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Honeywell SUPER TRADELINE S8610U Installation Instructions Manual

Universal intermittent pilot gas ignition control
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S8610U Universal Intermittent Pilot Gas
Ignition Control
SUPER TRADELINE
APPLICATION
The SUPER TRADELINE
Intermittent Pilot Gas Ignition Control Module is designed
to provide easy field replacement of a wide range of
intermittent pilot ignition modules manufactured by
Honeywell, Robertshaw, Johnson Controls, and others.
The S8610U control provides ignition sequence, flame
monitoring, and safety shutoff for intermittent pilot central
furnaces, residential boilers, and other heating
appliances. The S8610U replaces existing flame
rectification type, intermittent pilot ignition modules with
the following characteristics:
• Single rod (local sense) or two rod (remote sense)
flame sensing
• Non-100 percent shutoff, 100 percent shutoff/lockout,
or 100 percent shutoff/continuous retry
• Natural or LP gas
• Shutoff/lockout times of 15 seconds or longer
• Prepurge configurable to 30 seconds or no prepurge
• Pilot burners with flow rates of 1,500 Btuh or less
• With or without integral damper connector
Table 1 describes the key features of the S8610U
control.
WARNING
Check Table 2 on page 2 before replacing an
existing intermittent pilot control with the S8610U.
If the existing control is not listed, do not use the
S8610U to replace it unless you are certain the
specifications match those of the existing control.
Valve Current
Igniter-Sensor
Rating
Type
@ 24 Vac
Separate
1.0 A Pilot
(two rod; remote
and
flame sensing)
2.0 A Main
or
Combination
(one rod; local
flame sensing)
®
S8610U Universal
Table 1. S8610U Universal Intermittent Pilot Gas Ignition Control.
Trial for
Prepurge
Pilot
Timing
Ignition
None or 30
15 or 90
seconds
seconds
(field
(field
selectable)
selectable)
Automatic Ignition Systems
ANSI Z21.20
®
®
A complete list of the specific Honeywell and other
modules that the SUPER TRADELINE
designed to replace is provided in Table 2 on page 2.
The SUPER TRADELINE
complete, easy-to-use instructions, plus the accessories
required to adapt the existing spark cable (Rajah, stud,
nail, or other) to the spark terminal on the control module.
It also help assure proper marking of the wires attached
to the existing control and a label with LED code
information that can be affixed in the appliance.
IMPORTANT
The S8610U control module is not designed to
replace controls with:
— Flame sensing other than by flame rectification
(White Rodgers Cycle-Pilot
thermal sensing)
— Standing pilot appliances
— Direct main burner ignition
The S8610U provides:
• Natural or LP gas
• Pilot burner ignition using an internally generated high
voltage spark
• Flame rectification circuit to monitor flame presence
• Monitoring of 24 Vac, pilot, and main gas valve
• Two LED indicators for flame presence/strength and
system status/errors
• EnviraCOM™ communication protocol for system
diagnostics
• Vent Damper connection
The S8610U is designed for a wide variety of natural or
liquid propane fueled applications.
Ignition
Ignition Sequence
Sequence
(After prepurge, if prepurge is
Type
Retry
Spark and pilot gas ON until 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
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.
INSTALLATION INSTRUCTIONS
®
S8610U is
®
S8610U package contains
®
, or Robertshaw
selected)
Included for use as
needed.
Integral
Damper
Connector
If initially installed
and powered up
with damper
attached, unit
must always have
a vent damper
connected.
69-1955

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  Summary of Contents for Honeywell SUPER TRADELINE S8610U

  • Page 1 S8610U Universal Intermittent Pilot Gas Ignition Control ® SUPER TRADELINE INSTALLATION INSTRUCTIONS APPLICATION A complete list of the specific Honeywell and other ® modules that the SUPER TRADELINE S8610U is ® The SUPER TRADELINE S8610U Universal designed to replace is provided in Table 2 on page 2.
  • Page 2 Table 2. S8610U Replaces These Table 2. S8610U Replaces These Table 2. S8610U Replaces These Modules (Continued) Modules (Continued) Modules Vendor / Model Vendor / Model Vendor / Model S8600H1022 Johnson Controls Honeywell S8600H1048 S8600H1055 CSA35A-617R S86A1001 S8600H1063 CSA35A-618R S86A1019 CSA42A-600R S86A1027 S8600H1071...
  • Page 3: Specifications

    The yellow Flame LED indicates G65BKG-2 Y79ABC-1 flame presence and flame G65BKG-3 Y79ABC-2 G65BKM-1 strength Y79ABC-3 G65BKM-2 Y79ABC-4 G65BKM-3 Y79ABC-5 G65BLG-1 Typical Gas Control: Honeywell Y79ABC-6 G65BLG-2 Y79ABC-7 models VR8204 and VR8304 G65DBG Y79ABD-1 G65DBM-1 Y79ABCD-2 G65DBM-2 Y79BBA-1 Operating Temperature: G65DBM-3 Y79BBA-2...
  • Page 4: Planning The Installation

    These applications require special When Installing This Product… Honeywell review; contact your Honeywell Sales 1. Read these instructions carefully. Failure to follow Representative for assistance. them could damage the product or cause a hazard- ous condition.
  • Page 5: Maintenance Requirements In Severe Environments

    S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL Any ignition control module should be replaced if it does CAUTION not perform properly on checkout or troubleshooting. In addition, replace any ignition control module if it is wet or looks like it has ever been wet. Protective enclosures as 1.
  • Page 6: Remove Old Ignition Control Module

