Operating and Maintenance Manual

AJAX BOILER INC.

Designed and Manufactured in Accordance with

ASME Code Section IV, Heating Boilers

E.T.L. Listed

ASME Code Construction and Stamped.

SCAQMD Rule 1146.2

Certified

Photo shown may vary from actual model.

Model “B_G” SeriesGas-Fired Copper Fin Water Heaters

E.T.L. Compliance

E.T.L. Canadian

Compliance

ASME

ASME

INSTALLATION and MAINTENANCEINSTRUCTIONS for

SERIES “E” and “G”COPPER FIN COIL HEATERS

FOR YOUR SAFETYIF YOU SMELL GAS

1. OPEN WINDOWS2. DON’T TOUCH

ELECTRICALSWITCHES

3. EXTINGUISH ANYOPEN FLAME

4. IMMEDIATELYCALL YOUR GAS SUPPLIER

FOR YOUR SAFETY

DO NOT STORE GASOLINE OR OTHERFLAMMABLE VAPORSAND LIQUIDS IN THEVICINITY OF THIS OR

ANY OTHER APPLIANCE

(1) Inspect the heater for shipping damage. Make sure that you open the box and visually inspect the heater. An

undamaged container does not guarantee undamaged contents.

(2) If the heater is damaged when received, a claim must be filed by you with the shipping company. Ace Boiler

Inc. is not responsible for any damage that the heater receives while in shipping. Although each shipping com-

pany has its own procedure for filing a claim, the information contained below should provide a guideline for fil-

ing a freight claim.

(3) Check and tighten the following as required: plumbing, gas supply, and electrical connections. Lift the fire

shield and inspect the burners. Tighten as required.

RECEIVING INSPECTION AND INITIALSTART UP PROCEDURES

“Quality, Value and Service Since 1919”

SECTION 250EFFECTIVE

DECEMBER 2002

ACEWATER

HEATERS ANDBOILERS

ACE BOILER INC.2701 S. HARBOR BLVD. • SANTA ANA, CA 92704PHONE: (714) 437-9050 • FAX: (714) 437-9060

Website: http://www.ajaxboiler.com • Email: info@ajaxboiler.comAce Boiler Inc., formerly Ace Buehler Inc., is a division of Ajax Boiler Inc.

ACE BOILER INC.

E.T.L. Listed

CAUTIONShould over heating occur, or the gas supply fail to shut off,turn off the manual gas valve to the appliance immediately.

A. INSTALLATION(1) THIS SECTION ADDRESSES THE INSTALLATION OF ACE BOILER INC. WATER HEATERS WITHIN MECHANICAL SYSTEMS, AND IS INTENDED

TO PROVIDE SOME EXPLANATION OF NORMAL SYSTEM HOOK-UP AND OPERATION AS WELL AS DESCRIPTIONS OF SOME COMMONLY

ENCOUNTERED SYSTEM PROBLEMS AND SOLUTIONS.(2) Install the heater in accordance with the following instructions. A qualified installation company should always be used.(3) The heater must be installed in accordance with all state and local codes, and all national codes, including, but not limited to:

· ANSI Z21.10.2, GAS WATER HEATERS· ANSI Z223.1, NATIONAL FUEL GAS CODE· ANSI / NFPA 70, NATIONAL ELECTRIC CODE.

(4) Install per heater-tank diagram located on page 4.(5) Connect the piping to draw cool water from the lower portion of the tank through the circulating pump to the bottom inlet heater connection. If a flow switch

is used it should be connected near the pump outlet.(6) Connect the hot water return line from the heater to the tank as shown in the hook-up diagram.(7) Connect the cold water inlet supply directly into the tank as shown in the hook-up diagram. Do not use a check valve on the cold water inlet line. If a

check valve is installed in the cold inlet line then a properly sized expansion tank should be added to the system to prevent the relief valve from popping.(8) The hot water outlet line should be connected at the highest part of the tank to avoid air entrapment, which can cause rapid corrosion at the top of the tank.(9) Install a thermometer, a drain valve, and a relief valve (anode if required) on the tank as shown in the hook-up diagram.

(10) Page 4 illustrates a normal installation for a single heater with a storage tank. Cold water is supplied to the storage tank while systemhot water is drawn from the top of the storage tank. Water is supplied to the water heater by a circulating pump which is normally wiredto operate on a continuous basis. Return Water temperature must be above 140 degrees F to avoid condensation damage.

Note: Page 4 depicts piping schematics for multiple heater installations with vertical and horizontal storage tanks.

B. IDENTIFICATION(1) Your Ace Water Heater carries two identification plates. The coil plate, which carries the ASME Code Stamping and Registration Number (when applica-

ble) is attached to the coil just inside the upper manifold assembly. The boiler nameplate lists information concerning the input and output of the unit, elec-trical and gas ratings, working pressure and clearance to adjacent construction figures. In addition the model and serial numbers are on the plate. You willneed these to order replacement parts from the manufacturing representative in your area or from the factory.

(2) The information on the National Board plate is the same as on the name plate with the exception of the National Board registration number, which isrequired in most states for installation of the unit.

