructions. Adjust thermostat soappliance will operate continuously.

a. Determine that the pilot is burning properly andthat main burner ignition is satisfactory byinterrupting and re-establishing the electricalsupply to the appliance in any convenient manner.

Determine manifold pressure in order to match inputafter the new control is installed.

� a. Visually determine that main burner gas is burningproperly; i.e., no floating, lifting or flashback. Adjustthe primary air shutter(s) as required.

b. If appliance is equipped with high and low flamecontrol or flame modulation, check for proper mainburner operation at low flame.

� Test for spillage at the draft hood relief opening afterfive minutes of main burner operation. Use a draftgauge, the flame of a match or candle, or smoke from acigarette, cigar or pipe.

Return doors, windows, exhaust fans, fireplacedampers and all other fuel-burning appliances to theirprevious conditions of use.

� Applicable only to warm air heating appliances. Checkboth limit controller and fan controller for properoperation. Limit controller operation can be checked bytemporarily disconnecting the electrical supply to theblower motor and determining that the limit control actsto shut off the main burner gas.

� Applicable only to boilers:a. Determine that the circulating water pumps are in

operating condition.b. Test low water cutoffs, automatic feed controls,

pressure and temperature limit controls and reliefvalves in accordance with the manufacturer’s re-commendations and instructions to determine theyare in operating condition.

Exhibit A Of ANSI Standard Z21.71 for Automatic Intermittent Pilot Ignition Systems for Field Installation.


68-0135—2 22

Exhibit BProcedure for Installing Automatic Intermittent Pilot Systems

Prior to beginning this procedure, a preliminary examinationof the appliance and the automatic intermittent pilot systemshould be made to determine that the automatic intermittentpilot system can be properly applied to the appliance.

This procedure is intended as a guide to aid in safelyinstalling a listed automatic intermittent pilot system on anexisting listed appliance equipped with an atmospheric gasburner(s) and not of the direct vent type.

This procedure is based on the assumption that the history ofthe specific installation has been one of safe and satisfactoryoperation.

This procedure is predicated on central furnace and boilerinstallations, and it should be recognized that generalizedprocedures cannot anticipate all situations. Accordingly, insome cases, deviation from this procedure may be necessaryto determine safe operation of the equipment.

The following steps should be followed in making themodifications:

� Perform a safety inspection of the existing applianceinstallation. See Exhibit A for a recommendedprocedure for such a safety inspection.

� Shut off all gas and electricity to the appliance. To shutoff gas, use the shutoff valve in the supply line to theappliance. Do not use the shut-off valve which isprovided as part of a combination control.

� Install the automatic intermittent pilot system in strictaccordance with the manufacturer’s installationinstructions.

� Turn on all gas and electricity to the appliance.� Determine that the appliance transformer has adequate

capacity by following the steps outlined below:a. Compute the approximate current draw by adding

the current draw of the automatic intermit-tentpilot system to (1) the current draw of theassociated valving, and (2) the current draw ofany relays or other devices operated by thetransformer.

b. Multiply the total current draw as computedabove by 24V to determine the total volt-ampere(VA) required.

c. The total VA required should be equal to or lessthan the VA rating of the transformer.

d. If the total VA required is greater than the VArating of the transformer, the transformer must bereplaced with a Class 2 transformer of adequaterating.

� Check the heat anticipator in the comfort thermostat todetermine if it is properly adjusted to the current draw ofthe control system. Follow the thermostatmanufacturer’s instructions.

� Make certain wiring connections are tight and wires arepositioned and secured so they will not be able tocontact high temperature locations.

� Conduct a Gas Leakage Test of the appliance pipingand control system downstream of the shutoff valve inthe supply line to the appliance.

a. Adjust the thermostat to its highest temperaturesetting, and test manifold pressure and adjust thepressure regulator to match original input asrequired (refer to Exhibit A, step 9b).

b. Visually determine that main burner is burningproperly; i.e., no floating, lifting or flashback. Adjustthe primary air shutter(s) as required.

If the appliance is equipped with high and low flamecontrol or flame modulation, check for proper mainburner operation at both high and low flame.

� Determine that the pilot is igniting and burning properlyand that main burner ignition is satisfactory byinterrupting and reestablishing the electrical supply tothe appliance in any convenient manner. Make thisdetermination with the appliance burner both cold andhot. Perform this step as many times as is necessary tosatisfy yourself that the automatic intermittent pilotsystem is operating properly.

� Test the pilot safety device (1) to determine if it isoperating properly, and (2) for turndown characteristicsaccording to the manufacturer’s installation instructions.No adjustments should be made other than thoserecommended by the system manufacturer.

Sequence the appliance through at least threeoperating cycles.

� Applicable only to furnaces. Check both the limitcontroller and the fan controller for proper operation.Limit control operation can be checked by blocking thecirculating air inlet or temporarily disconnecting theelectrical supply to the blower motor and determiningthat the limit controller acts to shut off the main burnergas.

� Applicable only to boilers:a. Determine that the circulating water pumps are in

operating condition.b. Test low water cutoffs, automatic feed water

controls, pressure and temperature limitcontrollers and relief valves in accordance withthe manufacturer’s recommendation to determinethey 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 FORFIELD INSTALLATION.


68-0135—223


68-0135—2 24

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Home and Building ControlHoneywell Limited-Honeywell Limitée155 Gordon Baker RoadNorth York, OntarioM2H 2C9

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Helping You Control Your World

68-0135—2 J.S. Rev. 8-96 Printed in U.S.A. customer.honeywell.com

Home and Building ControlHoneywell Inc.Honeywell PlazaP.O. Box 524Minneapolis MN 55408-0524

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68-0135 - S8610U Universal Intermittent Pilot Modulesame as those of standard models except as...

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