Honeywell S8610U User Manual

Name: Honeywell S8610U
Brand: Honeywell
SKU: 2550295
Rating: 4 (2 reviews)

4 (2)

69-1955-01

Automatic Ignition Systems ANSI Z21.20

S8610U Universal Intermittent

WARNING

Pilot Gas Ignition Control

SUPER TRADELINE

APPLICATION

The SUPER TRADELINE® S8610U Universal Intermittent Pilot Gas Ignition Control Module is designed to provide easy field replacement of a wide range of intermittent pilot ignition modules manufactured by Honeywell, Robertshaw, Johnson Controls, and others. The S8610U control provides ignition sequence, flame monitoring, and safety shutoff for intermittent pilot central furnaces, residential boilers, and other heating appliances. The S8610U replaces existing flame rectification type, intermittent pilot ignition modules with the following characteristics:

• 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 15 seconds or longer

• Prepurge configurable to 30 seconds or no prepurge

• Pilot burners with flow rates of 1,500 Btuh or less

• With or without integral damper connector

Table 1 describes the key features of the S8610U control.

Check Table 2 on page 2 before replacing an existing intermittent pilot control with the S8610U. If the existing control is not listed, do not use the S8610U to replace it unless you are certain the specifications match those of the existing control.

Table 1. S8610U Universal Intermittent Pilot Gas Ignition Control.

Igniter-Sensor

Typ e

Separate (two rod; remote flame sensing)

Combination (one rod; local flame sensing)

Valve Current

Rating

@ 24 Vac

1.0 A Pilot and

2.0 A Main

Prepurge

Timing

None or 30 seconds (field selectable)

Trial fo r

Pilot

Ignition

15 or 90 seconds (field selectable)

INSTALLATION INSTRUCTIONS

A complete list of the specific Honeywell and other modules that the SUPER TRADELINE designed to replace is provided in Table 2 on page 2.

The SUPER TRADELINE® S8610U package contains complete, easy-to-use instructions, plus the accessories required to adapt the existing spark cable (Rajah, stud, nail, or other) to the spark terminal on the control module. It also help assure proper marking of the wires attached to the existing control and a label with LED code information that can be affixed in the appliance.

IMPORTANT

The S8610U control module is not designed to replace controls with:

— Flame sensing other than by flame rectification

(White Rodgers Cycle-Pilot

thermal sensing) — Standing pilot appliances — Direct main burner ignition

The S8610U provides:

• Natural or LP gas

• Pilot burner ignition using an internally generated high voltage spark

• Flame rectification circuit to monitor flame presence

• Monitoring of 24 Vac, pilot, and main gas valve

• LED indicator for flame presence/strength and system status/errors

• Vent Damper connection

• Connections for flame reading via standard microammeter.

The S8610U is designed for a wide variety of natural or liquid propane fueled applications.

Ignition

Sequence

Typ e

Retry Spark and pilot gas ON until lightoff or trial

Ignition Sequence

(After prepurge, if prepurge is

selected)

for ignition ends.

• If established flame is lost, trial for ignition restarts immediately.

• If pilot fails to light, pilot gas and spark Off (100% shutoff). After 5 minute delay, a new trial for ignition is initiated. This sequence continues until lightoff or “Call for Heat” is removed.

S8610U is

, or Robertshaw

Included for use as needed.

• If initially installed

Integral Damper

Connector

and powered up with damper attached, unit must always have a vent damper connected.

S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL

For module replacement, the following table indicates the proper Dip Switch settings for Prepurge timing (SW1) and Trial For Ignition timing (SW2). See “Settings and Adjustments” on page 15 for Dip Switch information.