Do not remove either of these plates from the unit for any reason.

C. LOCATION(1) Set the heater on a non-combustible floor. If the floor is combustible, a special "Combustible Floor Base" (CFB) must be used. Locate the heater so that leakage from tank or

connections will be directed to a floor drain and will not damage adjacent area or lower level floors.(2) The minimum clearance between a heater and a storage tank is 6". For multiple heater installations a minimum of 6" clearance between heaters shall be

maintained. For alcove installation, the minimum clearance to combustible construction is 24" to side and rear walls and 36" from the top of the heater tothe ceiling. The front of the alcove shall remain open. Local and state codes may require greater clearances.

(3) Allow sufficient space in front of heater for cleaning and removal of burners, replacement of the draft hood and controls, and the adjustment of all parts requiring such attention.Keep the area around the heaters free from combustibles and flammable liquids.

(4) Minimum ventilation and combustible air openings to the room in which the heater is located must be provided in accordance with NATIONAL FUEL GAS CODEANSI Z21.13.

D. COMBUSTION AND VENTILATION AIR

CAUTIONThe lack of adequate combustion air is the single biggest

problem encountered with gas fired water heaters.

(1) Ace recommends that two permanent openings to outside air be provided, one 6" from the floor and the other 6" from the ceiling. The combined area ofthe two openings should not be less than 200 sq. in. for the first 100,00 BTUH heater input, and 100 sq. in. for each additional 100,000 BTUH heater input.

(2) All additional gas fired equipment should be considered when calculating the necessary air supply.(3) The openings should have permanent, non-adjustable louvers properly designed so that they provide a baffling effect under wind conditions. Wood louvers may be consid-

ered to have 20-25% free area, and metal louvers may be considered to have 60-75% free area.(4) It is important to locate the heaters so that they are not adversely affected by wind, draft or freezing conditions that may exist in the room.(5) Air may be supplied by the use of ducting, fans, etc. It is extremely important, however, that any system be designed and installed by a qualified profes-

sional in such a manner that no positive or negative air pressure exists in the room in which the heaters are installed. Such a problem will result in improp-er combustion and sooting problems.

(6) Required draft at the outlet stack must be within the range of -.02 to -.04 inches water column.

E. ELECTRICAL CONNECTIONS(1) A junction box is provided on the heater jacket for the electrical service connection.(2) For multiple heater installations, each heater is to be wired in parallel with all the other heaters so that each heater will operate independently.(3) The circulating pump (and the return pump if used) should be wired in parallel with the heater(s) to run continuously.(4) The heater(s) when installed, must be electrically grounded in accordance with state and local codes and in accordance with the NATIONAL ELECTRICAL

CODE ANSI / NFPA 70-1984.(5) If any of the original wiring as supplied with the heater/boiler is replaced, it must be replaced with 18" AWG TFF wire or its equivalent.

INSTRUCTIONSFor Ace Gas Fired Copper Fin Volume Water Heaters

SECTION 250CONTINUED

SECTION 250CONTINUEDF. RELIEF VALVES

(1) The storage tank should be protected with a pressure (or combination temperature and pressure) relief valve set so as not to exceed the maximum tank operating pressure. The relief valve should be located within 6" of the top of the tank. Refer to local codes for the type of relief valve required.

(2) Each heater should be protected with its own pressure relief valve. The relief valve should be rated for the BTU/hr or LBS/hr of heater output.(3) The pressure relief valves and pressure relief elements of combination valves, when supplied, shall comply with applicable performance provisions of the

American National Standard for Relief Valves and Automatic Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22-1979.(4) Manually operate relief valves at least once a year.(5) If the temperature and pressure relief valve(s) on the appliance(s) discharge periodically, a problem exists and service to the water system is required. Periodic

discharge may be due to thermal expansion in a closed water system.

CAUTION!!!To prevent scalding and/or personal injury, pipe outlet of relief valve(s)

to a floor drain with NO intervening valves or restrictions.

G. AIR ELIMINATION(A) All of the air must be removed from the water piping in the system before the system will function properly. Therefore, all high points in the system must be

vented or purged. Relief valves may be used to purge air when they are at the high point.(B) If a water heater is installed in a closed water system, contact the water heater supplier or local plumbing inspector on methods to allow proper system expan-

sion. A weeping pressure or temperature relief valve may be due to thermal expansion (i.e. expansion tanks) in a closed water system. Do not plug the tem-perature and pressure relief valve.

H. VENTING SYSTEM (FLUE GASES)(1) Vents for the heater(s) may be run individually or manifolded. Two or more heaters may be vented through a common vent connector or manifold. The common vent

connector or manifold shall be located at the highest level consistent with available head room or clearance to combustible material, and shall be sized in accordance withapproved engineering methods. The area of the common vent connector or manifold shall not be less than the combined area of the individual draft hood outlets or theindividual vent connectors.

See the NATIONAL FUEL GAS CODE ANSI Z21.13-1984 Section 1.5 "Venting of Appliances" for more detailed information.

