-

D.T.

Rev. 5-93

THE Y8610F.H ARE COMPLETE KITS FOR CONVERTING

CONVENTIONAL STANDING PILOT SYSTEMS TO INTER-

MIT-TENT PILOT SYSTEMS. THEY ARE USED ON GAS-

FIRED ATMOSPHERIC FURNACES, BOILERS, AND

HEATING APPLIANCES. NOT FOR USE ON DIRECT VENT

OR POWER BURNER EQUIPMENT. MEETS ANSI 221.71

STANDARD FOR AUTOMATIC INTERMITTENT

IGNITION SYSTEMS FOR FIELD INSTALLATIONS.

PILOT

II! Y861OF kits are for use on natural gas only; they continue trial for ignition until either the pilot lights or the system is shut down manually.

2 Y8610H kits are available for either natural or LP gas; they provide timed trial for ignition and 100 percent pilot shutoff on loss of flame. iJ Each kit includes:

- S861OF or H Intermittent Pilot Module

- VR8440Aor M orVR8204A Dual Valve Combination Gas

Control

- 392431 Igniter-Sensor

- 394800-30 Ignition Cable

- Wiring Harness

- 393690-14Straight Flange Kit (3/4 inch) (VR8204Aappli- cations only)

- Reducer adapters for gas control

- Adhesive mounting option for S8610

- Installation hardware

IJ Temperature Rating:

- VR8204A: 0” to 175” F [-18” to 79” C]

- VR8440A: -40” to 175” F [-40” to 79” C]

- VR8440M: 32” to 175” F [O“ to 79” C]

MODULE

0 Uses rectification principle for flame sensing.

U Provides 13 kV peak capacitive discharge spark output

(at 25 pf load).

GAS CONTROL n Straight through body pattern. Some models have 112 in. plugged side outlets.

0 Capacities at 1 inch WC pressure drop [0.25 kPa pressure drool: u

\jR8204A (with or without l/2” x 3/4’ adapter):

150 fP/hr [4.2 m3/hr]

VR8440A,M with l/2” x 3/4” NPT inlet x outlet

VR8440A,M

OFF position.

OBSOLETE

0 Two main automatic valves-ne other diaphragm operated.

IGNITER/SENSOR solenoid operated, the

I7 Single electrode made of Kanthal provides both ignition and flame sensing. iI Rated for 1775” F [968” C] at electrode tip, 1250” F [677” C] at ceramic insulator.

Form Number 68-0102-2

@Honeywell inc. 1993

IMPORTANT

THE SPECIFICATIONS GIVEN IN THIS PUBLICATION DO NOT INCLUDE NORMAL MANUFACTURING

TOLERANCES. THEREFORE, UNITS MAY NOT MATCH THE LISTED SPECIFICATIONS EXACTLY. ALSO,

UNITS ARE TESTED AND CALIBRATED UNDER CLOSELY CONTROLLED CONDITIONS, AND SOME MINOR

DIFFERENCES IN PERFORMANCE CAN BE EXPECTED IF THOSE CONDITIONS ARE CHANGED.

TRADELINE MODELS

TRADELINE models are selected and packaged for ease of handling, ease of stocking, and maximum replace- ment value. TRADELINE model specifications are the same as those of standard models, except as noted.

TRADELINE MODELS AVAILABLE:

Y86lOF Intermittent Pilot Retrofit Kit:

All models meet ANSI 221.71 Automatic Intermittent

Pilot Ignition Systems for Field Installation.

For natural gas applications only.

Ignition trial continues until either the pilot lights or the system manually shuts down.

S86lOF Intermittent Pilot Module. Available with or without vent damper plug (specify when ordering).

VR8204A or VR8440A or M Dual Valve Combination

Gas Control (specify when ordering).

Refer to Fig. 1 for other components.

Y861 OH Intermittent Pilot Retrofit Kit: l

All models meet ANSI 221.71 Automatic Intermittent

*

Pilot Ignition Systems for Field Installation.

I “I llCll”,cl, “I LI y-3 rA~~“‘“U.‘“‘I”. l l l l

90 second maximum ignition trial. 100 percent pilot shutoff on loss of flame.

S861 OH Intermittent Pilot Module.

VR8204A or VR8440Aor M Dual Valve Combination

Gas Control (specify when ordering).

Refer to Fig. 1 for other components.

AMBIENT TEMPERATURE RATING:

VR8204A: 0 to 175” F [-I 8 to 79” C].

VR8440A: -40 to 175” F [-40 to 79” C].

VR8440M: 32 to 175” F [0 to 79” C].

Also refer to Igniter-Sensor specifications.

ELECTRICAL RATINGS:

Voltage and Frequency: 20.5 to 28.5 Vat (24 Vat nominal), 60 Hz.

Current Rating: 0.7A (includes both module and gas control).

Thermostat Anticipator Setting: 0.7A plus current rat- ings of other devices in thermostat control circuit.

RELATIVE HUMIDITY RATING: 5 to 90 percent at 95“ F

[35” C].

THERMOSTAT COMPATIBILITY:

Compatible with any Honeywell 24V thermostat and with competitive 24V thermostat that is powered inde- pendently of the module.

TRANSFORMER SIZING:

Add current ratings of Y8610, vent damper, and any cwctcam pnmnnnpnts

Iltinlw this tntnl hv

24V to determine the transformer VA requirement.

WIRING CONNECTIONS:

Between the module and gas control: 30 inch [762 mm] wiring harness with 114 inch quick-connect terminals.

Between the module and the igniter-sensor: 30 inches

[762 mm] ignition cable with stud terminal and l/4 inch quick-connect terminal.

,.

. :f :. .,

I 1: . .

:

~f&#!#S@.~~Q;

. :

‘:’

FOR ORDERING INFORMATION WHEN PURCHASING REPLACEMENT AND MODERNIZATION PRODUCTS

FROM YOUR TRADELINE WHOLESALER OR YOUR DISTRIBUTOR, REFER TO THE TRADELINE CATALOG

OR PRICE SHEETS FOR COMPLETE ORDERING NUMBER, OR SPECIFY:

IF

1. TRADELINE order number.

2. Natural or LP gas application.

3. Ambient temperature rating.

YOU HAVE ADDITIONAL

4. Gas control inlet and outlet size.

5. Vent damper plug on module, if desired.

PRODUCTS OR SERVICES, PLEASE WRITE OR PHONE:

1.

RESIDENTIAL AND BUILDING CONTROLS SALES OFFICE (CHECK WHITE

PAGES OF PHONE DIRECTORY).

2. RESIDENTIAL AND BUILDING CONTROLS CUSTOMER SERVICES

HONEYWELL INC.,

1885 DOUGLAS DRIVE NORTH

MINNEAPOLIS, MINNESOTA 55422

(612) 542-7500

IIN banana-

CONTROLS

740 ELLESMERE ROAD

L!M!TED

SCARBOROUGH, ONTARIO Ml P 2V9)

INTERNATIONAL

SALES AND SERVICE OFFICES IN ALL PRINCIPAL CITIES OF THE WORLD.