Table 2. S8610U Replaces These

Modules

Vendor / Model SW1 SW2

Honeywell

S86A1001 S86A1019 S86A1027 S86A1035 S86B1009 S86B1017 S86B1025 S86C1007 S86C1015

S86C1023 OFF ON

S86C1031 S86C1049 S86C1056 S86D1005

S86D1013 OFF ON

S86D1021 S86E1002 S86E1010 S86E1028 S86E1036 S86E1044 S86E1051 S86E1069 S86E1077 S86E1101 S86 E1119 S86E1127 S86F1000 S86F1018 S86F1026 S86F1042 S86F1059 S86F1067 S86F1075 S86F1083 S86F1091 S86G1008 S86G1016

S86G1024 OFF ON

S86G1032 S86G1057 S86G1073 S86H1006

S86H1014 OFF ON

S86H1022 S86H1048 S86H1055

S86H1063 OFF ON

S86H1089 S86H1097 S86H1105

S86H1113 OFF ON

S86H1121 OFF OFF

S86H1139 OFF ON

S86H1147 S90A1005 S90B1003 S90B1011

S860C1000 S860D1009

S860D1017 ON ON

S8600A1001 S8600B1009

S8600B1025 S8600B3005

S8600B3013 S8600C1015 S8600C3003 S8600F1000 S8600F1034 S8600F1042 S8600H1006

S8600H1014 OFF ON

69-1955—01 2

OFF OFF

ON OFF

OFF OFF

OFF ON

OFF OFF

Table 2. S8610U Replaces These

Modules (Continued)

Vendor / Model SW1 SW2

S8600H1022 S8600H1048 S8600H1055

S8600H1063 OFF ON

S8600H1071 S8600H1089 S8600H1097 S8600H1105 S8600H3002

S8600H3010 OFF ON

S8600M1005 S8600M1013 S8600M1021 S8600M2003 S8600M3001 S8600M4009 S8610A1009 S8610B1007 S8610B1015

S8610B1023 S8610B3003

S8610C1005 S8610C1013 S8610C3001 S8610F1008 S8610F1016 S8610F1024 S8610F1032

S8610H1004 OFF ON

S8610H1012 OFF OFF

S8610H1020 OFF ON

S8610H1038 S8610H1046 S8610H1053

S8610H1061 OFF ON

S8610H1079 S8610H1095 S8610H3000

S8610H3018 OFF ON

S8610H3026 S8610M1003

S8610M1011 OFF ON

S8610M1029 S8610M3009

S8610M3017 OFF ON

S8610U1003 S8610U1011

S8620C1003 S8620C1011

S8620H1002 OFF OFF

S8620H1010 OFF ON

S8620H1028 OFF OFF

S8660D1002 ON OFF

S8660D1010 ON ON

S8660J1008 S8660J1016 S8660J1024 S8660K1006 S8660K1014 S8660K1022 S8670D1000 S8670D1018

S8670D1026 S8670D3006

S8670D3014 S8670E1007 S8670E3003

S8670J3002 ON ON

OFF OFF

OFF ON

OFF OFF

OFF ON

ON OFF

ON ON

ON OFF

Table 2. S8610U Replaces These

Modules (Continued)

Vendor / Model SW1 SW2

S8670J3010 S8670K3000

S8680J1004 ON ON

ON OFF

Johnson Controls

CSA35A-617R CSA35A-618R CSA42A-600R CSA42A-601R CSA42A-602R CSA42A-603R CSA42A-604R CSA43A-600R CSA44A-600R CSA45A-601R CSA45A-602R CSA46A-600R CSA48A-600R CSA49A-600R CSA49A-605R CSA51A-601R CSA52A-600R

G60AAA-1 G60AAG-1 G60AAG-2 G60AAG-3 G60AAG-4 G60AAG-5 G60AAG-6 G60AAG-7 G60CAA-1 G60CAA-3 G60CAG-1 G60CAG-2 G60CAG-3 G60CAG-4 G60CAG-5 G60CAG-6 G60CAG-7 G60CAG-8 G60CAG-9 G60CBA-1 G60CBA-2 G60CBA-3 G60CBG-1 G60CBG-2 G60CBG-3 G60CBG-4 G60CBG-5 G60CBG-6 G60CBG-7 G60CBG-8 G60CBG-9 G60CBG-10 G60CBG-11 G60CBG-12 G60CBG-13 G60CBG-14 G60CBG-15 G60CBG-16 G60CBG-17 G60CCA-1 G60CCG-1 G60CPG-1 G60DBG-1 G60DCG-1 G60DCG-2 G60DCG-3 G60DCG-4 G60PAG-1 G60PAG-2 G60PAG-3 G60PAG-4 G60PAG-5 G60PAG-6 G60PAJ-1 G60PAK-1 G60PAK-2 G60PFH-1 G60PFH-2 G60PFL-1 G60PFQ-1 G60PVL-1 G60QAG-1 G60QAG-2 G60QAG-3

