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
S8600F,H,M; S8610F,H; S8660D; S8670D
MV MV/PV PV
GND
(BURNER)
24V
GND
24V
TH-W
(OPT)
VENT
5
DAMPER
PLUG (OPT)
SPARK
5
L1
(HOT)
L2
1
AIR
PROVING
SWITCH
Q345, Q346,
Q348, Q362,
Q381PILOT
BURNER/
IGNITERSENSOR
COMBUSTION
AIR BLOWER
MOTOR
VALVE
MAIN
STAGE 2
MAIN
VALVE
2ND
OPERATOR
STAGE 1
COM
GROUND
PILOT
1ST
OPERATOR
TWO STAGE DUAL VALVE
COMBINATION GAS CONTROL
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
1
ALTERNATE LIMIT CONTROLLER LOCATION.
2
MAXIMUM CABLE LENGTH 3 ft [0.9 m].
3
CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER.
4
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.
THERMOSTAT
LIMIT
CONTROLLER
RW2W1
2
4
1
L2
L1
(HOT)
COMBUSTION
AIR BLOWER
RELAY
PILOT
BURNER
GROUND
PILOT GAS
SUPPLY
3
M1178C
Fig. 6—S8600F,H,M; S8610F,H; S8660D; S8670D connections in a heating system with a two-stage gas control and
power-assisted combustion.
7 69-0463
S8600F,H,M; S8610F,H; S8660D; S8670D
MV MV/PV PV
GND
(BURNER)
24V
GND
24V
TH-W
(OPT)
VENT
5
DAMPER
PLUG (OPT)
SPARK
5
MOTOR
1K3
1
6
ORANGE
D80B
1K2
1K1
R
1K
2345
RED
THERMOSTAT
OR
CONTROLLER
LIMIT
CONTROLLER
MAIN
2ND
OPERATOR
VALVE
L2
L1
(HOT)
PILOT GAS
SUPPLY
LIMIT
CONTROLLER
1
PILOT
BURNER
GROUND
4
TRANSFORMER
2
END SWITCH
N.O. N.C.
BLACK
PILOT COM
1ST
OPERATOR
DUAL VALVE COMBINATION
GAS CONTROL
Q345, Q346,
Q348, Q362, Q381
PILOT BURNER/
IGNITER-SENSOR
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
2
3
MAXIMUM CABLE LENGTH 3 ft [0.9 m].
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.
6
COLORS REFER TO WIRE HARNESS, IF USED.
3
BLUE
YELLOW
M1180C
Fig. 7—S8600F,H,M; S8610F,H; S8660D; S8670D in a heating system with an atmospheric burner and a D80B vent
damper.
8
S8600F,H,M; S8610F,H; S8660D; S8670D
MV MV/PV PV
GND
(BURNER)
24V
GND
24V
VENT
5
TH-W
DAMPER
(OPT)
PLUG (OPT) SPARK
L2
L1
(HOT)
LIMIT
CONTROLLER
FAN
MOTOR
1
L
C H
PILOT COM
1ST
OPERATOR
DUAL VALVE COMBINATION
GAS CONTROL
THERMOSTAT
R
G
W Y
R8239
FAN
CENTER
R C
4
WGY
COIL
FAN
CONTROL
2ND
OPERATOR
COOLING
CONTROL
L1
(HOT)
MAIN
VALVE
1
2
L2
COMBUSTION
AIR BLOWER
MOTOR
COMBUSTION
AIR BLOWER
RELAY
AIR PROVING
SWITCH
PRESSURE
CONTROLLER
PILOT
BURNER
GROUND
3
M1182C
5
Q345, Q346,
Q348, Q362,
Q381PILOT
BURNER/
IGNITERSENSOR
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
2
MAXIMUM CABLE LENGTH 3 ft [0.9 m].
3
CONTROLS IN 24V CIRCUIT MUST NOT BE IN
4
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.
PILOT GAS
SUPPLY
Fig. 8—S8600F,H,M; S8610F,H; S8660D; S8670D connections in a heating-cooling system with power-assisted
combustion.
