Honeywell Y8610U User Manual
Put UPC Code Here
®
Automatic Ignition Systems
ANSI Z21.20
Y8610U Intermittent Pilot Retrofit Kit
PRODUCT DATA
— 392431 Igniter-Sensor
— 394800-30 Ignition Cable
— 393691 Natural to LP Gas Conversion Kit
— Wiring Harness
— 393690-14 Straight Flange Kit (3/4 in.)
— Reducer adapters for gas control with VR8304M
— Installation hardware
Temperature Ratings:
— S8610U: -40°F to 165°F (-40°C to 74°C)
— VR8304M: -40°F to 175°F (-40°C to 79°C)
— VR8204A: 0°F to 175° F (-18°C to 79°C)
Intermittent Pilot Gas Ignition Control Module
• Uses flame rectification for flame sense
• Internal spark generator lights pilot gas; main burner lights
GENERAL
The Y8610U is a complete kit for converting conventional
standing pilot systems to intermittent pilot systems. It is used
on gas-fired atmospheric furnaces, boilers, and heating
appliances. Not for use on direct vent, induced draft, or power
burner equipment. Meets ANSI Z21.71 standard for automatic
intermittent pilot ignition systems on central furnaces and
boilers.
FEATURES
• Y8610U kits can be used with either natural or LP gas.
• The S8610U ignition control provides a 90 second
maximum ignition trial, shuts off, waits five minutes
nominal, then re-initiates the pilot ignition sequence. The
ignition trial, shutoff, and wait cycle repeat until the pilot
lights or the call for heat ends.
Each kit includes:
— S8610U Intermittent Pilot Module
— VR8304M Dual Valve Combination Gas Control
or
VR8204A Dual Valve Combination Gas Control
after pilot flame lights and proves
• 100% shutoff of pilot and main gas if burner fails to light
• Continuous retry ignition sequence prevents nuisance
lockouts
• Two LEDs indicate system status and flame signal strength
Gas Control Valve
• Straight through body pattern
• VR8304M capacity is 270 ft
• VR8204A capacity with or without 1/2” x 3/4” adapter is
• Manual ON-OFF valve blocks gas flow into the gas control
• Two main automatic valves: one solenoid-operated, and
Igniter-Sensor
• Single electrode made of Kanthal provides both ignition
• Rated for 1775°F (968°C) at electrode tip; 1250°F (677°C)
3
150 ft
/hr (4.2 m3/hr)
when in the OFF position
one a servo-operated diaphragm system
and flame sensing
at ceramic insulator
3
/hr (7.6 m3/hr)
Contents
General .............................................................................1
Specifications ...................................................................2
Planning the Installation ....................................................6
Installation ........................................................................7
Settings ............................................................................14
Checkout ..........................................................................15
Operation ..........................................................................16
Troubleshooting ................................................................17
Ansi Standards .................................................................22
68-0291-03
Y8610U INTERMITTENT PILOT RETROFIT KIT
Table 1. S8610U Universal Intermittent Pilot Gas Ignition Control Module.
Valve
IgniterSensor
Type
Combination
(one rod;
local flame
sensing)
Current
Rating
@ 24 Vac
1.0 A Pilot
and
2.0 A Main
Prepurge
Timing
(field selectable)
0 (zero) or 30
seconds;
0 (zero) seconds
recommended
(field selectable)
15 or 90
seconds;
90 seconds
recommended
Trial for
Pilot Ignition
Ignition
Sequence
Type
Retry Spark and pilot gas ON until
Ignition Sequence
(After prepurge,
if prepurge is selected)
lightoff or trial for ignition ends.
If established flame is lost, trial
for ignition restarts immediately.
If pilot fails to light, pilot gas and
spark turned off (100% shutoff).
After 5 minute delay, a new trial
for ignition is initiated.
This sequence continues until
lightoff or “Call for Heat” is
removed.
Integral
Damper
Connector
Included for use
as needed.
If initially installed
and powered up
with damper
attached, unit
must always have
a vent damper
connected.