S8610 INTERMITTENT

PILOT MODULE WITH

WIRING HARNESS

392431 IGNITER - SENSOR

ASSEMBLY

IGNITER-SENSOR

ALSO INCLUDED:

-

392125 IGNITION CABLE

(30 INCHES [760

mm])

-

393690-14 STRAIGHT FLANGE KIT

(VR6204A ONLY)

- REDUCER BUSHINGS FOR GAS CONTROL

-SCREWS

-WIRE NUTS (3)

ADAPTER

-

FIG. l-Y8610 RETROFIT KIT COMPONENTS.

INTERMITTENT PILOT MODEL SPECIFICATIONS

MODELS:

S861 OF Intermittent Pilot Module, for natural gas appli-

DIMENSIONS:

OBSOLETE mum at 1 .O uf flame current.

IGNITION TIMING:

S861OF: Until pilot lights or system is shut down water or dust accumulation. Fasten with No. 6-32 machine screws or No. 8 sheet metal screws of appro- priate length. Refer to Fig. 13.

SAFETY LOCKOUT TIMING:

S861 OF: None. Ignition trial continues until pilot lights or system is manually shut down.

S8610H: 70 seconds nominal. 90 seconds maximum.

Provides 100 percent gas shutoff if pilot does not light.

SPARK GENERATOR OUTPUT: 13 kV peak at 25 pf load

(16kV peak open circuit).

TERMINALS: l/4 inch male quick-connects. S861 OF1016 manually. has Molex plug for connection to Honeywell D80D Vent

S861 OH: Until pilot lights or lockout occurs.

Damper or Penn Baso G60 or G66 Vent Damper. Once the S861OF has powered a vent damper, the module

MOUNTING: Mounts in any pcsition except with terminals will work only if the vent damper is connected. up. Recommended mounting position is with terminals down to provide maximum protection from dripping

3 68-0102-2

MI123 n

PLUG.

FIG. 2-S8610F,H MODULE DIMENSIONS.

ADJUSTMENT

(UNDER CAP SCRE

INLET

OUTLET

P,,_DT OUTLET

PlLDT ADJUSTMENT

(“NDER CAP SCREW)

VR8204

OBSOLETE

-

-

-

FIG. 3-VR8204A MOUNTING DIMENSIONS IN INCHES AND [MILLIMETERS].

4

I c

VR8440

DUAL VALVE COMBINATION GAS CONTROL

SPECIFICATIONS

MODELS:

VR8204A Dual Valve Combination Gas Control.

VR8440A Dual Valve Combination Gas Control.

VR8440M Dual Valve Combination Gas Control.

AMBIENT TEMPERATURE RATING:

VR8204A: 0 to 175” F [-18 to 79” C].

VR8440A: -40 to 175” F [-40 to 79” C].

VR8440M: 32 to 175” F [0 to 79” C].

CAPACITIES AND PIPE SIZES:

Model

VR8204A

VR8440A,M

Pipe Size

(Inlet X Outlet)

l/2 x l/2

1 I2 x 3/4b

112x314

Capacitf

FT3/HR M3/HR

150

150

190

4.2

4.2

5.4

314 x 314 200 5.7 aBased on 1,000 Btuh/ft3, 0.64 specific gravity natural gas at 1 inch WC pressure drop [37.3 MJ/m3, 0.64 specific gravity natural gas at 0.25 kPa pressure drop]. bWith a l/2 x 3/4 inch straight flange (included).

DIMENSIONS:

VR8204A: Refer to Fig. 3.

VR8440A,M: Refer to Fig. 4.

MOUNTING: Can be mounted

from 0 to 90 degrees, in any direction, from the gas control upright position. Two No. lo-32 UNF tapped mounting holes in the base for bracket mounting (VR8440A,M only).

PRESSURE RATING: l/2 psig [3.45 kPa] inlet pressure.

TERMINALS:

VR8204A; 114 inch male quick-connect terminals.

VR8440A,M: Combination screw terminals and 114 inch male quick-connect terminals.

IGNITER-SENSOR SPECIFICATIONS

MODEL: 392431 Igniter-Sensor. Includes igniter-sensor assembly, ground rod, and adapter (Refer to Fig. 1).

DIMENSIONS: Refer to Fig. 5.

ELECTRODE/FLAME ROD MATERIAL: Kanthal.

MAXIMUM TEMPERATURE RATINGS:

Ground rod tip: 1775” F [968” C].

Ceramic insulator: 1250” F [677” C].

MOUNTING: Replaces the thermocouple on the existing pilot burner.

-i

Q1291f

1

I.0198

\

IG. 5-392431

IGNITER-SENSOR MOUNTING DI-

MENSION IN INCHES AND [MILLIMETERS].

5 68-0102-2

Intermittent pilot systems are used on a variety of central heating equipment and on heating appliancessuch as commercial cookers, agricultural equipment, industrial heating equipment, and pool heaters. Some of these applications may make heavy demands on the controls, either because of frequent cycling or because of moisture, corrosive chemicals, dust, or excessive heat in the envi- ronment. In these applications, special steps may be required to prevent nuisance shutdowns and premature control failure. These applications require Honeywell Resi- dential and Building Controls Engineering review; contact your Honeywell Sales Representative for assistance.

FREQUENT CYCLING

These controls are designed for use on space heating appliances that typically cycle 3 to 4 times an hour during the heating season and not at all during the cooling season. In applications with significantly greater cycling rates and longer heating seasons, we recommend monthly checkout because the controls may wear out more quickly.

WATER OR STEAM CLEANING

Once a module or gas control has been wet, it may operate unreliably and must be replaced. If the appliance will be cleaned with water or steam, the controls and associated wiring should be covered so water or steam flow cannot reach them. The controls should be high enough above the cabinet bottom so flooding or splashing water will not reach them during normal cleaning proce- dures. If necessary, shield the controls to protect them from splashing water. A NEMA 4 enclosure is recom- mended for the ignition module; see the Electronic Ignition

Service Manual, form 70-6604.

HIGH HUMIDITY OR DRIPPING WATER

Over time, dripping water or high ambient humidity can create unwanted electrical paths on the module circuit board, causing the module to fail. Never install an appli- ance where water can drip on the controls.

In addition, high ambient humidity can cause the gas control to corrode, and finally to fail.

Where the appliance may be installed in a humid atmosphere, make sure air circulation around the module and gas control is adequate to prevent condensation. It’s also important to regularly check out the system. A NEMA

4 enclosure may be needed; see the Electronic Ignition

Service Manual, form 70-6604.

CORROSIVE CHEMICALS

Corrosive chemicals can also attack the module and gas control and eventually cause a failure. Where chemi- cals may be used routinely for cleaning, make sure the cleaning solution cannot reach the controls. Where chemi- cals are likely to be suspended in air, as in some industrial and agricultural applications, protect the ignition module from exposure with a NEMA 4 enclosure; see the Elec- tronic Ignition Service Manual, form 70-6604.

DUST OR GREASE ACCUMULATION

Heavy accumulation of dust or grease may cause the controls to malfunction. Where dust or grease may be a problem, provide covers

for the module and the gas control that will limit environmental contamination. A NEMA 4 enclosure is recommendedforthe ignition module; see the

Electronic Ignition Service Manual, form 70-6604.