OFF OFF

S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL

Table 2. S8610U Replaces These

Modules (Continued)

Vendor / Model SW1 SW2

G60QAG-4 G60QAK-1 G60QBG-1 G60QBG-2 G60QBG-3 G60QBG-4 G60QBG-5 G60QBG-6 G60QBG-7 G60QBG-8 G60QBG-9 G60QBH-1 G60QBK-1 G60QBK-2 G60QBK-3 G60QBL-1 G60QBL-2 G60QCG-1 G60QCJ-1 G60QCL-1 G60QDG-1 G60QFL-1 G60QGH-1 G60QHL-1 G60QHL-2 G60QJL-1 G60QLG-1 G60QLK-1 G60QPL-1 G60QRH-1 G60QRH-2 G60QRH-3 G60QRL-1 G60QRL-2 G60QRL-3 G60QSL-1 G60QTH-1 G60QTL-1 G60RAG-1 G60RAK-1 G60RBG-1 G60RBG-2 G60RBG-3 G60RBK-1 G60RBK-2 G60RCG-1 G60RCG-2 G60RCJ-1 G60RDG-1 G60RDK-1 G60RGL-1 G60RHL-1 G60RHP-1 G60RPL-1 G60RSL-1 G60TTL-1 G60ZAG-1 G60ZAG-2

G65BBG-1 G65BBG-2 G65BBG-3 G65BBG-4 G65BBG-5 G65BBG-6 G65BBG-7 G65BBG-8 G65BBM-1 G65BBM-2 G65BBM-3 G65BBM-4 G65BCG-1 G65BCM-1 G65BFG-1 G65BFM G65BKG-1 G65BKG-2 G65BKG-3 G65BKM-1 G65BKM-2 G65BKM-3 G65BLG-1 G65BLG-2 G65DBG G65DBM-1 G65DBM-2 G65DBM-3 G65DCM-1 G65DFG G65DFM-1 G65DKG G65DKM G65DKM-1 G65DLM-1 G65FBG G65FFG G65FKG

OFF OFF

Table 2. S8610U Replaces These

Modules (Continued)

Vendor / Model SW1 SW2

G66AG-1 G66AG-2 G66BG-1 G66MG-1 G66MG-2 G66NG-1

G67AG-3 G67AG-4 G67AG-7 G67AG-8 G67AG-9 G67AG-10 G67AG-11 G67BG-2 G67BG-3 G67BG-4 G67BG-5 G67MG-1 G67MG-2 G67MG-3 G67MG-4 G67NG-2 G67NG-4

G600AX-1 G600AX-2 G600AX-3 G600AY-1 G600LX-1 G600LX-2 G600LY-1 G600MX-1 G600NX-1 G600RX-1

G670AW-1 G670AW-2 G670GA-1

G770LGA-1 G770LGA-2 G770LGC-1 G770LGC-2 G770LGC-3 G770LGC-4 G770LHA-1 G770LHA-2 G770LHC-1 G770MGA-1 G770MGA-2 G770MGA-3 G770MGC-1 G770MGC-2 G770MGC-3 G770MGC-4 G770MGC-5 G770MGC-6 G770MHA-1 G770MHA-2 G770MHC-1 G770NGA-1 G770NGC-4 G770NGC-5 G770NGC-6 G770NGC-7 G770NHA-1 G770NHC-1 G770RGA-1 G770RHA-1 G770RHA-2

G775RGA-1 G775RHA-1 G775RHA-2

G779 OFF OFF

Y79ABC-1 Y79ABC-2 Y79ABC-3 Y79ABC-4 Y79ABC-5 Y79ABC-6 Y79ABC-7 Y79ABD-1 Y79ABCD-2 Y79BBA-1 Y79BBA-2

OFF OFF

Table 2. S8610U Replaces These

Modules (Continued)

