Honeywell S8600, S8670, S8660, S8610 User Manual
INTERMITTENT PILOT MODULES
S8600, S8610, S8660, S8670
APPLICATION
These ignition modules provide ignition sequence, flame
monitoring and safety shutoff for intermittent pilot central
furnaces and heating appliances. S8600 and S8660 models provide up to 1.0 A pilot and 1.0 A main valve current
rating. S8610 and S8670 provide up to 1.0 A pilot and 2.0
A main valve current rating. Minimum ambient temperature
IGNITER- 100
MODEL TYPE OF GAS TIMING SHUTOFF TIMING SEQUENCE
S8600A, Separate Natural None No No Spark on until pilot
S8610A lightoff or manual
S8600F, Combination shutoff; pilot valve
S8610F open until manual
S8600B, Separate Natural None Yes, at 15 or 90 Spark on until
S8610B or LP lockout sec. max., lightoff or lockout;
S8600H, Combination as ordered pilot valve closes
S8610H on lockout.
S8600M Combination Natural None Yes, at 90 No, Spark and pilot gas
S8660D, Combination Natural 45 sec. Yes, at 15 or 90 Ignition trial follows
S8670D or LP lockout sec. max., prepurge; spark on
a
If established flame is lost, all models restart ignition trial.
PLANNING THE INSTALLATION
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 failure.
These applications require Honeywell Residential Division
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 an application with significantly greater cycling rates and
closer to year-round use, 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 is
SENSOR TYPE PREPURGE PERCENT LOCKOUT IGNITION
TABLE 1—INTERMITTENT PILOT IGNITION MODULES.
or LP sec. max. continuous on until shutoff.
rating is -40° F [-40° C]. Maximum ambient rating is +175°
F [+79° C] for S8600, S8660 and for S8610, S8670 used
with 1.0 A or less main valve. Maximum ambient rating for
S8610, S8670 used with 1.0 to 2.0 A main valve is +165° F
[+74° C]. See Table I for a summary of other differences
between models.
shutdown.
retry After 5 min. min.
as ordered until lightoff or
likely to 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 bottom of the cabinet so they will not be subject
to flooding or splashing during normal cleaning procedures.
If necessary, shield the controls to protect them from
splashing water. A NEMA 4 enclosure is recommended 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.
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.
(6 min. nom.) delay,
ignition starts again.
Ignition, wait, retry
repeats until pilot
lights or system is
shut down manually.
lockout; pilot valve
closes on lockout.
Never
install an appliance
a
J.A. Form Number 69-0463
11-89 ©Honeywell Inc. 1989.
CORROSIVE CHEMICALS
Corrosive chemicals can also attack the module and gas
control and eventually cause a failure. Where chemicals
may be used routinely for cleaning, make sure the cleaning
solution cannot reach the controls. Where chemicals 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 Electronic
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 recommended for the 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 temperature at the control locations will not exceed the rating of the
control. If the appliance normally operates at very high
temperatures, insulation, shielding, and air circulation may
be necessary to protect the controls. Proper insulation or
shielding should be provided by the appliance manufacturer; make sure adequate air circulation is maintained
when the appliance is installed.
INSTALLATION
WHEN INSTALLING THIS IGNITION SYSTEM…
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 SERIOUS INJURY OR DEATH.
1. The ignition module can malfunction if it gets
wet, leading to accumulation of explosive gas.
• Never install where water can flood, drip or
condense on module.
• Never try to 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 pilot or operate electric
switches, lights, or appliances until you are
sure the appliance area is free of gas.
1. Disconnect power supply before beginning wiring
to prevent electrical shock or equipment damage.
2. If a new gas control is to be installed, turn off gas
supply before starting installation. Conduct Gas
Leak Test according to gas control manufacturer’s instructions after the gas control is installed.
3. If module must be mounted near moisture or
water, provide suitable waterproof enclosure.
PERFORM PREINSTALLATION SAFETY INSPECTION
The preinstallation checks described in ANSI Standard
Z21.71 on page 19
module is installed. If a condition which could result in
unsafe operation is detected, the appliance should be shut
off and the owner advised of the unsafe condition. Any
potentially unsafe condition must be corrected before proceeding with the installation.
Maintenance Requirements in Severe Environments
Regular preventive maintenance is important in any
application, but especially so in commercial cooking, agricultural, and industrial applications because:
CAUTION
must
be done before the replacement
• 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 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 check-
out of the system as outlined under Checkout, page 11.