HEAT

The controls can be damaged by excessively high temperatures. Make sure the maximum ambient tempera- ture at the control locations will not exceed the rating of the control. If the appliance normally operates at very high temperatures, insulation, shielding, and aircirculation may be necessary to protect the controls. Proper insulation or shielding should be provided by the appliance manufac- turer; make sure adequate air circulation is maintained when the appliance is installed.

4

4 application.

WHEN INSTALLING THlS PRODUCT...

1. Read these instructions carefully. Failure to follow condition.

OBSOLETE

3. Ensure the installer is a trained, experienced service technician.

4. After completing installation, use these instructions to check product operation.

IMPORTANT

1. Installer must comply with local codes and ordi- nances of the National Fuel Code (ANSI

2223.1-NFPA No. 54.) and National Electrical

Code (ANSI NFPA No. 70).

2. Installer must fill in and attach label to appliance being converted.

3. UseY8610 retrofit kit only with atmospheric burn- ers. Do not use on direct vent appliances or power burners.

4. Do not use the Y8610 retrofit kit with mercury pilots or 250 to 750 mV pilot systems.

6

L

\

-

CAN CAUSE PROPERTY DAMAGE, SEVERE IN-

JURY, OR DEATH

Follow these warninqs exactly:

1.

Disconnect the power supply before wiring to

2.

prevent electrical shock or equipment damage.

To avoid dangerous accumulation of fuel gas, turn off gas supply at the appliance service valve before starting Installation and perform Gas Leak

3.

4.

Test following the installation.

Never install where water can flood, drip, or condense on module or gas control. Never use a module or gas control that has been wet. If wet, controls can malfunction and lead to an accumu- lation of explosive gas.

Do not light or operate electric switches, lights, or appliances until you are sure the appliance area is free of gas. Liquefied petroleum (LP) gas is heavier than air and will not vent upward natu- rally.

Intermittent use: Appliances that are used season- ally should be checked before shutdown and again before the next use.

Consequence of unexpected shutdown: Where the cost of an unexpected shutdown is high, the system should be checked more often.

Dusty, wet, or corrosive environment:

Since, these environments can cause the controls to deteriorate more rapidly, the system should be checked more often.

Any control should be replaced if it does not perform properly on Checkout or Troubleshooting. In addi- tion, replace any module if it is wet or looks like it has ever been wet. Protective enclosures as outlined under “Planning the Installation” are recommended regardless of checkout frequency.

SHUT DOWN APPLIANCE

1. Turn off gas supply at the appliance service valve. Do not use the gas control knob.

2. Turn off the electricity at the service entrance.

CHECK APPLIANCE WIRING

The standing pilot gas control wires will be used with the

Y8610 kit. Carefully identify and tag the wires before disconnecting. Refer to Fig. 6 for the most common types of terminal arrangements.

PERFORM THE PREINSTALLATION SAFETY

INSPECTION

The preinstallation checks described in ANSI Standard

221.71 on page 24 must be performed before installing the

Y8610. If an unsafe condition is detected, the appliance should be shut off and the owner advised of the unsafe condition. Any potentially unsafe condition must be cor- rected before proceeding with the Installation.

COMMON

COMMON

Maintenance Requirements In Severe Environments

Regular preventive maintenance is important in any application, but especially so in commercial cooking, agri- cultural, and industrial applications because l

In many applications, particularly commercial cook- ing, the equipment operates 100,000 to 200,000 cyclesperyear. Such heavycyclingcan wearout the

FIG. GWIRING CONNECTIONS ON STANDING PILOl

GAS CONTROLS.

gas control in one to two years. A normal forced air furnace, for which the controls were originally in- tended, typically operates less than 20,000 cycles

REMOVE STANDING PILOT GAS CONTROL

per year. l

1. If the gas control has common terminal(s), remove

I

Exposure to water, dirt, chemicals, and heat can damage the module or the gas control and shut down the control system. A NEMA 4 enclosure can reduce exposure to environmental contaminants.

See Electronic Ignition Service Manual, form 70-

6604.

The maintenance program should include regular sys-

OBSOLETE

CAN CAUSE PROPERTY DAMAGE, SEVERE IN-

JURY, OR DEATH

Do not attempt to disassemble or clean the module.

Improper reassembly and cleaning may cause un- together with one of the wire nuts provided.

2. Tag and remove the remaining wires.

Do not bend the pilot gas tubing at the gas control or at the pilot burner. Gas leakage at the connection will result.

3. Disconnect the pilot tubing at the gas control. Cut off and discard the compression fitting. Do not disturb the compression fitting or pilot tubing at the pilot burner.

4. Disconnect the thermocouple lead at the gas control.

5. Disconnect the gas piping at the gas control.

6. Discard the gas control.

REMOVE THERMOCOUPLE

Unscrew or snap the thermocouple out of the pilot reliable operation. the wires connected to the common terminal(s) and splice

1 burner and discard. Refer to Fig. 7.

Maintenance frequency must be determined individu- ally for each application. Some considerations are: l

Cyc/jng frequency: Appliances that cycle more than

20,000 times annually should be checked monthly.

NOTE: It may be necessary to pull main burner out for access to the pilot burner. Do not move or relocate the pilot burner. Do not bend tubing near the pilot burner.

7

68-0102-2

INSTALL THE GAS CONTROL

THERMOCOUPLE

1743

IG. 7--REMOVE THERMOCOUPLE FROM PlLOl

BURNER.

INSTALL THE IGNITER-SENSOR ASSEMBLY

1.

Install the ground rod if needed. Refer to Fig. 8. l l l

Mount adapter to ground rod (if needed).

Line up ground rod so clip will hug pilot burner and keep ground rod from rotating. Refer to Fig. 9.

Insert ground rod in place of thermocouple on pilot burner. Push ground rod all the way up.

Fasten as shown in Fig. 8.

2. Slide igniter-sensor mounting bracket over ground rod top.

3. Adjust electrode position so electrode tip and spark gas are in pilot flame. Turn ground rod to move igniter- sensor up and down.

4. Check that the chosen position allows room to con- nect the ignition cable to the stud terminal.

5. Tighten the setscrews on mounting bracket using hex wrench brovided.

SCREW-IN TYPE

PUSH-IN TYPE

FIRE OR EXPLOSION HAZARD

CAN CAUSE PROPERTY DAMAGE, SEVERE IN-

JURY, OR DEATH

Follow these warnings exactly:

1. Do not bend the pilot gas tubing at gas control or at the pilot burner after compression fitting is tightened. Gas leakage at the connection

2. may result.

Always install a sediment trap in the gas sup- ply line to prevent contamination of the gas

3. control.

Do not force the gas control knob. Use only your hand to turn the gas control knob. If the gas control knob will not operate by hand, the gas control should be replaced by a qualified service technician. Force or attempted repair may result in a fire or explosion.

These gas controls are shipped with protective seals over the inlet and outlet tappings Do not remove the seals until ready to connect piping.

/

INSTALL ADAPTERS TO GAS CONTROL (if used)

393690-14 Straight Flange (3/4 inch) (VR8204 only)

1. Remove seal over gas control inlet or outlet.

2. Ensure that the O-ring is fitted in the flange groove. If the O-ring is not attached or missing, do not use the flange.

3. With the O-ring facing the gas control, align the gas control threaded holes with the flange clearance holes.

4. Insert and tighten the screws provided with the flange. Tighten the screws to 25 inch pounds of torque to provide a gas tight seal.