9 69-0463
S8600F,H,M; S8610F,H; S8660D; S8670D
MV MV/PV PV
GND
(BURNER)
24V
GND
24V
VENT
4
TH-W
DAMPER
(OPT)
PLUG (OPT) SPARK
PILOT COM
1ST
OPERATOR
DUAL VALVE COMBINATION
GAS CONTROL
2ND
OPERATOR
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
2
CUT PLUG OFF MODULE END OF D80D WIRE HARNESS, CONNECT LEADWIRE COLORS AS SHOWN.
3
MAXIMUM CABLE LENGTH 3 ft [0.9 m].
FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT THERMOSTAT TO TH-W.
4
LEAVE 24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.
5
LEAVE TP-Z AND Z-W JUMPERS IN PLACE.
MAIN
VALVE
CABLE
L1
(HOT)
L2
1
2
1K
N.C.
N.O.
YELLOW
G
L1
1K3
L2
THERMOSTAT
D80 MOTOR
C.
1K3
BLUE
5
D80D
1K2
BLACK
TP
1K
ZB3W T
1K1
ORANGE
TV
1234
BR
1K2
AUTO
MANUAL
SWITCH
B2 C2
4
Q345, Q346,
Q348, Q362,
Q381PILOT
BURNER/
IGNITERSENSOR
B1
L8148J
C1
1K1
PILOT
BURNER
GROUND
PILOT GAS
SUPPLY
FAN
MOTOR
3
M1181C
Fig. 9—S8600F,H,M; S8610F, H; S8660D; S8670D connections in a hydronic heating sytem with a D80D vent damper.
10
MVMV/PVPV
GND
(BURNER)
24V
GND
S8610
U
24
V
TH-W
(OPT)
4
VENT
DAMPER
PLUG
SENSE
SPARK
MAIN
PILOT
1ST
OPERATOR
DUAL VALVE COMBINATION
GAS CONTROL
1
2
3
4
5
6
COM
2ND
OPERATOR
POWER SUPPLY. PROVIDE DISCONNECT
MEANS AND OVERLOAD PROTECTION AS
REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
MAXIMUM CABLE LENGTH 3 ft [0.9 m].
CONTROLS IN 24V CIRCUIT MUST NOT BE IN
GROUND LEG TO TRANSFORMER.
DO NOT REMOVE VENT DAMPER PLUG.
REMOVE JUMPER AND CONNECT SENSE
TERMINAL ON TWO ROD APPLICATION ONLY.
VALVE
5
(HOT)
L1
L8100
2
ECO
CONTROLLER
4
1
L2
6
GROUND
PILOT GAS
SUPPLY
3
M1179A
Fig. 10—S8600F,H,M; S8610F,H; S8660D; S8670D connections in a commercial water heater control system.
CHECKOUT
Check out the gas control system:
• At initial installation of the appliance.
• As part of regular maintenance procedures. Mainte-
nance intervals are determined by the application.
See PLANNING THE INSTALLATION, page 1, for
more information.
• As the first step in troubleshooting.
• Any time work is done on the system.
WARNING
FAILURE TO HEED THESE WARNINGS MAY
CAUSE FIRE OR EXPLOSION WITH PROPERTY
DAMAGE, INJURY, OR LOSS OF LIFE.
1. If you smell gas or suspect a gas leak, turn off
gas at manual service valve and evacuate the
building. Do not try to light any appliance, do
not touch any electrical switch or telephone in
the building until you are sure no spilled gas
remains.
2. Gas leak test must be done as described in
Steps 1 and 5 below on initial installation and
any time work is done involving the gas piping.
STEP 1: Perform Visual Inspection.
❏ With power off, make sure all wiring connections are
clean and tight.
❏ Turn on power to appliance and ignition module.
❏ Open manual shutoff valves in the gas line to the
appliance.
❏ Do gas leak test ahead of gas control if piping has been
disturbed.
GAS LEAK TEST: Paint pipe joints with rich soap and water
solution. Bubbles indicate gas leak. Tighten joints to stop
leak. Recheck with soap and water.
STEP 2: Review Normal Operating Sequence and Module
Specifications.
❏ See OPERATION, page 12, and APPLICATION,
page 1.
STEP 3: Reset the Module.
❏ Turn the thermostat to its lowest setting.
❏ Wait one minute.
As you do Steps 4 and 5, watch for points where operation
deviates from normal. Refer to Troubleshooting Chart to
correct problem.
STEP 4: Check Safety Shutoff Operation.