SPECIFICATIONS
IMPORTANT
The specifications given in this publication do not
include normal manufacturing tolerances. Therefore,
units might not match the listed specifications
exactly. Also, units are tested and calibrated under
closely controlled conditions, and some minor differences in performance can be expected if those conditions are changed.
Y8610U Intermittent Pilot Retrofit Kit
Electrical Ratings:
• Voltage and Frequency: 24 Vac, 60 Hz
• Current Rating: 0.7A (includes both module and gas
control)
• Thermostat Anticipator Setting: 0.7A plus current ratings of
other devices in the thermostat control circuit
S8610U Intermittent Pilot Gas Ignition Control Specifications
Control Voltage: Line 24 Vac (18-30 Vac) 50/60 Hz
Trial for Ignition: See Table 1 above
Prepurge: See Table 1 above
Flame Failure Response Time: 2 seconds maximum
LEDs:
The green LED provides system status, error codes and
indicates flame sensing
Operating Temperature:
Minimum ambient temperature rating is -40°F (-40°C)
Maximum ambient temperature rating when used with
2.0 A main valve is 165°F (74°C)
Relative Humidity: 0% to 95% non condensing
Dimensions: See Fig. 2 on page 4.
Thermostat Compatibility:
Compatible with any Honeywell 24V thermostat and with
competitive 24V thermostats that are powered independently of the module.
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.
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 Honeywell Automation and Control Products Sales Office (check white pages of your phone directory).
2. Honeywell Customer Care
1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386
3. http://customer.honeywell.com
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Toronto, 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.
68-0291—03 2
or http://customer.honeywell.ca
Y8610U INTERMITTENT PILOT RETROFIT KIT
Transformer Sizing:
Add current ratings of Y8610, vent damper, and any other
control system components. Multiply this total by 24V to
determine the transformer VA requirement.
Mounting:
Mounts in any position except with terminals up. Recommended mounting position is with terminals down to provide
maximum protection from dripping water or dust accumulation. Refer to Fig. 14 on page 12.
Fasten with No. 6-32 machine screws or No. 8 sheet metal
screws or 8-18 x 5/8 pan head tapping screws of appropriate length.
Wiring Connections:
— Between the module and gas control: 30 in. (762 mm)
wiring harness with 1/4 in. quick-connect terminals.
— Between the module and the igniter-sensor: 30 in.
(762 mm) ignition cable with stud terminal and 1/4 in.
quick-connect terminal.
Terminals:
1/4 in. male quick-connects. S8610U has Molex plug for
connection to a vent damper harness. Once the S8610U
has powered a vent damper, the module works only if the
vent damper is connected.
VR8204A and VR8304M Dual Valve Combination Gas Controls Specifications
Table 2. VR8204A and VR8304M Dual Valve Combination Gas Controls Specifications.
Model Capacity
VR8204A
VR8304M
a
Based on 1,000 Btu/ft3, 0.64 specific gravity natural gas at 1 in. wc pressure drop (37.3 MJ/m3, 0.64 specific gravity natural gas at
0.25 kPa pressure drop).
b
3/4 in. straight flange included to provide 3/4” NPT outlet if needed.
3
150 ft
/hr (4.2 m3/hr); (with or
without 1/2” x 3/4” adapter)
3
270 ft
/hr (7.6 m3/hr)
a
Pipe Size Ambient Temperature Rating Dimensions
1/2 in. X. 1/2 in. NPT
inlet x outlet
1/2 in. X. 3/4 in. NPT
inlet x outlet
b
0° to 175° F (-18° to 79° C) See Fig. 4 on page 5
-40° to 175°F (-40° to 79°C) See Fig. 3 on page 5
Mounting:
Can be mounted from 0 to 90 degrees, in any direction,
from the gas control upright position
Pressure Rating: 1/2 psig (3.45 kPa) inlet pressure
Terminals: 1/4 in. male quick-connect terminals
Igniter-Sensor Specifications
Model:
392431 Igniter-Sensor; includes igniter-sensor assembly,
ground rod, and adapter (refer to Fig. 1 on page 4)
Electrode/Flame Rod Material: Kanthal
Maximum Temperature Ratings:
Ground Rod Tip: 1775°F (968°C)
Ceramic Insulator: 1250°F (677°C)
Dimensions: See Fig. 5 on page 6.