Bushings:

1.

Remove seal over gas control inlet or outlet.

TIGHTEN NUT

BE

SURE THE GRO”ND CUP IS SNAPPED ONTO THE

PLOT BURNER OR ITS GAS

LINE.

1 I.01~

FIG. &MOUNT GROUND ROD ON PILOT BURNER

-

2. Apply moderate amount of good quality pipe com- pound to bushing, leaving two end threads bare. On LP installation, use compound resistant to LP gas. Do not use

Teflon Tape.

3. Insert bushing in gas control and thread pipe

carefully

OBSOLETE

whichever applies. Tubing installation must comply with approved standards and practices.

1. Use new, properly reamed pipe free from chips. If tubing is used, ensure that ends are square, deburred, and clean. All tubing bends must be smooth and without deformation.

2. Run new pipe or tubing to the gas control. If tubing is used, obtain a tube-to-pipe coupling to connect tubing to gas control.

3. Install a sediment trap in the gas supply line. Refer to

Fig. 10.

%G~

11.0728

IG. O-FASTEN IGNITER-SENSOR TO GROUNt

ROD.

-

-

DROP

HORIZONTAL, hl

1

I

PIPED

I/I

GAS

SUPPLY

-L

I

I

4. Apply a moderate amount of good quality pipe com- pound to pipe only, leaving two end threads bare. DO NOT

USE TEFLON TAPE. In LP installations, use compound resistant to LP gas. Refer to Fig. 11.

5.

Remove protective seals over the gas control inlet and outlet, if necessary.

6.Connect pipe to the gas control inlet and outlet.

Tighten the inlet and outlet connections using a wrench on the gas control projecting wrench boss. Refer to Figs. 3 or

4. t

II

PIPED

GAS

SUPPLY

L3 in.

176 mm]

MlNlM”M

A

TO PREVENT GAS FROM FILLING THE WORK AREA. TEST FOR GAS LEAK.

AGE WHEN INSTALLATION IS COMPLETE.

69110

FIG. lo--INSTALL SEDIMENT TRAP.

MOUNT GAS CONTROL

1. The gas control can be mounted from 0 to 90 de- grees, in any direction, from the upright position of the gas control knob, including vertically.

2. Mount the gas control so gas flow is in same direction as the arrow on the gas control bottom.

3. Thread the pipe as listed in Table

1.

NOTE: Do not thread the pipe more than listed in Table 1.

If pipe is inserted too deeply into gas control, second main valve or safety valve may distort or malfunction.

TABLE l-NPT PIPE THREAD LENGTH (INCHES).

Maximum Depth

Pipe Can Be

Pipe

Size

318 l/2

314

Overall Thread

Length

9/l 6

314

13116

Inserted Into

Gas Control

318 l/2

USE MODERATE AMOUNT OF DOPE

THREAD PIPE RIGHT LENGTH LEAVE 2 END THREADS BARE

313s

IG. ll-USE MODERATE

COMPOUND.

AMOUNT OF PIP1

CONNECT PILOT GAS TUBING

1. Cut the pilot gas tubing and bend as necessary for routing to the pilot burner. l

Do not make sharp bends or deform tubing. l

Do not bend tubing at the gas control after the compression nut has been tightened. Gas leakage at the connection may result.

2. Square off and remove burrs from the tubing end.

3. Unscrew the brass compression fitting from pilot gas outlet (Refer to Figs. 3 or 4). Slip the fitting over the pilot gas tubing and slide out of the way.

NOTE: When replacing a gas control, cut off the old compression fitting and replace with the new compres- sion fitting provided on the new gas control. Never use the old compression fitting as it may not provide a gas tight seal. Refer to Fig. 12.

4. Push pilot gas tubing into pilot gas tapping until it bottoms. While holding tubing all the way

in, slidecompres- sion fitting into place and engage threads. Turn until finger tight. Using a wrench, tighten one more turn. Do not overtighten.

5. Connect other end of pilot gas tubing to pilot burner according to pilot burner manufacturer’s instructions.

GAS CONTROL BODY TIGHTEN NUT ONE TURN

BEYOND FINGER TIGHT

PILOT TUBING

P

FITTING BREAKS OFF

AND CLINCHES TUBING

AS NUT IS TIGHTENED

7363A

I

FIG. 12-ALWAYS

FITTING.

USE A NEW COMPRESSlOh

MOUNTING S8610 INTERMITTENT PILOT MODULE

Select a location close to the pilot burner to allow the ignition cable to run to the igniter-sensor. The ambient temperature and other conditions should match those listed in Specifications.

We recommend mounting the module with the termi- nals down so the terminals are protected from dripping water and dust. It can also be mounted with the terminals on either side. Do not mount the module with the terminals pointing up. Refer to Fig. 13 for mounting recommenda- tions. Fasten securely with four No. 6-32 machine screws or No. 8 sheetmetal screws of appropriate length.

9

68-0102-2

MOUNT THE $3610 IN ANY OF THESE POSITIONS:

TERMINALS FACING DOWN

TERMINALS FACING LEFT TERMINALS FACING RIGHT

DO NOT MOUNT THE S8610 WITH TERMINALS FACING UP

WIRING THE SYSTEM

Disconnect the power supply before making wiring connections

I_....““”

quick-connect

OBSOLETE

Igniter-Sensor.

Connect the Vent Damper

The D80D Vent Damper can be used with all ignition modules, although the Molex plug provided on some fuse has blown, the module won’t work unless the vent damper is connected.

To connect the plug-in vent damper:

1. Remove and discard the vent damper plug from the module terminal strip.

2. Using the wiring harness supplied, insert the match- ing pin plug into the receptacle on the module and the other end to the vent damper.

To connect the D80B Vent Damper follow the wiring diagrams supplied with the vent damper.

Connect S8610 Module

1. Connect the gas control and other remaining system components to the ignition module terminals as shown in the Figs. 14 through 16.

Fig. 14 shows a basic circuit for a heating only atmospheric burner system.

Fig. 15 shows a heating only atmospheric burner system with a D80D Vent Damper. modules simplifies wiring connections when used with the

D80D Plug-in Vent Damper. Once a module with a vent

damper plug has powered a vent damper circuit it cannot

be used in a gas system without a vent damper. A replace- able fuse in the module blows on initial power-up. Once this l l

10

‘- l

Fig. 16 shows a heating only system with a D80B

Vent Damper.

2. Adjust the thermostat heat anticipator to match sys- tern current draw. The current draw equals the total current required for the ignition module (0.2A) plus the gas control and any other auxiliary equipment in the control circuit.

Connect Ground Control System

The igniter, flame sensor, and ignition module must share a common ground with the main burner.

1. Fit one end of the ground wire with a female l/4 inch quick-connect terminal and connect it to the male quick- connect GND (BURNER) terminal on the ignition module.

2. Strip the other end of the wire and fasten it under the igniter bracket mounting screw. If necessary, use a shield to protect the ground wire from radiant heat.

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

NOTE: “Earth” ground is not required.