This step applies to lockout and continuous retry modules
only.
❏ Turn gas supply off.
❏ Set thermostat or controller above room temperature to
call for heat.
❏ Watch for spark at pilot burner either immediately or
following prepurge. See device label.
❏ Time spark from start to shutoff. See device label.
On S8600M, wait 6 min. nom. Ignition sequence should
start again followed by shutoff after 90 sec. max.
❏ Open manual gas cock and make sure no gas is flowing
to pilot or main burner.
❏ Set thermostat below room temperature and wait one
minute before continuing.
STEP 5: Check Normal Operation.
❏ Set thermostat or controller above room temperature to
11 69-0463
call for heat.
❏ Make sure pilot lights smoothly when gas reaches the
pilot burner.
❏ Make sure main burner lights smoothly without flash-
back.
❏ Make sure burner operates smoothly without floating,
lifting, or flame rollout to the furnace vestibule or heat
buildup in the vestibule.
OPERATION
Module operation can be conveniently divided into two
phases for S8600, S8610 and three for S8660, S8670. The
phases are
• Prepurge (S8660, S8670 only)
• Trial for ignition (all models)
• Main burner operation (all models)
Figs. 11 and 12 summarize the normal operating sequences of the modules.
1
START
1
THERMOSTAT (CONTROLLER)
CALLS FOR HEAT
❏ If gas line has been disturbed, complete gas leak test.
GAS LEAK TEST: Paint gas control gasket edges and all
pipe connections downstream of gas control, including pilot
tubing connections, with rich soap and water solution.
Bubbles indicate gas leaks. Tighten joints and screws or
replace component to stop gas leak. Recheck with soap
and water.
❏ Turn thermostat or controller below room temperature.
Make sure main burner and pilot flames go out.
PREPURGE (S8660,S8670 ONLY)
When the S8660 is used in a fan-assisted combustion
system, the combustion air blower starts on a call for heat.
On proof of airflow, the air proving switch closes and
energizes the S8660, S8670. When the module is used in
an atmospheric system, the call for heat energizes the
module.
In either case, the module first initiates a 45 sec. delay
to allow system prepurge. After prepurge, the module starts
the pilot ignition sequence.
STAGE 1
TRIAL FOR
IGNIITION
STAGE 2
MAIN BURNER
OPERATION
END
2
SPARK GENERATOR POWERED
First valve (pilot) operator opens
3
Pilot burner lights.
Module senses
flame current.
4
FLAME CURRENT SENSED
Spark generator off.
Second valve operator (main)
opens.
5
MAIN BURNER OPERATION
Module monitors pilot flame
current.
6
THERMOSTAT (CONTROLLER)
SATISFIED
Valves close, pilot and main
burners are off.
PILOT BURNER OPERATION
OR
Pilot burner does not light.
Module Response
S8600A,F
S8610A,F
S8600B,H
S8610B,H
S8600M
a
Shutoff/lockout timing is stamped on module
POWER INTERRUPTION
System shuts off, restarts when power is
restored.
PILOT FLAME FAILURE
Main valve closes.
Module starts trial for ignition.
Ignition spark continues, pilot
valve remains open until system
is reset
After 15 or 90 sec system
locks out; must be
manually reset.
After 90 sec. system shuts off;
after 5 minutes min. (6 minutes
nom.), module restarts trial for
ignition; ignition trial, shutoff, wait
sequence repeats until pilot lights
or call for heat ends.
a
a
M1172B
Fig. 11—S8600, S8610 normal operating sequence.
12
TRIAL FOR IGNITION
Pilot Ignition
Following prepurge timing (S8660, S8670), or on the call
for heat (S8600, S8610), the module energizes the first
main valve operator. The first main valve opens, which
allows gas to flow to the pilot burner. At the same time, the
electronic spark generator in the module produces an over
10,000 volt spark pulse output. The voltage generates a
spark at the igniter (S8600A,B; S8610A,B) or igniter-sensor
(S8600F,H,M; S8610F,H; S8660; S8670) that lights the
pilot.
If the pilot does not light, or the pilot flame current is not
at least 1.0 µA and steady, the module will not energize the
second (main) valve and the main burner will not light.
S8600A,F; S8610A,F will continue to spark as long as the
thermostat calls for heat, or until the pilot lights.