WARNING
FIRE OR EXPLOSION HAZARD
MAY CAUSE PROPERTY DAMAGE, SEVERE
INJURY OR DEATH
Do not attempt to take the 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
than 20,000 times annually should be checked
monthly.
•
Intermittent use
should be checked before shutdown and again before the next use.
•
Consequence of unexpected shutdown
cost of an unexpected shutdown would be high, the
system should be checked more often.
•
Dusty, wet, or corrosive environment.
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 addition, 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.
MOUNT IGNITION MODULE
Select a location close enough to the burner to allow a
short (3 ft. [0.9 m] max.), direct cable route to the igniter.
Ambient temperature at the module must be within the
range listed under APPLICATION, page 1. The module
must be protected from water, moisture, corrosive chemicals and excessive dust and grease.
2
. Appliances that may cycle more
. Appliances that are used seasonally
. Where the
Since these
We recommend mounting the module with the terminals
down to protect them from dripping water and dust. It can
also be mounted with the terminals on either side. DO NOT
MOUNT with terminals pointing up. Fasten securely with
four No. 6-32 machine or No. 8 sheetmetal screws.
MOUNT THE SYSTEM CONTROLS
Mount any required controls, such as the gas control,
spark igniter, flame sensor, thermostat, limit and transformer according to manufacturer’s instructions.
WIRE THE SYSTEM
CAUTION
1. Check the wiring diagram furnished by the appliance manufacturer, if available, for circuits differing from the wiring hookups shown. 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. As shown in the wiring diagrams, 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 may 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 0.2 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 4.8 VA (for the ignition module).
The result is the minimum transformer VA rating.
Use a Class II transformer if replacement is required.
Connect Ignition Cable
Use Honeywell ignition cable or construct an ignition
cable that conforms to suitable national standards such as
Underwriters Laboratories Inc. See Tables 2 and 3.
TABLE 2—HONEYWELL PREASSEMBLED IGNITION
CABLE
PART MODULE IGNITER
NUMBER LENGTH END END
394800-30 30 in. 1/4 in. quick Rajah connec-
394801-30 30 in. 1/4 in. quick Rajah connec-
TABLE 3—RECOMMENDED IGNITION CABLE FOR
CABLE VOLTAGE RATING
TYPE RATING (rms) C F
UL Style 3217 10,000 150 302
UL Style 3257 10,000 250 484
IMPORTANT
CABLES (UL STYLE 3257).
connect, tor receptacle,
insulated 90 deg. rubber
boot
connect, tor receptacle,
insulated straight rubber
boot
FIELD ASSEMBLY.
TEMPERATURE
Cable must be no longer than 36 in. [0.9 m]. 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 will be greatly reduced.
Use ceramic or plastic standoff insulators as required.
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/igniter-sensor.
Connect Vent Damper
The D80B Vent Damper can be used with all ignition
modules, although the Molex plug provided on some modules simplifies wiring connections when used with the D80D
Plug-In Vent Damper.
plug has powered a vent damper circuit, it cannot be used
in a gas system without a vent damper
fuse in the module blows on initial power-up. Once this fuse
has blown the module won’t work unless the vent damper
is connected.
To connect the plug-in model to D80D:
1. Remove the plug from the terminal strip on the ignition
module case and discard.
2. Using the wiring harness supplied, insert the matching
pin plug into receptacle on case and other end to vent
damper.
To connect the D80B, follow the wiring diagrams supplied with the vent damper or see Fig. 7 for typical connections.
Connect Ignition Module
1. Connect remaining system components to the ignition
module terminals as shown in the appropriate wiring diagram, Figs. 1 to 10.
• Fig. 1 is a basic circuit for a heating only atmospheric burner with S8600F,H,M; S8610F,H;
S8660D or S8670D.
• Fig. 2 shows S8600F,H,M; S8610F,H with vent
damper plug in a heating only atmospheric burner
system with D80D vent damper.
damper in an LP gas system or in a fan-assisted
combustion system.
• Figs. 3 and 4 show S8600A,B; S8610A,B with
separate sensor and igniter, with and without the
D80D vent damper.
• Figs. 5-10 show S8600F,H,M; S8610F,H; S8660D;
and S8670D in a variety of systems, with alternate
connections for modules with vent damper plug.