GND

MV MViPV PV (BURNER)

S861OF H

24V TH-W

GND 24V (OPT)

B

VENT

DAMPER

PLUG (OPT) SPARK

.A

VRBZMA

COMBINATION

GAS CONTROL

COMBINATION

GAS CONTROL

J I

I

------------

--------------A

CONTROLLER

PILOT

BURNER

GROUND

A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REDUIRED

A ALTERNATE LIMITCONTROLLER LOCATION.

B

A

A

V8610 INCLUDES EITHER VR6204A. VR8440A. OR VR6440M COMBINATION

CONTROLS IN 24VClRCUlT

24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.

GAS CONTROL

MUST NOT BE IN GROUND LEG TO TRANSFORMER.

FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT THERMOSTAT TO TH-W. LEAVE

OBSOLETE

M 553

FIG. 14-Y8610 IN TYPICAL ATMOSPHERIC BURNER HEATING SYSTEM.

11

68-0102-2

a

VR82C.4.A

COMBINATION

GAS CONTROL

GND

MV

I

PV

PV/MV

El5l

MV MV/PV PV (BURNER)

I l,l,l,

S6610F.H

24V

GND 24V TH-W a VENT

DAMPER

PLUG g l-l

------------

------------e-2

GAS CONTROL

J I

I

J

D80D VENT

DAMPER

SPARK

--j

PILOT

BURNER

GROUND

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

A ALTERNATE LIMIT CONTROLLER LOCATION.

8 YE1610 INCLUDES EITHER VR62C44 VR644oA. OR VR6440M COMBINATION GAS CONTROL.

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

A REMOVE PLUG ONLY IF USING VENT DAMPER. FUSE BLOWS ON STARTUP WHEN PLUG IS REMOVED

AND VENTDAMPER WIRING HARNESS IS INSTALLED; THEN MODULE WILL OPERATE ONLY WHEN VENT

M 554

DAMPER IS CONNECTED.

OBSOLETE

FIG. 16-Y8610 IN A TYPICAL ATMOSPHERIC BURNER HEATING SYSTEM WITH A D80D VENT DAMPER.

12

GND

MV MVA’V PV (BURNER)

I, I,I

7

I

24V TH-W

GND 24V (OPT)

--1

A VENT

DAMPER

PLUG (OPT) r---l

I

!.__A

I

I- l--h

END SWITCH

N.O. N.C.

Dt3OB

SPARK

VR8204A

COMBINATION

GASCONTROL

VRt3440A.M

COMBINATION

GASCONTROL lK3

J

THERMOSTAT

PILOT

BURNER

GROUND

A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTON AS REQUIRED

8 ALTERNATE LIMIT CONTROLLER LOCATION.

A YE%10 INCLUDES EITHER A VR&?C.%A, VR6440A. OR VR8440M COMBINATION GAS CONTROL a CONTROLS IN 24V CIRCUIT MUST IdOT BE IN GROUND LEG TO TRANSFORMER

A

A

FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT VENT DAMPER

TERMINAL 1 TO TH-W. LEAVE 24V OPEN. W NOT REMOVE VENT DAMPER PLUG.

COLORS REFER TO WIRE HARNESS, IF USED.

OBSOLETE

FIG. 16-Y8610 IN A TYPICAL FAN ASSISTED COMBUSTION BURNER HEATING SYSTEM.

13

68-0102-2

l

See OPERATION, page 16, and SPECIFICA-

TIONS, page 2.

Check out the gas control system: l

At initial appliance installation. l

As part of regular maintenance procedures. Mainte- nance intervals are determined by the application. l l

See PLANNING THE INSTALLATION, page 6, for more information.

As the first Troubleshooting step.

Any time work is done on the system.

STEP 3: Reset the Module. l

Turn the thermostat to its lowest setting. l

Wait one minute.

As you perform Steps 4 through 9, watch for

points where operation deviates from normal. Refer to Troubleshooting

Chart to correct problem.

~1

.:.:;:

‘:

._(:

‘i :

CAN CAUSE PROPERTY DAMAGE, SEVERE IN-

JURY, OR DEATH

1. If you smell gas or suspect a gas leak, turn off gas at the manual service valve and evacuate the building. Do not try to light any appliance and do not touch any electrical switch or telephone in the building until no spilled gas remains.

2. Perform the Gas LeakTest after initial Installa- tion and any time work is done to the gas piping.

STEP 4: Check Safety Shutoff Operation. l

Turn gas supply off at the manual shutoff valve. l

Set thermostat or controller above room tempera- ture to call for heat. l l l

Watch for spark at pilot burner.

Time spark from start to shutoff. See SPECIFICA-

TIONS, page 2.

Open gas control knob and ensure no gas is flowing l to pilot or main burner.

Set thermostat below room temperature and wait one minute before continuing.

STEP 5: CHECK AND ADJUST GAS INPUT TO MAIN

URNER

STEP 1: Perform a Visual Inspection. l

With the power off, ensure all wiring connections are l l clean and tight.

Turn off all power to appliances and ignition module.

Open manual shutoff valves in the gas line to the l appliance.

Perform Gas Leak Test.

1. Do not exceed the input rating stamped on the appliance nameplate,’ or manifactur&‘s recom- mended burner orifice pressure for the size orifice(s) used. Ensure the main burner primary air supply is properly adjusted for complete com- bustion (refer to the appliance manufacturer’s instructions).

IFCHECKING GAS INPUT BY CLOCKING THE

GAS METER:

Ensure that they only gas flow through the meter is that of the appliance being tested.

Ensure that other appliances are turned off

CAN CAUSE PROPERTY DAMAGE, SEVERE IN- and that their pilot burners are extinguished

1 JURY, OR DEATH _ . /

Check for gas leaks with rich soap and water

solution any time work is done on a gas control.

GAS LEAK TEST

1. Paint all pipe connections upstream of the gas control leak.

3.Stand

OBSOLETE

(including adapters) and gas control inlet and outlet with rich soap and water solution.

5. If another gas leak is detected, tighten adapter screws, joints, and pipe connections.

(or deduct their gas consumptions from the meter reading).

Convert the flow rate to Btuh as described in the Gas Controls Handbook (form number 70-

6202) and compare to the Btuh input rating on the appliance nameplate.

IF CHECKING GAS INPUT WITH A MANOME-

TER (PRESSURE GAUGE):

Ensure the gas control knob is in the PILOT position before removing the outlet pressure tap plug to connect the manometer.

Turn the gas control knob back to PILOT when removing the manometer and replacing outlet pressure tap plug.

Shut off the gas supply at the appliance serv- ice valve or, for LP gas, at the gas tank before removing outlet the pressure tap plug and

6. Replace the part if gas leak can not be stopped. before disconnecting the manometer and re- placing the outlet pressure tap plug.

Perform the Gas Leak Test at the inlet pres- sure tap plug.

STEP 2: Review Normal Operating Sequence and Module

Specifications.

4

4

-J

4

-’

14

“y

1. The gas control output pressure should match the manifold pressure listed on the appliance nameplate.

2. With the main burner operating, check the gas control flow rate using the meter clocking method or check the gas pressure using a manometer connected to the gas control outlet pressure tap. Refer to Figs. 3 or 4.

3. If necessary, adjust the pressure regulator to match the appliance rating.

Gas control outlet pressure is normally set at 3.5 inches

WC [0.9 kPa] nominal for natural gas. It can be adjusted from 3 to 5 inches WC [0.74 to 1.2 kPa].

