The S8610U Universal Replacement Ignition Module is
designed to provide easy field replacement of a wide range of
intermittent pilot ignition modules manufactured by
Honeywell, Robertshaw, Johnson and others. The S8610U
Module provides ignition sequence, flame monitoring, and
safety shutoff for intermittent pilot central furnaces, residential
boilers, and other heating appliances.
S8610U
PRODUCT DATA
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 or
combination igniter-sensor. Q345, Q348, Q362, Q373
or Q381 Igniter-sensor recommended as combination
igniter-sensor; Q179C with igniter and sensor
mounted on one bracket, or Q354 Sensor with Q345,
Q348, Q362, Q373 or Q381 Igniter-sensor
recommended as separate igniter and sensor.
• Q3450/Q3480 Hot Surface Pilot hardware plugs
directly into system control.
• Can be used on natural or LP gas; provides 100
percent shutoff on ignition failure. Waits six minutes
nominal following shutoff, then reinitiates the pilot
ignition sequence. The ignition trial-shutoff-wait cycle
repeats until the pilot lights or the call for heat ends.
• Replaces numerous Honeywell and competitor
modules.
• 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.
The specifications given in this publication do not
include normal manufacturing tolerances. Therefore,
units may not exactly match the listed specifications
Also, units are tested and calibrated under closely
controlled conditions, and some minor differences in
performance can be expected if those conditions are
changed.
SUPER TRADELINE® Models
SUPER TRADELINE® models are selected and packaged for
ease of handling, ease of stocking, and maximum replacement
value. SUPER TRADELINE® model specifications are the
same 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 main
gas).
Continuous Retry:
Five-minute minimum (six-minute nominal) delay if pilot fails
to light during trial for ignition. After delay, trial for ignition is
repeated. This sequence (trial, delay, trial, delay) continues
until pilot lights or call for heat ends.
Spark Generator Output:
13 kV peak at 25 pF load.
Thermostat Anticipator Setting:
0.2A plus pilot valve rating plus main valve rating.
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 Honeywell
D80D 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 to
provide maximum protection from dripping water or dust
accumulation. Fasten with no. 6-32 machine or no. 8
sheetmetal screws of appropriate length. See Fig. 1.
Underwriters Laboratories Inc. Component Recognized:
File no. MH15564, Guide no. MCCZ2.
IAS Design Certified: C2030011.
Other System Components
These modules provide operating control of an intermittent
pilot system. Additional components required to complete the
system 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.
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.
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.
ORDERING INFORMATION
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the
TRADELINE® 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 or
phone:
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 North
Minneapolis, 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.
68-0135—2
2
3-3/16
(81)
3-15/16
(100)
3-3/8
(86)
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
3/16
(2)
(5)
2 (51)
2-5/8 (67)
1/4
(6)
Fig. 1. Approximate ignition module dimensions in in. (mm).
Table 1. Pilot Burner/Igniter-Sensors.
Pilot Burner/
Igniter-Sensor
Flow Rate*
cfhm
3
/hr
CombinedQ3450.80.02
Q3481.50.04
Q3620.50.014
Q3730.80.02
Q3810.50.014
SeparateQ179C1.80.05
Q354 with Q345, Q348, Q362 or Q381.
*With natural gas at 7.0 in. wc (1.7 kPa).
Ignition Cable:
Use Honeywell preassembled cable, see Table 2, or
assemble locally. Use the cable recommended in Table 3 (or
equivalent), insulated female 1/4 in. quick connect and
insulated Rajah connector receptacle. Maximum
recommended length is 36 in. (914 mm).
Table 2. Honeywell Preassembled Ignition Cables
(UL Style 3257).
Cable
PartModule
Number
Length
394800-3030 in.1/4 in. quick
End
connect,
insulated
Igniter End
Rajah connector
receptacle, 90
degree rubber
boot
394801-3030 in.1/4 in. quick
connect,
insulated
Rajah connector
receptacle, straight
rubber boot
1-1/32
(26)
3-3/8 (86) (2)
5-7/16 (138)
3/16
(5)
(2)
M1123A
Table 3. Recommended Ignition Cable for Field Assembly.
Temperature Rating
°C°F
Cable Type
Voltage
Rating (rms)
UL Style 321710,000150302
UL Style 325710,000250484
Transformer:
Add current ratings of module, pilot valve, main valve, vent
damper and any other components of the control system to
determine transformer-size requirement. Use a 30 VA or
larger transformer if a vent damper will be connected to the
S8610U Vent Damper Connector.
Thermostat:
Use open-close switch type, or independently-powered
electronic, 24V thermostat capable of switching rated control
system load. Before using electronic thermostat powered
through the heating/cooling controls, consult thermostat
manufacturer to assure proper control system operation.
High Limit and Other Auxiliary Controls:
As specified by the heating appliance manufacturer.