Vendor / Model SW1 SW2

RobertShaw

780-001 780-002

780-003 ON OFF

780-845 780-715 780-735 780-736 780-737

SP715 SP715A SP735 SP735D SP735L

USI715U OFF OFF

OFF OFF

White-Rodgers

50D49-350 50D49-360

50D49-361 ON OFF

50D49-401 OFF OFF

OFF OFF

Camstat

IPI-24-00 OFF OFF

Fenwal

05-203025-005 05-203026-005

OFF OFF

HSC

1003-3 1003-300

OFF OFF

SPECIFICATIONS

Control Voltage:

Line 24 V (18-30 Vac) 50/60 Hz

Anticipator Setting:

0.1 A plus valve load @ 24 Vac

Trial for Ignition:

See Table 1 on page 1

Prepurge: See Table 1 on page 1

Flame Failure Response Time:

2 seconds maximum

LED:

The green Status LED provides

system status, error codes, and flame strength when in run mode.

Typical Gas Control: Honeywell

models VR8204 and VR8304

Operating Temperature:

Minimum ambient temperature

rating is -40°F (-40°C)

Maximum ambient rating when

used with 2.0 A main valve is 165°F (74°C)

Relative Humidity:

0% to 95% non condensing

3 69-1955—01

S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL

WARNING

PLANNING THE INSTALLATION

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

1. Plan the installation as outlined below.

2. Plan for frequent maintenance as described in the Maintenance section.

Intermittent pilot systems are used on a wide variety of central heating equipment and on heating appliances such 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 environment. In these situations, special steps may be required to prevent nuisance shutdowns and premature control module failure. These applications require special Honeywell review; contact your Honeywell Sales Representative for assistance.

Review the following conditions that can apply to your specific installation and take the precautionary steps suggested.

Frequent Cycling

These controls are designed for use on appliances that typically cycle three to four times an hour only during the heating season. In year-round applications with greater cycling rates, the control module can wear out more quickly; perform a monthly checkout.

suspended in air, as in some industrial or agricultural applications, use a NEMA 4 enclosure for the ignition control module.

Dust or Grease Accumulation

Heavy accumulations of dust or grease can cause controls to malfunction. Where dust or grease can be a problem, provide covers for the ignition control module and the gas control to limit contamination. A NEMA 4 enclosure is recommended for the ignition control module.

Heat

Excessively high temperatures can damage controls. Make sure the maximum ambient temperature at the control module does not exceed the rating of the control module. If the appliance operates at very high temperatures, use insulation, shielding, and air circulation, as necessary, to protect the controls. Proper insulation or shielding should be provided by the appliance manufacturer; verify proper air circulation is maintained when the appliance is installed.

INSTALLATION

When Installing This Product…

1. Read these instructions carefully. Failure to follow

them could damage the product or cause a hazardous condition.

2. Check the ratings given in these instructions to make sure the S8610U module is suitable for your application.

3. Installer must be a trained, experienced service technician.

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

Water or Steam Cleaning

If the control module gets wet, replace it. If the appliance is likely to be cleaned with water or steam, protect (cover) the controls and wiring from water or steam flow. Mount the controls high enough above the bottom of the cabinet so they do not get wet during normal cleaning procedures. Use a NEMA 4 enclosure for the ignition control module.

High Humidity or Dripping Water

Dripping water can cause the control module to fail. Never install an appliance where water can drip on the controls.

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

If the appliance is in a humid atmosphere, make sure air circulation around the controls is adequate to prevent condensation. Also, regularly check out the system. A NEMA 4 enclosure is recommended for the ignition control module.

Corrosive Chemicals

Corrosive chemicals can attack the ignition control module and gas control, eventually causing a failure. If chemicals are used for routine cleaning, make sure they do not reach the controls. Where chemicals are

69-1955—01 4

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

1. The ignition control module can malfunction if it gets wet, leading to accumulation of explosive gas.

—Never install where water can flood, drip or

condense on the ignition control module.

—Never try to use an ignition control module

that has been wet; replace it.