Gas control outlet pressure is normally set at 10 inches wc [2.5 kPa] nominal for LP gas. It can be adjusted from

8 to 12 inches WC [2 to 3 kPa]. a. Remove the pressure regulator adjustment cap and screw. b. Using ascre driver, turn the inner adjustment screw clockwise /“i n to increase or counterclockwise to decrease the main burner gas pressure. c. Always replace the cap screw and tighten firmly to ensure proper operation.

4. If the desired outlet gas pressure or gas flow rate cannot be achieved by adjusting the gas control, checkthe gas control inlet pressure using a manometer at the inlet pressure tap. If the inlet pressure is in the normal range, replace the gas control. Otherwise, take the necessary steps to provide proper gas pressure to the gas control.

I

I

,IGNITER.SENSOR TIP IN PlLOT FLAME

\ \ -

GROW0 ROD

ELECTRODE SCREW

IGNITER-SENSOR

ST”0 TERMINAL mm--mm_

‘._______\r-~----*

,__v.

____

FIG. l-/-PROPER FLAME ADJUSTMENT.

STEP 7: Check Other System Components l

ON FURNACES: Ensure the limit controller and fan controller are operating in accordance with the appli- ance manufacturer’s instructions. l

ON BOILERS: Ensure the circulating water pumps, low water cutoffs, automatic feed controllers, pres- sure and temperature limit controllers, and relief valves are operating in accordance with the appli- ance manufacturer’s recommendations.

STEP 6: Adjust Pilot Flame

The pilot flame should envelop 3/8 to l/2 inch [I 0 to 13 millimeters] of the ground rod and tip of the igniter-sensor.

Refer to Fig. 17. To adjust the pilot flame:

1. Remove the pilot adjustment cover screw. Refer to

Figs. 3 or 4.

2. Turn the inner adjustment screw clockwise n decrease or counterclockwise fl to to increase the pilot flame.

3. Always replace the cover screw after adjustment and tighten firmly to ensure proper operation.

STEP 8: Check Normal Operation

Set thermostat or controller above room tempera- ture to call for heat.

Ensure pilot lights smoothly when gas reaches the pilot burner.

Ensure main burner lights smoothly without flash- back.

Ensure main burner operates smoothly without floating, lifting, or flame rollout to the furnace vesti- bule or heat buildup in the vestibule.

If gas line has been disturbed, complete the Gas

Leak Test, page 14.

Turn thermostat or controller below room tempera- ture. Ensure the main burner and pilot flames go out.

OBSOLETE

15 68-0102-2

System operation is divided into two stages:

1. Trial for ignition.

2. Main burner operation

Refer to Fig. 19 for the normal operating sequence.

START

THERMOSTAT (CONTROLLER)

CALLS FOR HEAT

I

STAGE 1

TRIAL FOR

IGNIITION

I

Fwst valve (pilot) operator opens

I

PILOT BURNER OPERATION

Pilot burner does not light.

OR ~

STAGE 2

MAIN BURNER

OPERATION

END

FLAME CURRENT SENSED

- Spark generator oft,

*

Second valve operator (main) opens.

Module monitors pilot flame current. r

SATISRED

Vakes dose. pilot and main burners are off.

I

System shuts off. restarts when power is

PILOT FLAME FAILURE

TRIAL FOR IGNITION

Pilot Ignition

FIG. 18--58610 NORMAL OPERATING SEQUENCE.

Following the call for heat, the module energizes the at the igniter-sensor

OBSOLETE second (main) valve and the main burner will not light.

S861OF will continue to spark as long as the thermostat calls for heat or until the pilot lights. goes into safety lockout. Lockout de-energizes the first main valve operator and closes the first main (pilot) valve in the gas control, stopping pilot gas flow. The control system must be reset by setting the thermostat below room temperature for one minute or by turning off power to the module for one minute.

MAIN BURNER OPERATION

When the pilot flame is established, a flame rectification circuit is completed between the sensor and burner ground. The flame sensing circuit in the module detects the flame current, shuts off the spark generator and energizes the second main valve operator. The second main valve opens and gas flows to the main burner, where it is ignited

Safety Lockout (S861 OH)

These modules provide 100 percent shutoff safety lockout. A timer in these models starts timing the moment the trial for ignition starts. Ignition sparkcontinues only until the timed trial for ignition period ends. Then the module by the pilot burner. On lockout models, the flame current also holds the safety lockout timer in the reset (normal) operating condition.

When the call for heat ends, both valve operators are de-energized, and both valves in the gas control close.

16

IMPORTANT

1. The following service procedures are provided as a general guide. Follow appliance manufacturer’s service instructions if available.

2.

On lockout and retry models, meter readings between gas control and ignition module must be taken within the trial for ignition period. Once the

3.

ignition module shuts off, lockout models must be reset by setting the thermostat down for at least one minute before continuing. On retry models, wait for retry or reset at the thermostat.

If any component does not function properly, make sure it is correctly installed and wired

4.

before replacing it.

The ignition module cannot be repaired. If it malfunctions, it must be replaced.

5.

Only trained, experienced service technicians should service intermittent pilot systems.

1

When performing the following steps, do not touch stripped end of jumper or SPARK terminal.

The ignition circuit generates over 10,000 volts and electrical shock can result.

i7 Energize the module and immediately touch one end of thejumperfirmly to the GND terminal on the module. Move the free end of the jumper slowly toward the SPARK terminal until a spark is established.

7 Pull the jumper slowly away from the terminal and note the length of the gap when sparking stops. Check table below.

ARC LENGTH ACTION

l-

.I

Perform the Checkout on page 14 as the first step in troubleshooting. Then check the appropriate troubleshoot- ing guide (Fig. 20) and the schematic diagram (Figs. 23-

25) to pinpoint the cause of the problem. If troubleshooting indicates an ignition problem, see Ignition System Checks below to isolate and correct the problem.

Following troubleshooting, perform the checkout pro- cedure (page 14) again to be sure system is operating normally.

No arc or arc less than l/8 in. [3 mm]

Arc 118 in. [3 mm] or longer.

Check external fuse, if provided. Verify power at module input terminal.

Replace module if fuse and power ok.

Voltage output is okay.

STEP 4: Check pilot and main burner lightoff.

0 Open the manual gas valve.

IGNITION SYSTEM CHECKS

0 Set the thermostat to call for heat.

STEP 1: Check ignition cable.

0 Watch the pilot burner during the ignition sequence. If

Make sure: the:

0 Ignition cable does not run in contact with any metal l ignition spark continues after the pilot is lit; l pilot lights and the spark stops, but main burner does surfaces.

0 Connections to the ignition module and to the igniter or not light; or l

SBGIOH only: the pilot lights, the spark stops, and igniter-sensor are clean and tight. r! Ignition cable provides good electrical continuity. main burner lights, but the system locks out.

Ensure adeauate flame current as follows:

STEP 2: Check ignition system grounding. Nuisanceshut-

Turn off furnace at circuit breaker or fuse box.

downs are offen caused by a poor or erratic ground.

L7 A common ground, usually supplied by the pilot burner

Clean the flame rod with emery cloth.