Mounting:
Attach the supplied ground rod and adapter, which replace
the thermocouple on the existing pilot burner
3 68-0291—03
Y8610U INTERMITTENT PILOT RETROFIT KIT
VR8304
S8610U INTERMITTENT
PILOT MODULE WITH
WIRING HARNESS
392431 IGNITERSENSOR ASSEMBLY
ALSO INCLUDED:
• 394800-30 IGNITION CABLE (30 IN. (760 mm))
• 393690-14 STRAIGHT FLANGE KIT
• 393691 NATURAL GAS TO LP CONVERSION KIT
• REDUCER ADAPTERS FOR GAS CONTROL (WITH VR8304M)
• SCREWS
• WIRE NUTS (3)
M32519
GROUND
ROD
IGNITER-SENSOR
ADAPTER
M32363
2 (51)
3 3/16
(81)
3 7/8
(98)
3 3/8
(86)
3/16 (5) x 2
5 1/2 (140)
3 3/8 (86) x 2
1 1/32
(26)
3/16
(5) x 2
68-0291—03 4
Fig. 1. Y8610U retrofit kit components.
Fig. 2. S8610U module dimensions in inches (mm).
Y8610U INTERMITTENT PILOT RETROFIT KIT
OUTLET
PRESSURE
TAP
INLET
OUTLET
WIRING
TERMINALS (3)
INLET
PRESSURE TAP
PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)
PILOT OUTLET
PILOT ADJUSTMENT
(UNDER CAP SCREW)
GAS
CONTROL
KNOB
M24885
3-15/16
(99)
1-7/16
(36)
2-11/16 (69)
4-1/16 (104)
4 IN. (102) MAX
SWING RADIUS
M24886
1/4 INCH
QUICK-CONNECT
TERMINALS
1 (25)
1/2
(13)
1
(25)
1/2
(13)
OUTLET
PRESSURE
TAP
INLET
OUTLET
WIRING
TERMINALS (3)
INLET
PRESSURE TAP
PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)
PILOT OUTLET
PILOT ADJUSTMENT
(UNDER CAP SCREW)
GAS
CONTROL
KNOB
M24887
3-1/2
(89)
1-7/16
(36)
2-11/16 (69)
3 5/8 (91) MAX
SWING RADIUS
M24888
1/4 INCH
QUICK-CONNECT
TERMINALS
1 (25)
1/2
(13)
1
(25)
1/2
(13)
PV
PV/MV
MV
4-1/8 (108)
Fig. 3. VR8304M mounting dimensions in inches (mm).
5 68-0291—03
Fig. 4. VR8204A mounting dimensions in inches (mm).
Y8610U INTERMITTENT PILOT RETROFIT KIT
WARNING
M6860
1-1/8 (29)
2-3/8
(60)
3-1/2
(89)
Fig. 5. 392431 Igniter-sensor mounting dimensions in
inches. (mm).
PLANNING THE INSTALLATION
Fire or Explosion Hazard.
Can cause severe injury, death or property damage.
1. Plan the installation as outlined below.
2. Plan for frequent maintenance as described in the
Maintenance section.
Intermittent pilot systems are used on a wide variety of central
heating equipment and on heating appliances such as
commercial cookers, agricultural equipment, industrial heating
equipment and pool heaters. Some of these applications may
make heavy demands on the controls, either because of
frequent cycling, or because of moisture, corrosive chemicals,
dust or excessive heat in the environment. In these situations,
special steps may be required to prevent nuisance shutdowns
and premature control module failure. These applications
require special Honeywell review; contact your Honeywell
Sales Representative for assistance.
Review the following conditions that can apply to your specific
installation and take the precautionary steps suggested.
Frequent Cycling
These controls are designed for use on appliances that
typically cycle three to four times an hour only during the
heating season. In year-round applications with greater cycling
rates, the control module can wear out more quickly; perform a
monthly checkout.
Water or Steam Cleaning
If the control module gets wet, replace it. If the appliance is
likely to be cleaned with water or steam, protect (cover) the
controls and wiring from water or steam flow. Mount the
controls high enough above the bottom of the cabinet so they
do not get wet during normal cleaning procedures. Use a
NEMA 4 enclosure for the ignition control module.