2. Liquefied petroleum (LP) gas is heavier than air and will not naturally vent upward.

—Do not operate electric switches, lights, or

appliances until you are sure the appliance area is free of gas.

Electrical Shock Hazard. Can cause severe injury, death or property damage.

Disconnect power supply before beginning wiring or making wiring connections to prevent electrical shock or equipment damage.

S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL

CAUTION

WARNING

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

2. Wiring errors can cause improper appliance operation and dangerous conditions such as bypassing safety features.

Equipment Damage Hazard. Water can cause equipment damage or malfunction.

If ignition control module must be mounted where there is the potential for exposure to water or moisture, provide a suitable waterproof enclosure.

Maintenance Requirements in Severe Environments

Regular preventive maintenance is important in any application, but especially so in commercial cooking, agricultural, and industrial applications because:

• In many such applications, particularly commercial cooking, the equipment operates 100,000-200,000 cycles per year. Such heavy cycling can wear out the gas control in one to two years. A normal forced air furnace, for which the controls were originally intended, typically operates less than 20,000 cycles per year.

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

The maintenance program should include regular checkout of the system as outlined under “Checkout” on page 15.

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

Do not attempt to take the ignition control module apart or to clean it. Improper reassembly and cleaning may cause unreliable operation.

Maintenance frequency must be determined individually for each application. Some considerations are:

• Cycling frequency – Appliances that may cycle more than 20,000 times annually should be checked monthly.

• Intermittent use – Appliances that are used seasonally should be checked before shutdown and again before the next use.

• Consequence of unexpected shutdown – Where the cost of an unexpected shutdown would be high, the 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 ignition control module should be replaced if it does not perform properly on checkout or troubleshooting. In addition, replace any ignition control 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.

Perform Pre-Installation Safety Check

The pre-installation checks described below must be done before the replacement ignition control module is installed. If a condition that could result in unsafe operation is detected, the appliance should be shut off and the owner advised of the unsafe condition. Correct any potentially unsafe condition before proceeding with the installation.

The following safety checklist should be followed in making the safety inspection:

1. Conduct 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 deficiencies that could cause an unsafe condition.

3. Shut off all gas to the appliance and shut off any other fuel-burning appliance within the same room. Use the shutoff valve in the supply line to each appliance.

4. Inspect burners and crossovers for blockage and corrosion.

5. Applicable only to warm air heating appliances. Inspect heat exchangers for cracks, openings or excessive corrosion.

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

7. Insofar 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. Turn on clothes dryers. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. If, after completing steps 7 through 12 in this safety checklist, it is believed sufficient combustion air is not available, refer to section 1.3.4 of the National Fuel Gas Code (Z223.1) for guidance.

8. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. a. Determine that the pilot is burning properly and

that main burner ignition is satisfactory by interrupting and reestablishing 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.

c. Visually determine that main burner gas is burn-

ing properly; i.e., no floating, lifting or flashback. Adjust the primary air shutter(s) as required.

d. If appliance is equipped with high and low flame

control or flame modulation, check for proper main burner operation at low flame.

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

5 69-1955—01

S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL

CAUTION

10. Return doors, windows, exhaust fans, fireplace

dampers and all other fuel-burning appliances to their previous conditions of use.

11. Applicable only to warm air heating appliances. Check both limit controller and fan controller for proper operation. Limit controller operation can be checked by temporarily disconnecting the electrical supply to the blower motor and determining that the limit control acts to shut off the main burner gas.

12. 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 relief valves in accordance with the manufacturer’s recommendations and instructions to determine they are in operating condition.

Remove Old Ignition Control Module

Disconnect power supply before doing any work on the unit. Disconnect and tag the wires from the old module. Remove the old module from its mounting location.

Wire the System

M29889

Fig. 1. Incorrect Mounting.

Mount New Ignition Control Module

The recommended mounting for the S8610U ignition control module is the same location as the old control module. Otherwise, select a location close enough to the burner to allow a short (3 ft. [0.9 m] maximum), direct cable route to the pilot burner. Ambient temperature at the control module must be within the range listed in the “Specifications” on page 3.