Remember, however, that a vent damper should
not be used in an fan-assisted combustion system
or an LP gas system and that the vent damper plug
must not be removed except to connect the module to a D80D with the plug-in cable. S8600A,B;
S8610A,B can be substituted in these drawings by
simply connecting the igniter and sensor as shown
in Figs. 3 and 4.
2. Refer to heating appliance manufacturer’s instruc-
tions for wiring auxiliary controls.
3. Adjust thermostat heat anticipator to match system
current draw. The current draw equals the total current
required for the ignition module (0.2 A) plus the gas control
and any other auxiliary equipment in the control circuit.
Connect Gas Control
Use No 18 gauge solid or stranded wire. Use 1/4 in.
female quick connects for module connections. Connect to
gas control terminals as shown in wiring diagrams, using
terminals appropriate to the gas control.
3 69-0463
Once a module with vent damper
. A non-replaceable
Never
use a vent
Ground Control System
The igniter, flame sensor and ignition module must
share a common ground with the main burner. Use thermoplastic insulated wire with a minimum rating of 105° C [221°
F] for the ground wire; asbestos insulation is not acceptable. If necessary, use a shield to protect the wire from
radiant heat generated by the burner. Connect the ground
wire as follows:
1. Fit one end of the ground wire with a female 1/4 in.
quick-connect terminal and connect it to the male quickconnect 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 good metal-to-metal contact between the burner
and ground, run a lead from the burner to ground.
NOTE: “Earth” ground is not required.
REPLACING MODULE WITH TH-R, TH-W TERMINALS
On modules that do not have a vent damper plug, the
thermostat must be connected between the transformer
and the 24V terminal on the module. To change out a
module with TH-R, TH-W terminals:
1. Remove the wires from the 25V(2) and TH-R terminals on the old module. Connect these two wires with a
solderless connector.
2. Tag and remove the remaining wires from the old
module.
3. Remove the old module and mount the new one in the
same location.
4. Reconnect the remaining wires as shown in Table 4.
5. Increase the thermostat anticipator setting by 0.2 A.
TABLE 4—TERMINAL CROSS REFERENCE.
TERMINAL ON TERMINAL ON
OLD MODULE: NEW MODULE:
25 V (1) 24 V (GND)
TH-W 24 V
MV MV
MV/PV MV/PV
PV PV
GND (Burner) GND (Burner)
S8600F,H,M; S8610F,H; S8660D; S8670D
MV MV/PV PV
PILOT COM
1ST
OPERATOR
DUAL VALVE COMBINATION
GAS CONTROL
2ND
OPERATOR
Q345, Q346,
Q348, Q362, Q381
PILOT BURNER/
IGNITER-SENSOR
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
2
ALTERNATE LIMIT CONTROLLER LOCATION.
MAXIMUM CABLE LENGTH 3 ft [0.9 m].
3
CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND
4
LEG TO TRANSFORMER.
FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT THERMOSTAT TO TH-W. LEAVE
5
24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.
MAIN
VALVE
GND
(BURNER)
PILOT GAS
SUPPLY
24V
GND
THERMOSTAT
PILOT BURNER
GROUND
24V
M1175C
TH-W
(OPT)
5
5
VENT
DAMPER
PLUG (OPT)
2
LIMIT
CONTROLLER
SPARK
3
4
L1
L2
(HOT)
1
Fig. 1—S8600F,H,M; S8610F,H; S8660D; S8670D connections in a heating system with an atmospheric burner.
4
S8600F,H,M; S8610F,H
MV MV/PV PV
GND
(BURNER)
24V
GND
24V TH-W
5
VENT
DAMPER
PLUG
SPARK
197516A
THERMOSTAT
LIMIT
CONTROLLER
2ND
OPERATOR
IGNITER
WIRING
HARNESS
D80D VENT
DAMPER
S8600A,B; S8610A,B
MV MV/PV PV
MAIN
VALVE
PILOT GAS
SUPPLY
MAIN
2ND
OPERATOR
VALVE
PILOT BURNER
GROUND
PILOT GAS
SUPPLY
2
4
PILOT COM
1ST
OPERATOR
DUAL VALVE COMBINATION
GAS CONTROL
PILOT COM
1ST
OPERATOR
DUAL VALVE COMBINATION
GAS CONTROL
Q345, Q346,
Q348, Q362, Q381
PILOT BURNER/
IGNITER-SENSOR
Fig. 2—S8600F,H,M; S8610F,H with a vent damper plug in a heating system with an atmospheric burner and a D80D
vent damper.