Make sure electrical connections areclean and tight. bracket, is required for the module and the pilot burner/

Replace damaged wire with moisture-resistant No. igniter sensor. l l

-

Check for good metal-to-metal contact between the pilot burner bracket and the main burner.

Check the ground lead from the GND(BURNER)

OBSOLETE

evidence of exposure to extreme heat, which can permit leakage to ground. Replace pilot burner/ igniter-sensor and provide shield if necessary.

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

18 wire rated for continuous duty up to 105” C

[221” F].

Check for cracked ceramic insulator, which can cause short to ground, and replace igniter-sensor if necessary.

At the gas control, disconnect main valve wire from the TH or MV terminal.

Turn on power and set thermostat to call for heat.

The pilot should light but the main burnerwill remain off because the main valve actuator is disconnected.

Check the pilot flame. Make sure it is blue, steady and envelops 3/8 to 112 in. [lo to 13 mm] of the flame rod. See Fig. 20 for possible flame problems and their causes.

If necessary, adjust pilot flame by turning the pilot

STEP 3: Check spark ignition circuit. You

will need a short jumper wire made from ignition cable or other heavily insulated wire.

I 1

Close the manual gas valve. ill Disconnect the ignition cable at the SPARK terminal on the module. adjustment clockwise n screw on the gas control to decrease or counterclockwise fl to increase pilot flame. Following adjustment, always replace pilot adjustment cover screw and tighten firmly to assure proper gas control operation.

Set thermostat below room temperature to end call for heat.

68-0102-2

17

.J

Recheck ignition sequence as follows. l l

Reconnect main valve wire.

Set thermostat to call for heat. l l

Watch ignition sequence at burner.

If spark still doesn’t stop after pilot lights, replace ignition module.

START

TURN GAS SUPPLY OFF.

TURN THERMOSTAT

(CONTROLLER) TO CALL

FOR HEAT

POWER TO MODULE

(24V NOMINAL)

NO

SPARK ACROSS

YES

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES

SPARK STOPS WHEN

PILOT IS LIT?

YES l

If main burner doesn’t light or if main burner lights but system locks out, check module, ground wire, and gas control as described in the troubleshooting chart, Fig. 19.

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

Check line voltage power. low voltage transformer. limit controller, thermostat (controller) and wiring. Also. check that vent damper [of used) IS open and end swtch is made.

Pull ignition lead and check spark at module.

Spark okay?

YES

On models with vent damper plug. make sure vent damper has not been installed, then removed. Replace vent damper

- Check ignition cable. ground wiring, ceramic insulator and gap. and correct.

- Check boot of the ignition cable for signs of melting or buckling. Take protective action to shield cable and boot from BxoBssive temperatures.

-

Check that all manual gas valves are open. supply tubing and pressures are gocd. and pilot burner orifice is not blocked.

- Check electrical connections between module and pilot operator on gas control.

-

Check for 24 Vat across PV-MVIPV terminals on module. If v&age is okay, replace gas contrd; if not. replan, module.

NOTE: If S661OH goes into lockout, reset system.

* Check continuity of ignition cable and ground wire.

*

Clean Ilam, rod.

-

Check electtical connedions between flame rod and module.

* Check for cracked ceramic flame rod ins&or.

-

Check that pilot flams covers flame rod and is steady and blue.

- Adjust pilot Ilame.

*

If problem persists. replace module.

*

Check for 24 Vat across MV-MVIPV terminals If no voltage. replace module.

-

Check electrical connections between module and gas control. If okay, replace gas control or gas control operator.

*

Check that pilot flame covers llame rod and is steady and blue.

- If checks are okay, replace module.

*

Check for proper thermostat (controller) qxration.

- Remove MV lead at module; if valve closes. recheck temperature controller and wiring; iI not. replace gas co”trol.

TROUBLESHOOTING

Repeat procedure until troubletree operation is obtained.

FIG. 19438610 TROUBLESHOOTING GUIDE. hi 559

18

APPEARANCE

SMALL BLUE FLAME

A

LAZY YELLOW FLAME

WAVING BLUE FLAME

I’

CAUSE

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

OF COMBUSTION

PRODUCTS

NOISY LIFTING BLOWING FLAME

CHECK FOR:

. HIGH GAS PRESSURE

HARD SHARP FLAME

THIS FLAME IS CHARACTERISTIC

OF MANUFACTURED GAS

CHECK FOR:

. HIGH GAS PRESSURE

- ORIFICE TOO SMALL

IG. PO-EXAMPLES

FLAMES.

OF UNSATISFACTORY PlLOl

i

Adjust Pilot Flame Current

The pilot flame current must measure at least 1 pA and steady or nuisance shutdowns may occur. Use a Hon- eywell WI36 to adjust the pilot flame current.

1. Disconnect the furnace power at the service en- trance.

2. Disconnect the control module green ground wire.

3.Connect the microammeter negative lead to the control module GND (BURNER) terminal and the positive lead to the green ground wire (Refer to Fig. 21).

4. Disconnect the red wire from the gas control TH or

MV terminal to disable the gas control.

5. Loosen the set screws holding the igniter-sensor on the ground rod.

6. Restore power and set thermostat to call for heat.

7. Wait until the pilot lights and sparking stops. The main burner will not light.

8.Adjust the igniter-sensor position and watch the microammeter reading.

9. When you find the igniter-sensor position that gives the maximum microammeter reading, tighten the set- screws to lock the igniter-sensor in place. This reading must be at least 1 .O pA and steady.

1 O.Turn off power, remove microammeter, and recon- nect red and green leads.

11

.Perform Checkout procedures.

I

GND

MV MV/PV PV (BURNER) sa610

24V TH-W

GND 24V (OPT)

VENT

DAMPER

PLUG (OPT) SPARK

RED (+)

PILOT

BURNER

GROUND

_

‘+

=

n

IGNITER-SENSOR UNTIL FLAME CURRENT EQUALS AT LEAST 1.0 uA (AND STEADY)

FIG. 21-ADJUSTING FLAME CURRENT.

19

M 560

68-0102-2

-’

THERMOSTAT OR

LIMIT

CONTROLLER r-_____jqq_)d”-l___-I i r-____________________J

ON-OFF

SWITCH

;

0

0

TyrrTy*-c,

2Kl

1i.b

+

SPARK

DRIVE

CIRCUIT

.

ARC

GAP

,_

0

LOW

VOLTAGE

POWER

,

SUPPLY

+

IK

.2K?,

3K ”

A a’ h

.

RELAY -+

)

DR’VERS +-

HYBRID ClRCUlf

TIMING

CIRCUITS

1Kl

Y, a lK2

,I a

3K2

YI

2K2

II =

3Kl

II =

SENSOR

BURER

GROUND

&I_ POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS AEOUIRED.

A ALTERNATE LIMITCONTROLLER LOCATION.

8 3K RELAY ON 100 PERCENT SHUTOFF MODELS ONLY. ON NON-SHUTOFF

WIRED AS FOLLOWS.

TO 24V

TO 24V (GND)

MODELS. PV AND MV

- INTERNAL WIRING

---EXTERNAL WIRING

0

41

-

-

-

-

20

Ll

(HOT) t____t9gj~~:__l

ON-OFF

LIMIT

-

[_____________________;

24V

r

VENT

DAMPER

PLUG

L____J

YELLOW

A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REOUIAED.