Ignition Modules Replaced
WARNING
Check Table 4 before replacing an existing intermittent
pilot module with the S8610U. If the existing module is
not listed, do not use the S8610U to replace it unless
you are certain the specifications of the S8610U
match those of the existing module.
3
68-0135—2
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
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.
• Pilot burners with flow rates of 1500 Btuh or less.
• With or without vent dampers.
A complete list of the specific Honeywell and other modules
that the SUPER TRADELINE® S8610U is designed to
replace is provided in Table 4.
The S8610U SUPER TRADELINE® 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 S8610U. It also provides
labels to help assure proper marking of the wires attached to
the existing module.
The S8610U SUPER TRADELINE® Universal Module is not
designed 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 four
seconds, or pilot burners larger than 1500 Btuh.
• Standing pilot appliances.
Honeywell provides additional control packages to
accomplish these replacements. See the Honeywell
Electronic Ignition Service Manual, form 70-6604, or call your
Honeywell wholesaler.
Frequent Cycling
These controls are designed for use on appliances that
typically cycle three to four times an hour only during the
heating season only. In year-round applications with greater
cycling rates, the control can wear out more quickly. Perform
a monthly checkout.
Water Or Steam Cleaning
If a module or gas control 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 module; see the Electronic
Ignition Service Manual, form 70-6604.
High Humidity or Dripping Water
Dripping water can cause the 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 module; see the
Electronic Ignition Service Manual, form 70-6604.
Corrosive Chemicals
Corrosive chemicals can attack the module and gas control,
eventually causing a failure. If chemicals are used for routine
cleaning, make sure they cannot reach the controls. Where
chemicals are suspended in air, as in some industrial or
agricultural applications, use a NEMA 4 enclosure for the
ignition module; see the Electronic Ignition Service Manual,
form 70-6604.
PLANNING THE INSTALLATION
WARNING
FIRE OR EXPLOSION HAZARD
CAN CAUSE PROPERTY DAMAGE, SEVERE
INJURY OR DEATH.
Follow these warnings exactly:
1. Plan the installation as outlined below.
2. Plan for frequent maintenance as described in
the Maintenance section.
When intermittent pilot systems are used on central heating
equipment in barns, greenhouses, and commercial properties
and on heating appliances such as commercial cookers,
agricultural equipment, industrial heating equipment and pool
heaters, heavy demands are made on the controls. Special
steps may be required to prevent nuisance shutdowns and
control failure due to frequent cycling, severe environmental
conditions related to moisture, corrosive chemicals, dust or
excessive heat. These applications require Honeywell Home
and Building Control Engineering review; contact your
Honeywell Sales Representative for assistance.
Review the following conditions that could apply to your
specific installation and take the precautionary steps
suggested.
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 module and the gas control to limit
contamination. A NEMA 4 enclosure is recommended for the
ignition module; see the Electronic Ignition Service Manual,
form 70-6604.
Heat
Excessively high temperatures can damage controls. Make
sure the maximum ambient temperature at the control does
not exceed the rating of the control. 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 that proper air circulation is maintained
when the appliance is installed.
1. Read these instructions carefully. Failure to follow them
could damage the components or cause a hazardous
condition.
2. Check the ratings given in the instructions and on the
components to make sure they are suitable for your
application.
3. Installer must be a trained, experienced service
technician.
4. After installation is complete, check out component
operation as provided in these instructions.
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY, OR
DEATH.
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 are
sure the appliance area is free of gas.
3. Do not attempt to disassemble or clean the
module. Improper reassembly and cleaning can
cause unreliable operation.
Mount New Ignition Module
We recommend mounting the S8610U Module in the same
location as the old module, if possible. Otherwise, select a
location close enough to the burner to allow a short (3 ft
(0.9m) maximum) direct cable route to the igniter. Ambient
temperature at the module must be within the range listed in
the Specifications section.
Mount the module with the terminals pointing down to protect
them from dripping water and dust. The module can also be
mounted with the terminals on either side. Do not mount with
terminals pointing up. Refer to Fig. 2 for mounting
recommendations. 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 or no. 8 sheetmetal screws.
Wire the Module
IMPORTANT
CAUTION
1. Disconnect the power supply before beginning
the wiring to prevent electrical shock or
equipment damage.
2. If a new gas control is to be installed, turn off the
gas supply before starting the installation.
Conduct a Gas Leak Test according to the gas
control manufacturer instructions after the gas
control is installed.
3. If the module must be mounted near moisture or
water, provide a suitable waterproof enclosure.
4. Using the wire labels provided, label all wires
before they are disconnected. Wiring errors can
cause improper appliance operation and
dangerous conditions such as bypassing safety
features.
Perform Preinstallation Safety Inspection
The preinstallation checks described in ANSI Standard
Z21.71 in Exhibit A must be done before the replacement
module is installed. If a condition is detected that could result
in unsafe operation, the appliance should be shut off and the
owner advised of the unsafe condition. Correct any potentially
unsafe condition before proceeding with the installation.