POWER SUPPLY. PROVIDE DISCONNECT MEANS
1
AND OVERLOAD PROTECTION AS REQUIRED.
2
ALTERNATE LIMIT CONTROLLER LOCATION.
MAXIMUM CABLE LENGTH 3 ft [0.9 m].
3
4
CONTROLS IN 24V CIRCUIT MUST NOT BE IN
GROUND LEG TO TRANSFORMER.
5
FOR MODULE WITH TH-W TERMINAL AND VENT
DAMPER PLUG, CONNECT THERMOSTAT TO TH-W.
LEAVE 24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.
M1186C
L1
(HOT)
L2
SENSOR
1
GND
(BURNER)
3
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
2
ALTERNATE LIMIT CONTROLLER LOCATION.
3
MAXIMUM CABLE LENGTH 3 FEET [0.9 METERS].
4
CONTROLS IN 24V CIRCUIT MUST NOT BE IN
GROUND LEG TO TRANSFORMER.
5
REMOVE PLUG ONLY IF USING VENT DAMPER.
FUSE BLOWS ON STARTUP WHEN PLUG IS REMOVED;
THEN MODULE WILL OPERATE ONLY WHEN VENT
DAMPER IS CONNECTED.
VENT
5
TH-W
(OPT)
5
THERMOSTAT
2
LIMIT
CONTROLLER
DAMPER
PLUG (OPT)
GROUND
24V
GND
24V
4
1
L2
L1
(HOT)
SENSE
M1176D
SPARK
3
Fig. 3—S8600A,B; S8610A,B connections in a heating system with an atmospheric burner.
5 69-0463
S8600A,B; S8610A,B
MV MV/PV PV
GND
(BURNER)
24V
GND
24V
TH-W
VENT
DAMPER
PLUG
5
SENSE
SPARK
3
M1177C
TH-W
(OPT)
5
AIR
PROVING
SWITCH
VENT
5
DAMPER
PLUG (OPT)
MAIN
VALVE
SENSOR
PILOT GAS
SUPPLY
THERMOSTAT
4
L1
L2
(HOT)
1
2
LIMIT
CONTROLLER
GROUND
SPARK
3
197516A
WIRING
HARNESS
THERMOSTAT
2
D80D VENT DAMPER
1
4
LIMIT
CONTROLLER
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
2
ALTERNATE LIMIT CONTROLLER LOCATION.
3
MAXIMUM CABLE LENGTH 3 ft [0.9 m].
4
CONTROLS IN 24V CIRCUIT MUST NOT BE IN
GROUND LEG TO TRANSFORMER.
FOR MODULE WITH TH-W TERMINAL AND VENT
5
DAMPER PLUG, CONNECT THERMOSTAT TO TH-W.
LEAVE 24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.
L2
L1
(HOT)
PILOT COM
2ND
1ST
OPERATOR
OPERATOR
DUAL VALVE COMBINATION
GAS CONTROL
POWER SUPPLY. PROVIDE DISCONNECT MEANS
1
AND OVERLOAD PROTECTION AS REQUIRED.
2
ALTERNATE LIMIT CONTROLLER LOCATION.
3
MAXIMUM CABLE LENGTH 3 FEET [0.9 METERS].
4
CONTROLS IN 24V CIRCUIT MUST NOT BE IN
GROUND LEG TO TRANSFORMER.
5
REMOVE PLUG ONLY IF USING VENT DAMPER.
M1185D
Fig. 4—S8600A,B; S8610A,B with vent damper plug in an atmospheric burner heating system with a D80D vent
damper.
S8600F,H,M; S8610F,H; S8660D; S8670D
MV MV/PV PV
PILOT COM
2ND
1ST
OPERATOR
OPERATOR
DUAL VALVE COMBINATION
GAS CONTROL
Q345, Q346,
Q348, Q362, Q381
PILOT BURNER/
IGNITER-SENSOR
MAIN
VALVE
GND
(BURNER)
PILOT
BURNER
GROUND
PILOT GAS
SUPPLY
24V
GND
L1
(HOT)
IGNITER
24V
L2
1
COMBUSTION
AIR BLOWER
RELAY
COMBUSTION
AIR BLOWER
MOTOR
Fig. 5—S8600F,H,M; S8610F,H; S8660D; S8670D connections in a heating system with power-assisted combustion.
6
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