Safety Lockout (S8600B,H; S8610B,H; S8660D; S8670D)
These modules provide 100 percent shutoff and safety
lockout. A timer in these models starts timing the moment
the trial for ignition starts. Ignition spark continues only until
the timed trial for ignition period ends. Then the module
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 tem-
perature for one minute or by turning off power to the
module for one minute.
Safety Shutoff with Continuous Retry (S8600M)
The S8600M provides 100 percent gas shutoff, followed
by retry for ignition. Operation on ignition failure is the same
as lockout modules, except that a timer starts timing immediately following shutoff. Six minutes nom. (five minutes
min.) after shutoff, the module restarts the ignition sequence. The ignition trial, shutoff, wait sequence continues
until either the pilot lights or the thermostat is set below
room temperature to end the call for heat. The module can
also be reset by setting down the thermostat 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 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 deenergized, and both valves in the gas control close.
START
STAGE 1
PREPURGE
STAGE 2
TRIAL FOR IGNITION
STAGE 3
MAIN BURNER
OPERATION
END
1
THERMOSTAT
CALLS FOR HEAT
2
PREPURGE
Combustion air blower starts.
3
SPARK GENERATOR POWERED
First valve (pilot) operator opens.
4
Pilot burner lights.
S8660, S8670 senses flame
current.
FLAME CURRENT SENSED
5
Spark generator off.
Second valve operator (main)
opens.
6
MAIN BURNER OPERATION
Module monitors pilot flame
current.
7
THERMOSTAT SATISFIED
Valves close, pilot and main
burners are off.
PILOT BURNER OPERATION
OR
POWER INTERRUPTION
System shuts off, restarts when power is
restored.
PILOT FLAME FAILURE
Main valve closes.
S8660, S8670 starts trial for ignition.
Pilot burner does not light.
After 15 or 90 sec , system
locks out; must be manually reset.
a
Lockout timing is
stamped on module.
a
M1171B
Fig. 12—S8660, S8670 normal operating sequence.
13 69-0463
TROUBLESHOOTING
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
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.
3. If any component does not function properly,
make sure it is correctly installed and wired before
replacing it.
4. The ignition module cannot be repaired. If it malfunctions, it must be replaced.
5. Only trained, experienced service technicians
should service intermittent pilot systems.
Perform the checkout on page 11 as the first step in
troubleshooting. Then check the appropriate troubleshooting guide (Fig. 14 or 15) and the schematic diagram (Figs.
16-17) 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 procedure (page 11) again to be sure system is operating
normally.
IGNITION SYSTEM CHECKS
STEP 1: Check ignition cable.
Make sure:
❏ Ignition cable does not run in contact with any metal
surfaces.
❏ Ignition cable is no more than 36 in. [0.9 m] long.
❏ Connections to the ignition module and to the igniter or
igniter-sensor are clean and tight.
❏ Ignition cable provides good electrical continuity.
STEP 2: Check ignition system grounding.
downs are often caused by a poor or erratic ground.
❏ A common ground, usually supplied by the pilot burner
bracket, is required for the module and the pilot burner/
igniter-sensor.
• Check for good metal-to-metal contact between the
pilot burner bracket and the main burner.
• Check the ground lead from the GND(BURNER)
terminal on the module to the pilot burner. Make sure
connections are clean and tight. If the wire is damaged or deteriorated, replace it with No. 14-18 gauge,
moisture-resistant, thermoplastic insulated wire with
105° C [221° F] minimum rating.
— Check the ceramic flame rod insulator for cracks
or 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.
STEP 3: Check spark ignition circuit.
jumper wire made from ignition cable or other heavily
insulated wire
❏ Close the manual gas valve.
❏ Disconnect the ignition cable at the SPARK terminal on
the module.
IMPORTANT
Nuisance shut-
You will need a short
.
WARNING
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.
❏ Energize the module and immediately touch one end of
the jumper firmly to the GND terminal on the module. Move
the free end of the jumper slowly toward the SPARK
terminal until a spark is established.
❏ Pull the jumper slowly away from the terminal and note
the length of the gap when sparking stops. Check table
below.
ARC LENGTH ACTION
No arc or arc less Check external fuse, if provided.
than 1/8 in. [3 mm] Verify power at module input
Arc 1/8 in. [3 mm] Voltage output is okay.
or longer.