High Humidity or Dripping Water
Dripping water can cause the control module and the gas
control to fail. Never install an appliance where water can drip
on the controls.
In addition, high ambient humidity can cause the control
module and the gas control to corrode and fail.
If the appliance is in a humid atmosphere, make sure air
circulation around the controls is adequate to prevent
condensation. Also, regularly check out the system. A NEMA 4
enclosure is recommended for the ignition control module.
Corrosive Chemicals
Corrosive chemicals can attack the ignition control module and
gas control, eventually causing a failure. If chemicals are used
for routine cleaning, make sure they do not reach the controls.
Where chemicals are suspended in air, as in some industrial or
agricultural applications, use a NEMA 4 enclosure for the
ignition control module.
Dust or Grease Accumulation
Heavy accumulations of dust or grease can cause controls to
malfunction. Where dust or grease can be a problem, provide
covers for the ignition control module and the gas control to
limit contamination. A NEMA 4 enclosure is recommended for
the ignition control module.
Heat
Excessively high temperatures can damage controls. Make
sure the maximum ambient temperature at the control module
does not exceed the rating of the control module. If the
appliance operates at very high temperatures, use insulation,
shielding, and air circulation, as necessary, to protect the
controls. Proper insulation or shielding should be provided by
the appliance manufacturer; verify proper air circulation is
maintained when the appliance is installed.
68-0291—03 6
Y8610U INTERMITTENT PILOT RETROFIT KIT
WARNING
WARNING
INSTALLATION
When Installing this Product…
1. Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous condition.
2. Check the ratings given in these instructions and on the
product to ensure the product is suitable for your application.
3. Installer must be a trained, experienced service technician.
4. After completing installation, use these instructions to
check product operation.
IMPORTANT
1. Installer must comply with local codes and ordinances
of the National Fuel Code (ANSI Z223.1—NFPA
No. 54) and National Electrical Code (ANSI NFPA
No. 70).
2. Installer must fill in and attach label to appliance being
converted.
3. Use Y8610 Retrofit Kit only with atmospheric burners.
Do not use on direct vent appliances, appliances with
induced draft, or power burners.
4. Do not use the Y8610 Retrofit Kit with mercury pilots
or 250 to 750 mV pilot systems.
• Exposure to water, dirt, chemicals, and heat can damage
the ignition control module or the gas control and shut down
the control system. A NEMA 4 enclosure can reduce
exposure to environmental contaminants.
The maintenance program should include regular checkout of
the system as outlined under “Checkout” on page 15.
FIRE OR EXPLOSION HAZARDCAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY, OR
DEATH.
Do not attempt to disassemble or clean the module.
Improper reassembly and cleaning can cause
unreliable operation.
Maintenance frequency must be determined individually for
each application based on:
• Cycling frequency: Appliances that cycle more than 20,000
times annually should be checked monthly.
• Intermittent use: Appliances that are used seasonally
should be checked before shutdown and again before the
next use.
• Consequence of unexpected shutdown: Where the cost of
an unexpected shutdown is high, the system should be
checked more often.
• Dusty, wet, or corrosive environment: Because these
environments can cause the controls to deteriorate more
rapidly, the system should be checked more often.
FIRE OR EXPLOSION OR ELECTRICAL SHOCK
HAZARD CAN CAUSE PROPERTY
DAMAGE,SEVERE INJURY, OR DEATH.
Follow these warnings exactly:
1. Disconnect the power supply before wiring to
prevent electrical shock or equipment damage.
2. To avoid dangerous accumulation of fuel gas, turn
off gas supply at the appliance service valve
before starting Installation and perform the Gas
Leak Test immediately following the installation.
(See “Checkout” on page 15.)
3. Never install where water can flood, drip, or
condense on module or gas control. Never use a
module or gas control that has been wet. If wet,
controls can malfunction and lead to an
accumulation of explosive gas.
4. Do not light or operate electric switches, lights, or
appliances until you are sure the appliance area is
free of gas. Liquefied petroleum (LP) gas is
heavier than air and does not vent upward
naturally.