Remove Old Module
Disconnect power supply before doing any work on the unit.
Disconnect and tag the wires from the old module using the
wire labels provided. Remove the old module from its
mounting location.
CAUTION
1. Check the wiring diagram furnished by the
appliance manufacturer, if available, and
compare with Tables 5 through 8. Carefully follow
any special instructions affecting the general
procedures outlined below.
2. Disconnect the power supply before making
wiring connections to prevent electrical shock or
equipment damage.
1. A common ground is required on:
a.The pilot burner mounting bracket, and
b.The GND (BURNER) terminal on the ignition
module. Failure to use the GND (BURNER)
terminal can result in intermittent loss of spark
and/or loss of flame current sensitivity.
2. Make sure the transformer has adequate VA. The
ignition module requires at least 0.2A at 24 Vac. Add
the current draws of all other devices in the control
circuit, including the pilot and main valves in the gas
control, and multiply by 24 to determine the total VA
requirement of these components. Add this total to
4.8 VA (for the ignition module). The result is the
minimum transformer VA rating. Use a Class II
transformer when replacement is required.
3. When a vent damper is connected to the S8610U
vent damper connector, be sure the system
transformer delivers at least 30 VA. The S8610U has
an internal fuse that is intended to prevent appliance
lightoff if the vent damper is not in place or wired
properly. Using a small transformer can interfere with
the proper operation of the fuse and bypass the
intended safety feature.
쐃 Connect the wires to the S8610U Ignition Module as
shown in Tables 5 through 8. Make sure that adequate
system ground is provided as indicated in the wiring
tables.
쐇 Verify the thermostat anticipator setting as explained in
the IMPORTANT above.
68-0135—2
6
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
MOUNT IN ONE OF THESE POSITIONS
TERMINALS FACING DOWN
TERMINALS FACING LEFTTERMINALS FACING RIGHT
NOTE: The wiring diagrams in Fig. 5 through 8 show typical
hookups for the S8610U Ignition Module and should
be used for reference only.
Modify Ignition Cable, If Necessary
Use existing ignition cable if it is in good condition. If the
existing ignition cable does not have a 1/4 in. quick-connect
on the 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, see Table 2. It may 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.
NOTE: The cable must not run in continuous contact with a
metal surface or spark voltage is greatly reduced.
Use ceramic or plastic standoff insulators as
required.
DO NOT MOUNT
WITH TERMINALS FACING UP
M2647
Fig. 2. Module mounting recommendations.
7
68-0135—2
S8610U UNIVERSAL INTERMITTENT PILOT MODULE
Replacement
ControlOld Control
Terminal FunctionS8610U1003S86A,CS86B,DS86E,F,G,H
S8600A,B,C
S8610A,B,C
S90A,B
S8600F,H,M
S8610F,H,MProcedural Notes
Main valve operatorMVMVMVMVMVMV
Main valve and pilot
common
MV/PVMV/PVMV/PVMV/PVMV/PVMV/PV
Pilot valve operatorPVPVPVPVPVPV
Burner ground
connection
GND
(BURNER)
GND GND GND
(BURNER)
GND
(BURNER)
GND
(BURNER)
Transformer
secondary
(unswitched leg)
24V GND25V (1)25V (GND)25V (1)e24V GND24V GND
Transformer
secondary
(switched leg)
24V*25V (2)25V25V (2)
e*
24V*24V** Important: If the old module had a vent damper
plug but a vent damper was not installed, or if it
did not have a vent damper plug: leave the vent
damper plug in position on the S8610 and
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.
25V (2) or 24V used only in systems where
plug-in cable connects damper to module.
If the old module
had
a vent damper with a plug
connection to a Molex connector, wire the
terminals as indicated in the table.
TH-WTH-R
a
TH-R
a
TH-R
a
TH-W
(This terminal
not included
on S90.)
TH-W
TH-WbTH-WTH-Wb
Flame sensorSENSE
f
dd d
SENSE
fd
Igniter/sensorSPARKIGN COIL
c
IGN COIL
c
IGN COIL
c
SPARKSPARK
a
If 25V (2) and TH-R have wires connected, disconnect and splice together with solderless connector.
b
If TH-R and TH-W are jumpered together, connect 25V (2) lead from S86 to TH-W on S8610U1003.
c
Use Rajah to quick connector adapter (supplied) or cut Rajah connector off ignition cable at module end; attach insulated quick
connect for connection to S8610.
d
Leave black jumper connected.
e
Terminals may be marked 25V on some models and 24V on later models. These are functionally equivalent.
f
On dual igniter and sensor models, remove jumper quick connect from S8610U1003 Sense terminal, cut jumper wire at circuit board
, and discard.
Table 5. Conversion from Honeywell S86, S90, S8600 and S8610 to S8610U1003.
68-0135—2
8
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