STEP 4: Check pilot and main burner lightoff.
❏ Set the thermostat to call for heat.
❏ Watch the pilot burner during the ignition sequence. See
if:
• Ignition spark continues after the pilot is lit.
• The pilot lights and the spark stops, but main burner
does not light.
•
S8600B,H,M; S8610B,H; S8660D; S8670D only:
pilot lights, the spark stops and main burner lights, but
the system shuts down.
❏ If so, ensure adequate flame current as follows.
• Turn off furnace at circuit breaker or fuse box.
• Clean the flame rod with emery cloth.
Fig. 13—Examples of unsatisfactory pilot flames.
terminal.
Replace module if fuse and
power ok.
The
14
• Make sure electrical connections are clean and tight.
Replace damaged wire with moisture-resistant No.
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 burner will remain off
because the main valve actuator is disconnected.
• Check the pilot flame. Make sure it is blue, steady and
envelops 3/8 to 1/2 in. [10 to 13 mm] of the flame rod.
See Fig. 13 for possible flame problems and their
causes.
• If necessary, adjust pilot flame by turning the pilot
Before troubleshooting, familiarize yourself with the startup and checkout procedure.
Models with TH-W terminal (7) must have call for heat 24 Vac supply connected to the TH-W terminal.
START
TURN GAS SUPPLY OFF.
TURN THERMOSTAT
(CONTROLLER) TO CALL
FOR HEAT
POWER TO MODULE?
(24V NOMINAL)
YES
SPARK ACROSS
IGNITER/SENSOR GAP?
(S8660, S8670, S8680
HAVE 45 SECOND [NOMINAL]
PREPURGE BEFORE SPARK
STARTS.)
YES
NO
NO
NOTE:
Models with no TH-W terminal must have call for heat 24 Vac supply connected to 24V terminal (6).
Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring. Also,
check air proving switch on combustion air blower system (if used) and that vent damper (if used) is open and
end switch is made.
Pull ignition lead and
check spark at module.
Spark okay?
YES
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 excessive temperatures.
adjustment screw on the gas control
clockwise to decrease or
counterclockwise 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.
❏ Recheck ignition sequence as follows.
• Reconnect main valve wire.
• Set thermostat to call for heat.
• Watch ignition sequence at burner.
• If spark still doesn’t stop after pilot lights, replace
ignition module.
• 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 appropriate troubleshooting
chart, Fig. 14 or 15.
NO
On models with vent damper plug, make sure vent damper
has not been installed, then removed. Replace vent damper
if necessary.
On other models, replace module.
TURN GAS SUPPLY ON
AND RECYCLE CALL
FOR HEAT
PILOT BURNER LIGHTS?
YES
SPARK STOPS WHEN
PILOT IS LIT?
YES
MAIN BURNER LIGHTS?
YES
SYSTEM RUNS UNTIL
CALL FOR HEAT ENDS?
YES
CALL FOR HEAT ENDS
SYSTEM SHUTS OFF?
YES
TROUBLESHOOTING
ENDS
NO
NO
NO
NO
NO
Repeat procedure until troublefree operation is obtained.
Check that all manual gas valves are open, supply tubing and pressures are good, and pilot burner orifice
is not blocked.
Check electrical connections between module and pilot operator on gas control.
Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay, replace gas control; if not,
replace module.
NOTE: It may be necessary to recycle the call for heat to clear the pilot supply tubes of air.
NOTE: If S86XXB,H,D,J goes into lockout, reset system. For S86XXC,M,U,J,K, wait 6 min.
nom. for retry or reset system.
Check continuity of ignition cable and ground wire.
Clean flame rod.
Check electrical connections between flame rod and module.
Check for cracked ceramic flame rod insulator.
Check that pilot flame covers flame rod and is steady and blue.
Adjust pilot flame.
If problem persists, replace module.
Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.
Check electrical connections between module and gas control. If okay, replace gas control or gas control
operator.
NOTE: If S86XXB,H,D,J goes into lockout, reset system. For S86XXC,M,U,J,K, wait 6 min.
nom. for retry or reset system.
Check continuity of ignition cable and ground wire.
NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though operation is normal at
the time of checkout.