8

ALTERNATE LIMIT CONTROLLER

8 3.0 AMP NONREPLACEABLE

LOCATION.

FUSE. FUSE BLOWS WHEN VENT DAMPER IS PLUGGED IN

A 3K RELAY ON 100 PERCENT SHUTOFF MODELS ONLY. ON NON-SHUTOFF MODELS, PV AND MV WIRED AS FOLLOWS

TO 24V ic MAIN

TO 24V (GND)

1c

- INTERNAL WIRING

---EXTERNAL WIRING

IG. 23-Y861OF,H

OBSOLETE

BURNER

GROUND

21 68-0102-2

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 determining 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 atmospheric gas burner(s) and not of the direct vent type. It should be recognized that generalized test procedures cannot anticipate all situations. Accordingly, in some cases, deviation from this procedure may be necessary to determine safe operation of the equipment. 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 and the owner advised of the unsafe condition.

The following steps should be

followed

in making the safety inspection:

1Conduct a Gas Leakage Test of the appliance piping and control system downstream of the shutoff valve in the supply line to the appliance.

2.Visually inspect the venting system for

proper size and horizontal pitch and determine there is no blockage or restrictions, leakage or corrosion or other deficien- ties which could cause an unsafe condition.

3Shut off all gas to the appliance and shut off any other fuel-burning appliance within the same room. Use operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. If, after complet- ing steps 7 through 12, it is believed sufficient combus- tion air is not available, refer to 1.3.4of the National Fuel

Gas Code (2223.1) for guidance.

8. Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

9.a. Determine that the pilot is burning properly and that main burner ignition is satisfactory by interrupting and re-establishing the electrical supply to the appliance in any convenient manner. b. Determine manifold pressure in order to match input after the new control is installed.

10.a. Visually determine that main burner gas is burning properly; i.e., no floating, lifting or flashback. Adjust the primary air shutter(s) as required. b. If appliance is equipped with high and low flame control or flame modulation, check for proper main burner operation at low flame.

11 .Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use a draft gauge, the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

12.Return doors, windows, exhaust fans, fireplace dampers and all other fuel-burning appliances to their the shutoff valve in the supply line to each appliance. If a manual gas valve is not in the gas supply line within

6 feet of the appliance in an accessible location, one previous conditions of use.

13.Applicable only to warm air heating appliances. shall be installed.

4.lnspect burners and crossovers for blockage and

Check both limit controller and fan controller for proper operation. Limit controller operation can be checked by temporarily disconnecting the electrical supply to the corrosion. blower motor and determining that the limit control acts

5Applicable only to warm air heating appliances.

Inspect heat exchangers for cracks, openings or exces- to shut off the main burner gas.

14. Applicable only to boilers: sive corrosion.

G.Applicable only to boilers. Inspect for evidence of water or combustion product leaks.

7.lnsofar as is practical, close all building doors and windows and all doors between the space in which the appliance is located and other spaces of the building. a. Determine that the circulating water pumps are in operating condition. b. Test low water cutoffs, automatic feed con- trols, pressure and temperature limit controls manufacturer’s recommendations and in-

Turn on clothes dryers. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will structions to determine they are in operating condition.

EXHIBIT A OF ANSI STANDARD 221.71 FOR AUTOMATIC INTERMllTENT PILOT IGNITION SYSTEMS FOR FIELD

INSTALLATION

t

--

22

-

-

EXHIBIT B

PROCEDURE FOR INSTALLING AUTOMATIC INTERMITTENT PILOT SYSTEMS

Prior to beginning examination this procedure, a preliminary of the appliance and the automatic inter- mittent pilot system should be made to determine that the automatic intermittent pilot system can be properly applied to the appliance.

This procedure is intended as a guide to aid in safely installing a listed automatic intermittent pilot system on an existing listed appliance equipped with an atmos- pheric gas burner(s) and not of the direct vent type.

This procedure is based on the assumption that the history of the specific installation has been one of safe and satisfactory 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 some cases, deviation from this proce- dure may be necessary to determine safe operation of the equipment.

The following steps should be followed in making the modifications:

6. Check the heat antiicipator in the comfort thermo- stat to determine if it is properly adjusted to the current draw of the control system. Follow the thermostat manufacturer’s instructions.

7. Make certain wiring connections

8.Conduct valve in the supply line to the appliance. are tight and wires are positioned and secured so they will not be able to contact high temperature locations. a Gas Leakage Test of the appliance piping and control system downstream of the shutoff

9. a. Adjust the thermostat to its highest tempera- ture setting, and test manifold pressure and adjust the pressure regulatorto match original input as required (refer to Exhibit A, step 9b). b. Visually determine that main burner is burning properly: i.e., no floating, lifting or flashback.

1 .Perform a safety inspection of the existing appli- ante installation. See Exhibit A for a recommended procedure for such a safety inspection.

2.Shut off all gas and electricity to the appliance. To shut off gas, use the shutoff valve in the supply line to the appliance. If a manual gas valve is not in the gas supply line within 6 feet of the appliance in an acessible location, one shall be installed. Do not use the shutoff valve which is provided as part of a combination control.

3.lnstall the automatic intermittent pilot system in strict accordance with the manufacturer’s installation instructions.

4.Turn on all gas and electricity to the appliance.

5.Determine low: that the appliance a. Compute the approximate transformer has adequate capacity by following the steps outlined be- current draw by add- ing the current draw of the automatic intermittent pilot system to (1) the current draw of the associ-

Adjust the primary air shutter(s) as required. lO.lf the appliance is equipped with high and low flame control or flame modulation, check for proper main burner operation at both high and low flame.

11 .Determine that the pilot is igniting and burning properly and that main burner ignition is satisfactory by interrupting and re-establishing the appliance determination the electrical supply to in any convenient manner. Make this with the appliance burner both cold and hot. Perform this step as many times as is necessary to satisfy yourself that the automatic system is operating properly. intermittent pilot

12.Test the pilot safety device (1) to determine if it is operating properly, and (2) for turndown characteristics according to the manufacturer’s installation instruc- tions. No adjustments should be made other than those recommended by the system manufacturer.

13.Sequence the appliance through at least three operating cycles.

14.Applicable only to furnaces. Check both the limit controller and the fan controller for proper operation.

Limit control operation can be checked by blocking the circulating air inlet or temporarily disconnecting the ated valving, and (2) the current draw of any relays or other devices operated by the trans- former. gas. b. Multiply the total current draw as computed above by 24 V to determine the total VA (volt- ampere) required. c. The total VA (volt-ampere) required should be equal to or less than the VA rating of the trans- former. d. If the total VA (volt-ampere) required is greater

15. Applicable only to boilers. a. Determine that the circulating water pumps are in operating condition. b. Test low water cutoffs, automatic feed water trollers and relief valves in accordance with the manufacturer’s recommendation limit con- to deter- than the VA rating of the transformer, the trans- former must be replaced with a Class 2 trans- electrical supply to the blower motor and determining that the limit controller acts to shut off the main burner former of adequate rating. ante. mine they are in operating condition.

16.Add the labels (see 1.6.1-n and -0) on the appli-

EXHIBIT B OF ANSI STANDARD 221.71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD

INSTALLATION.

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