Mount the ignition control module with the terminals down to protect them from dripping water and dust. The control module can also be mounted with the terminals on either side. Do not mount with the terminals pointing up. Fig. 1 on page 6 illustrates the incorrect mounting position. When it is necessary to drill new mounting holes, use the S8610U as a template to mark the mounting hole pattern. Drill new holes, as required. Fasten securely with four — No. 6-32 machine screws, or No. 8 sheet metal screws, or 8-18 x 5/8 Pan Head tapping screws.

Location

The mounting location must provide:

— Good, clear access to the field wiring terminals. — Operating ambient temperatures between

-40°F (-40°C) and 165°F (74°C). — Relative humidity below 95% non condensing. — Protection from water, steam or corrosive chemicals

that are used to clean the appliance.

— Protection from dripping water, such as from an

overfilled humidifier or from condensation.

— Protection from dust or grease accumulation.

IMPORTANT

Do not mount with terminals facing up.

69-1955—01 6

Equipment Damage Hazard.

Disconnect power supply before beginning wiring or making wiring connections to prevent electrical shock or equipment damage.

All wiring must comply with local codes and ordinances. Refer to Fig. 2 and Table 9 on page 11 for typical connections.

IMPORTANT

1. As shown in the wiring diagrams, a common ground is required on: The pilot burner mounting bracket, and the GND (BURNER) terminal on the ignition control module. Failure to use the GND (BURNER) terminal may result in intermittent loss of spark and/or loss of flame current sensitivity.

2. Make sure the transformer has adequate VA. The ignition control module requires at least

0.1 A at 24 Vac. Add the current draws of all other devices in the control circuit, including the pilot and main valves in the gas control, and multiply by 24 to determine the total VA requirement of these components. Add this total to 2.4 VA (for the ignition control module). The result is the minimum transformer VA rating. Use a Class II transformer if replacement is required.

Connect Vent Damper (Optional)

If the ignition control module is to be used with a damper connected to the module’s integral damper connector in an atmospheric appliance, perform the following to connect it to the module:

IMPORTANT

After the initial power-up, the ignition control module senses the presence of the vent damper connection. If the vent damper is connected for 10 ignition cycles, the ignition control module permanently configures itself to operate only with the damper connected.

Once an ignition control module completes 10 ignition cycles with a vent damper connected, the module will not function without a vent damper being connected.

S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL

CAUTION

1. Using the wiring harness on the appliance, insert

the matching 6-pin plug into the connector (labeled P1; see Fig. 2 on page 11) on the S8610U ignition control module and connect the other end to the vent damper.

NOTE: The connector (P1) accepts a Molex 03-06-2061

plug.

Connect Ignition Cable

Use existing ignition cable if it is in good condition. If the existing ignition cable does not have a 1/4 in. quick connect on the module end, either use the Rajah adapter or strip the wire and replace with the 1/4 in. insulated quick connect supplied. If the cable must be replaced, order a Honeywell ignition cable (Table 3) or refer to Table

4. It might be necessary to replace the connector at the pilot burner end to match the pilot burner spark termination.

NOTE: When using an S8610U to replace an S86, use

the enclosed adapter to convert the S86 Ignition Cable to an S8610U Ignition Cable. Then, install the adapter and cable to the S8610U Ignition Module.

Table 3. Honeywell Pre-assembled Ignition Cables

CABLE

PAR T

NUMBER LENGTH

394800-30 30 inches 1/4 inch quick

394801-30 30 inches 1/4 inch quick

(UL Style 3257).

MODULE

END PILOT BURNER

connect, insulated

Rajah connector receptacle, 90 degree rubber boot

Rajah connector receptacle, straight rubber boot

Connect Ignition Control Module

Equipment Damage Hazard.

Check the wiring diagram provided on the appliance and compare with Table 5 through Table 8 beginning on page 8. Carefully follow any special instructions affecting the general wiring procedures outlined in this section.

1. Connect the wires to the module as shown in the wiring tables (Table 5 through Table 8). Make sure that adequate system ground is provided as indicated in the wiring tables. (Refer to Fig. 2 and Table 9 on page 11 for wiring connections on the S8610U module.)