    S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL 11. Applicable only to warm air heating appliances. IMPORTANT Check both limit controller and fan controller for Do not mount with terminals facing up. 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.
  • Page 7 If the cable must be replaced, cated in the wiring tables. order a Honeywell ignition cable (Table 3) or refer to (Refer to Fig. 2 and Table 9 on page 11 for wiring Table 4. It might be necessary to replace the connector at connections on the S8610U module.)
  • Page 8 S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL The following four tables describe the wiring connections necessary for conversion: Table 5. Conversion from Honeywell Intermittent Pilot Modules. Replacement Control Old Control S90A,B S8600A,B,C S8610A,B,C S8610U1003 S8620C, S8600F,H,M S8660D,J S8610F,H,M Terminal S8670D,J...
  • Page 9 S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL Table 6. Conversion from Johnson Controls CSA — (All), G60, G65, G66, G67, G600, G670 and G770. Replacement Control Control CSA45A-60R , G60, G65, G66, G67, G600, or G670 Installation with Lockout Modules as follows: Terminal Function S8610U...
  • Page 10 S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL Table 7. Conversion from Robertshaw SP715 and SP735C (includes 780-XXX and USI715U). Replacement Control Old Control Terminal Function S8610U 7000D Valve 7100D Valve 7100K Valve Procedural Notes Main Valve — Operator (to Valve TH) (to Valve M) (to Valve TR) Main Valve and...
  • Page 11: Wiring Connections

    S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL Make Flame Sense Connection For an ignition module used in remote flame sensing (separate igniter and sensor rods) applications, the sense jumper wire is not used. See Fig. 2 and Table 9 on page 11 and perform the following: SPARK —...
  • Page 12 S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL S8610U ENVIRA REMOTE COM ™ (BRN) GND 24V TH-W SENSE SPARK JUMPER WIRE WIRING MAIN HARNESS PILOT VALVE VENT OPERATOR OPERATOR DAMPER DUAL VALVE COMBINATION THERMOSTAT GAS CONTROL LIMIT CONTROLLER L1 (HOT) PILOT BURNER/ IGNITER PILOT...
  • Page 13 S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL S8610U ENVIRA REMOTE COM ™ (BRN) GND 24V TH-W SENSE SPARK MAIN JUMPER PILOT VALVE WIRE OPERATOR OPERATOR DUAL VALVE COMBINATION THERMOSTAT GAS CONTROL LIMIT CONTROLLER L1 (HOT) PILOT BURNER/ PILOT IGNITER BURNER GROUND PILOT GAS SUPPLY...
  • Page 14 S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL S8610U ENVIRA REMOTE SPARK COM ™ (BRN) GND 24V TH-W SENSE JUMPER WIRE MAIN PILOT VALVE PROVING THERMOSTAT SWITCH OPERATOR OPERATOR DUAL VALVE COMBINATION GAS CONTROL COMBUSTION AIR BLOWER RELAY LIMIT CONTROLLER PILOT BURNER/ (HOT) 1 COMBUSTION IGNITER...
  • Page 15: Settings And Adjustments

    S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL SETTINGS AND ADJUSTMENTS DIP Switch (S1) Settings When replacing an existing ignition control with the S8610U, refer to Table 2 on page 2 for the correct DIP switch settings. NOTE: Refer to Table 11 for lockout control of DIP M23587 switch timing settings.
  • Page 16: Trial For Pilot Ignition

    S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL Step 1: Perform Visual Inspection. 6. Set thermostat below room temperature and wait one minute before continuing. 1. With power off, make sure all wiring connections are clean and tight. Step 6: Check Normal Operation. 2.
  • Page 17: Failed Trial For Pilot Ignition

    S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL Failed Trial for Pilot Ignition pilot lights and is proved or the “Call for Heat” ends. The five minute delay time can be bypassed by cycling the The S8610U control module provides multiple trials for system thermostat or removing and restoring system ignition (TFI).
  • Page 18: Troubleshooting

    S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL TROUBLESHOOTING STEP 2: Check Ignition System Grounding. Nuisance shutdowns are often caused by a poor or erratic ground. A common ground, is required for the ignition WARNING control module and the pilot burner bracket. 1.
  • Page 19: Led Status And Troubleshooting

    S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL STEP 4: Check Pilot and Main Burner Lightoff. CAUSE APPEARANCE 1. Set the thermostat to “Call for Heat.” 2. Watch the pilot burner during the ignition sequence. SMALL BLUE FLAME CHECK FOR LACK OF GAS FROM: See if one of the following occurs: •...
  • Page 20 S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL • Flame LED (Yellow) • Status LED (Green) — Indicates flame presence and strength. See — Indicates system operation status and error condi- Table 13. tions. See Table 14 and the “Troubleshooting Guide” on page 21. Table 13.
  • Page 21: Troubleshooting Guide

    S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL Troubleshooting Guide Refer to the following guide for troubleshooting the S8610U control module. START: BEFORE TROUBLESHOOTING, FAMILIARIZE YOURSELF WITH THE NOTE: 24 VAC “CALL FOR HEAT” IS ALWAYS CONNECTED TO THE TH-W TERMINAL ON THE MODULE. STARTUP AND CHECKOUT PROCEDURES.
  • Page 22 S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL 69-1955...
  • Page 23 S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL 69-1955...
  • Page 24 S8610U UNIVERSAL INTERMITTENT PILOT GAS IGNITION CONTROL Automation and Control Solutions Honeywell International Inc. Honeywell Limited-Honeywell Limitée 1985 Douglas Drive North 35 Dynamic Drive Golden Valley, MN 55422 Toronto, Ontario M1V 4Z9 customer.honeywell.com ® U.S. Registered Trademark © 2006 Honeywell International Inc. 69-1955 M.S. 11-06...