Maintenance Requirements in Severe
Environments
Regular preventive maintenance is important in any
application, but especially so in commercial cooking,
agricultural, and industrial applications because:
• In many such applications, particularly commercial cooking,
the equipment operates 100,000-200,000 cycles per year.
Such heavy cycling can wear out the gas control in one to
two years. A normal forced air furnace, for which the
controls were originally intended, typically operates less
than 20,000 cycles per year.
Any ignition control module or gas control should be replaced if
it does not perform properly on checkout or troubleshooting. In
addition, replace any ignition control module or gas control if it
is wet or looks like it has ever been wet. Protective enclosures
as outlined under “Planning the Installation” on page 6 are
recommended regardless of checkout frequency.
Perform the Pre installation Safety Inspection
The pre-installation checks described below must be
completed before the Y8610U Intermittent Pilot Retrofit Kit is
installed. If a condition that could result in unsafe operation is
detected, the appliance should be shut off and the owner
advised of the unsafe condition. Correct any potentially unsafe
condition before proceeding with the installation. See “Exhibit
A” on page 22.
The following safety checklist should be followed in making the
safety inspection:
1. Conduct a Gas Leakage Test of the appliance piping and
control system downstream of the shut-off 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 supply line to each appliance. If a
manual gas valve is not in the gas supply line within 6
feet of the appliance in an accessible location, one shall
be installed.
4. Inspect burners and crossovers for blockage and corrosion.
7 68-0291—03
Y8610U INTERMITTENT PILOT RETROFIT KIT
WARNING
TO
TRANSFORMER
TO
THERMOSTAT
TO
TRANSFORMER
TO
THERMOSTAT
TO
TRANSFORMER
TO
THERMOSTAT
COMMON
COMMON
M6858
10. Perform the following tests:
11. Test for spillage at the draft hood relief opening after 5
12. Return doors, windows, exhaust fans, fireplace dampers
13. Applicable only to warm air heating appliances. Check
14. Applicable only to boilers:
5. Applicable only to warm air heating appliances. Inspect
heat exchangers for cracks, openings or excessive corrosion.
6. Applicable only to boilers. Inspect for evidence of water
or combustion product leaks.
7. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliance is located and other spaces of the building. Turn on
clothes dryers. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at
maximum speed. Do not operate a summer exhaust fan.
Close fireplace dampers. If, after completing steps 7
through 12, 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. Determine the following:
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 con-
trol or flame modulation, check for proper main
burner operation at low flame.
minutes of main burner operation. Use a draft gauge, the
flame of a match or candle, or smoke from a cigarette,
cigar or pipe.
and all other fuel-burning appliances to their previous
conditions of use.
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.
a. Determine that the circulating water pumps are in
operating condition.
b. Test low water cutoffs, automatic feed controls, pres-
sure and temperature limit controls and relief valves
in accordance with the manufacturer’s recommendations and instructions to determine they are in operating condition.
Shut Down Appliance
1. Turn off the gas supply at the appliance service valve.
Do not use the gas control knob.
2. Turn off the electricity at the service entrance.
Check Appliance Wiring
The existing standing pilot gas control wires are used to control
Y8610U Retrofit Kit. Carefully identify and tag the wires before
disconnecting. See Fig. 6 for the most common types of
terminal arrangements.
Fig. 6. Wiring connections on standing pilot gas controls.
Remove Standing Pilot Gas Control
1. If the gas control has a common terminal(s), remove the
wires connected to the common terminal(s) and splice
together with one of the wire nuts provided.
2. Label and remove the remaining wires.
FIRE OR EXPLOSION HAZARDCAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY, OR
DEATH.
Do not bend the pilot gas tubing at the gas control or at
the pilot burner to prevent gas leakage at the
connection.
3. Disconnect the pilot tubing at the gas control. Cut off and
discard the compression fitting. Do not disturb the compression fitting or pilot tubing at the pilot burner.
4. Disconnect the thermocouple lead at the gas control.
5. Disconnect the gas piping at the gas control.
6. Discard the gas control.
68-0291—03 8
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