2. Verify the thermostat anticipator setting as explained in the Important notes in the wiring tables.

NOTE: Refer to Fig. 2 and Table 9 on page 11 for the

location of each connection on the S8610U module.

The wiring diagrams in Fig. 3 through Fig. 5 beginning on page 12 describe typical hookups with the S8610U module and should be used for reference only.

• Fig. 3 shows a basic circuit used only for heating systems with atmospheric burners and damper control. (Shown with local and remote flame sensing.)

• Fig. 4 shows a basic circuit used only for heating systems with atmospheric burners without damper control. (Shown with local and remote flame sensing.)

• Fig. 5 shows a circuit for power assisted combustion applications.

Table 4. Recommended Ignition Cable for Field

CABLE TYPE

UL Style 3217 10,000 302°F (150°C)

UL Style 3257 10,000 484°F (250°C)

Cable must be no longer than 36 in. (0.9 m). Solid conductor cable recommended. To construct a cable, fit one end of ignition cable with 1/4 in. diameter Rajah connector receptacle and the other with a 1/4 in. female quick connect. Protect both ends with insulated boots.

NOTE: The cable must not run in continuous contact

with a metal surface or spark voltage may be greatly reduced. Use ceramic or plastic standoff insulators as required. Resistive spark cable reduces spark voltage and may impact appliance performance.

Assembly.

VOLTAGE RATING

(rms)

TEMPERATURE

RATING

To install:

1. Connect one end of the cable to the male quick connect SPARK terminal on the ignition module.

2. Connect the other end of the cable to the igniter or igniter-sensor stud on the pilot burner/ignitersensor.

7 69-1955—01

S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL

The following four tables describe the wiring connections necessary for conversion:

Table 5. Conversion from Honeywell Intermittent Pilot Modules.

Replacement

Control Old Control

S90A,B S8600A,B,C S8610A,B,C S8610U1003

S8620C,

Ter min al Function

Main Valve Operator

Main Valve and Pilot Common

Pilot Valve Operator

Burner Ground Connection

Transformer Secondary (unswitched leg)

Transformer Secondary (switched leg)

Flame Sensor

Igniter / Sensor

Terminals may be marked 25V on some models and 24V on later models. These are functionally equivalent.

If 25V (2) and TH-R have wires connected, disconnect and splice together with solderless connector.

If TH-R and TH-W are jumpered together, connect 25V (2) lead from S86 to TH-W on S8610U.

On dual igniter and sensor models, remove jumper wire quick connect from S8610U Remote Sense terminal, then cut jumper wire at circuit board and discard.

Leave black jumper connected.

Use Rajah to quick connector adapter (supplied) or cut Rajah connector off ignition cable at module end and attach insulated quick connect for connection to S8610U.

MV/PV MV/PV MV/PV MV/PV MV/PV MV/PV —

PV PV PV PV PV PV —

GND (BURNER)

24V GND

24V *25V (2) 25V

TH-W

SENSE

SPARK

GND GND GND

25V (2)

TH-R

TH-W

IGN COIL

(BURNER)

25V

TH-R

TH-W

25V (2)

25V (2) a *24V * 24V *

25V (2) or 24V used only in systems where plug-in cable connects damper to module

TH-R

TH-W

IGN COIL fIGN COIL fSPARK

S8660D,J S8670D,J S8680D,J

GND (BURNER) GND (BURNER) —

24V GND

TH-W (This terminal is not included on S90.)

SENSE

S8600F,H,M S8610F,H,M

S8660E,K S8670E,K

24V GND

TH-W

Procedural NotesS8610U S86A,C S86B,D S86E,F,G,H

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* IMPORTANT

If the old module had a vent damper connector but a vent damper was not installed, or if it did not have a vent damper connector, then connect the 25V (2) or 24V wire from the old module to the TH-W terminal on the S8610U. Do not use the 24V terminal on the S8610U.

If the old module had a vent damper, connect it to the P1 connector on the module, and wire the terminals as indicated in the table.

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SPARK

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69-1955—01 8

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