Check that pilot flame covers flame rod and is steady and blue.
If checks are okay, replace module.
Check for proper thermostat (controller) operation.
Remove MV lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas
control.
Fig. 14—S8600, S8610 troubleshooting guide.
15 69-0463
M1174F
START
TURN GAS SUPPLY OFF.
TURN THERMOSTAT TO
CALL FOR HEAT
POWER TO MODULE
(24V NOMINAL)
YES
45 SECOND
DELAY
YES
SPARK ACROSS
IGNITER/SENSOR GAP
YES
NOTE: Before troubleshooting, familiarize yourself with the startup and checkout procedure.
Check line voltage power, low voltage transformer, limit controller, thermostat and wiring. Also, check air
NO
NO
NO
proving switch on combustion air blower system and that vent damper (if used) is open and end switch is
made.
Replace S8670.
Pull ignition lead and check
spark at S8670.
Spark okay?
YES
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 excessive temperatures.
Replace module.
NO
TURN GAS SUPPLY ON
PILOT BURNER LIGHTS?
YES
SPARK STOPS WHEN
PILOT IS LIT?
YES
MAIN BURNER LIGHTS?
YES
SYSTEM RUNS UNTIL
CALL FOR HEAT ENDS?
YES
CALL FOR HEAT ENDS
SYSTEM SHUTS OFF?
YES
TROUBLESHOOTING
ENDS
NO
NO
NO
NO
NO
Repeat procedure until troublefree operation is obtained.
Check that all manual gas cocks are open, supply tubing and pressures are good, and pilot burner orifice is
not blocked.
Check electrical connections between module and pilot operator on gas control.
Check for 24 Vac across PV-MV/PV terminals on module; If voltage is okay, replace gas control; if no
voltage, replace module.
NOTE: If module goes into lockout, reset system.
Check continuity of ignition cable and ground wire.
Clean flame rod.
Check electrical connections between flame rod and module.
Check for cracked ceramic flame rod insulator.
Check that pilot flame covers flame rod and is steady and blue.
Adjust pilot flame.
If checks are okay, replace module.
Check for 24 Vac (nominal) across MV-MV/PV terminals. if no voltage, replace module.
Check electrical connections between module and gas control. If okay, replace gas control.
NOTE: If module goes into lockout, reset system.
Check continuity of ignition cable and ground wire.
NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though operation is normal at the
time of checkout.
If checks are okay, replace module.
Check for proper thermostat (controller) operation.
Remove MV lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas
control.
M1173C
Fig. 15—S8660, S8670 troubleshooting guide.
16
THERMOSTAT OR
CONTROLLER
L1
L2
LIMIT
CONTROLLER
2
24V
TRANSFORMER
ON-OFF
SWITCH
(HOT)
1
24V
ARC
2K1
SPARK
DRIVE
CIRCUIT
FLAME
DETECTOR
CIRCUIT
HYBRID CIRCUIT
TIMING
CIRCUITS
MAIN
VALVE
MV
PILOT
VALVE
PV
TO 24V (GND)TO 24V
MV/
1K1
2K2
1K2
3K1
1K
2K
3K
RELAY
DRIVERS
3
3K2
1K2
LOW
VOLTAGE
POWER
SUPPLY
1K1
2K2
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
2
3K RELAY ON 100 PERCENT SHUTOFF MODELS ONLY. ON NON-SHUTOFF MODELS, PV AND MV
3
WIRED AS FOLLOWS.
GAP
SPARK
PV
IGNITER
SENSOR
MV
PV
INTERNAL WIRING
EXTERNAL WIRING
BURNER
GROUND
MAIN
VALVE
PILOT
VALVE
GND
(BUR-
NER)
24V
(GND)
MV/
M1165C
PV
Fig. 16—Representative schematic for S8600F,H, M; S8610F,H. See Fig. 1 for hookup. S8660 and S8670 are similar
except the timing circuit includes a purge timer. See Fig. 6 for hookup.
17 69-0463
THERMOSTAT OR
CONTROLLER
L1
L2
LIMIT
CONTROLLER
2
24V
TRANSFORMER
ON-OFF
SWITCH
(HOT)
1
24V
ARC
MV/
PV
GAP
SENSE
SPARK
2K1
SPARK
DRIVE
CIRCUIT
FLAME
DETECTOR
CIRCUIT
HYBRID CIRCUIT
TIMING
CIRCUITS
MAIN
VALVE
MV
PILOT
VALVE
PV
TO 24V (GND)TO 24V
1K1
2K2
1K2
3K1
1K
RELAY
2K
DRIVERS
3K
3
3K2
1K2
LOW
VOLTAGE
POWER
SUPPLY
1K1
2K2
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
1
PROTECTION AS REQUIRED.
ALTERNATE LIMIT CONTROLLER LOCATION.
2
3K RELAY ON 100 PERCENT SHUTOFF MODELS ONLY. ON NON-SHUTOFF MODELS, PV AND
3
MV WIRED AS FOLLOWS.
SENSOR
IGNITER
MV
PV
INTERNAL WIRING
EXTERNAL WIRING
GND
(BURNER)
BURNER
GROUND
MAIN
VALVE
PILOT
VALVE
M1166C
24V
(GND)
MV/
PV
Fig. 17—Representative schematic for S8600A,B; S8610A,B. See Fig. 3 for hookup.
18
ANSI STANDARDS
RECOMMENDED PROCEDURE FOR SAFETY INSPECTION OF AN EXISTING
APPLIANCE INSTALLATION AS A PRELIMINARY STEP TO APPLYING
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 instal-
lation.
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 condi-
tion.
The following steps 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
which 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 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
AN AUTOMATIC INTERMITTENT PILOT SYSTEM
EXHIBIT A
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers. If, after completing steps 7 through 12, it is believed sufficient combustion air is not available, refer to 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.
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.
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
previous conditions of use.
13. 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.
14. 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.
EXHIBIT A OF ANSI STANDARD Z21.71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD
INSTALLATION
19 69-0463
EXHIBIT B
PROCEDURE FOR INSTALLING AUTOMATIC INTERMITTENT PILOT SYSTEMS
Prior to beginning this procedure, a preliminary examination of the appliance and the automatic intermittent 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 atmospheric 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 procedure may be necessary to determine safe operation of
the equipment.
The following steps should be followed in making the
modifications:
1. Perform a safety inspection of the existing appliance 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. Do not use the shutoff valve which is provided as part of a combination control.
3. Install 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 that the appliance transformer has
adequate capacity by following the steps outlined below:
a. Compute the approximate current draw by adding
the current draw of the automatic intermittent pilot
system to (1) the current draw of the associated
valving, and (2) the current draw of any relays or
other devices operated by the transformer.
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 transformer.
d. If the total VA (volt-ampere) required is greater
than the VA rating of the transformer, the transformer
must be replaced with a Class 2 transformer of
adequate rating.
6. Check the heat anticipator in the comfort thermostat to determine if it is properly adjusted to the current
draw of the control system. Follow the thermostat
manufacturer’s instructions.
EXHIBIT B OF ANSI STANDARD Z21.71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR FIELD
INSTALLATION.
7. Make certain wiring connections are tight and
wires are positioned and secured so they will not be able
to contact high temperature locations.
8. Conduct a Gas Leakage Test of the appliance
piping and control system downstream of the shutoff
valve in the supply line to the appliance.
9. a. Adjust the thermostat to its highest tempera-
ture setting, and test manifold pressure and adjust
the pressure regulator to 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. Adjust the primary air shutter(s) as required.
10. If 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 electrical supply to
the appliance in any convenient manner. Make this
determination with the appliance burner both cold and
hot. Perform this step as many times as is necessary to
satisfy yourself that the automatic intermittent pilot system is operating properly.
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 instructions.
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
electrical supply to the blower motor and determining
that the limit controller acts to shut off the main burner
gas.
15. Applicable only to boilers.
a. Determine that the circulating water pumps are
in operating condition.
b. Test low water cutoffs, automatic feed water
controls, pressure and temperature limit controllers and relief valves in accordance with the
manufacturer’s recommendation to determine
they are in operating condition.
16. Add the labels (see 1.6.1-n and -o) on the appliance.
Home and Building Control Home and Building Control
Honeywell International, Inc. Honeywell Limited—Honeywell Limitée
1985 Douglas Drive North 35 Dynamic Drive
Golden Valley, MN 55422 Scarborough, Ontario M1V 4Z9
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