(2) Only locally approved code type venting should be installed.(3) The draft hood furnished with each heater/boiler must be installed as shown on the hook-up diagram.(4) The sheet metal collar included with the heater musted be installed between the heater & the draft hood.

I. GAS CONNECTION(1) The gas line should be a separate line running directly from the gas meter to the heater, unless the existing gas line is of ample capacity. Verify the capacity of

the existing gas piping if it is to be used.(2) Install a union at the connection to the heater manifold.(3) Refer to the rating plate on the shell of the heater for proper gas manifold pressure. The manifold pressure is measured downstream of the gas pressure regu-

lator. Do not exceed the maximum gas pressure specified on the rating plate.(4) A trap (drip leg) must be installed upstream of the gas pressure regulator.(5) The heater must be disconnected from the gas supply piping system during any pressure testing of the gas supply piping.(6) Gas connections and heater should be properly tested for leaks before being put into operation.(7) Gas supply lines should be purged of air at the heater before startup.(8) The flow rate is determined by controls preset at the factory. There is no field adjustment for the minimum input rate.

J. TESTING(1) Your heater has been pressure tested in accordance with ASME CODE SECTION IV and fire tested in accordance with U.L. 795.(2) It is recommended that the heater and the system into which it is installed be tested before operating the system. The exact nature of the test(s) are deter-

mined by the system's component(s), but will generally consist of a water pressure test and a gas leak test. This testing should be completed as part of thenormal installation procedure by the installing company.

(3) Once the entire installation is complete, the unit should have an operation test to insure that the ignition system safety shut of device works properly.Instructions in the manufacturer's literature shall be followed in conducting this test.

K. MAINTENANCE

CAUTIONThe following inspections and tests should be performedat regular intervals at least every three to six months.

Failure to do so may void your warranty.

(1) Turn the Operating Thermostat and High Limit Aquastat down, then up until heater turns off and on to verify that the controls are operating satisfactorily.(2) Check the High Limit Aquastat Well for lime. If 1/16" lime is deposited on the outside of the well, the coil needs to be delimed.(3) Inspect the coil and burner assembly to make sure that they are free from dust, lint, dirt, etc. If they are dirty, remove all foreign material by washing, flushing,

or air cleaning, etc.(4) Inspect venting system to make sure that it is free of dirt and corrosion.(5) Make periodic visual checks of burners and pilot flames.(6) Check combustion air inlets in the room to see that they are clear of obstructions.

L. AQUASTAT INFORMATION(1) The Heater is equipped with two aquastats - a high limit safety aquastat in the upper (hot out) manifold and an operating aquastat (Thermostat ) in the lower

(tank water in) manifold. The operating aquastat “Thermostat” should be set approximately 10°F lower than the desired tank tamperature setting. The HI limitaquastat should be set at least 60°F higher than the thermostat setting. For example: if desired water temperature in tank is 140°F set the thermostat at130° F and Hi limit at 200°F; for 150°F tank water temperature set the thermostat at 140°F and the Hi limit at 210°F. etc. When 2 or more heaters are operatedtogether, set the 2nd heater thermostat 3° to 5° lower than the first heater thermostat and the third heater thermostat 3° to 5° lower than the 2nd heater thermo-stat, etc. Check the tank thermometer and correct thermostat so that the heater shuts off at desired tank water temperature. Note: tank aquastat may be used interchangeably with the heater operating aquastat.

(2) Water entering heater below 140 °F will cause the heater to condense, limiting its service life.

6666

DraftHood DraftHood DraftHood

AA1

A2

c

R

GT

PRV P&T

OP

OP

P&T

PRV

CP

Cold In

HotOut

GT

PRV P&T

OP c

R

PRV

Cold In

HotOut

CP

P&T

Hook-Up with Hor izontal TankHook-Up with Ver t ical Tank

Circu la t ion F lowfrom Ace Sect ion 235

c

GT

R

CP

PRV

P&T

OP

OP

Check Valve

Pressure Relief Valve

Pressure &Temp. Gauge

Primary OperationalAquastat

Unit CirculationPump

SystemRecirculationPump

Check Valve

Pilot SafetyRelay

Ground

Hi LimitAquastat

Control Panel

Gas Train

Optional TankAquastatThese are factory recommended hook-ups. They have been

tested and proved over the years and should be followed exactlyEVEN THOUGH YOU ARE USED TO DOING

THINGS DIFFERENTLY.

side viewfront view

SECTION 250CONTINUED

SCALE:

DATE:

DRAWN BY

REVISED

REV.

SIZE

CONTROL NUMBER

DRAWING NUMBER

APPROVED BY:

A

PB

2/01/00

ACE HEATER GAS TRAIN STANDARD FOR CSD-1

G-22225

N/A

HEADER

COMB.

GAS

VALVE

SHUT-OFF

VALVE

PILOT

LINE

PILOT

LINE

TYP

COMB.

GAS

VALVE

TYP

HEADER

SHUT-OFF

VALVE

B2 THRU B8 INDOOR/OUTDOOR

CSD-1 GAS TRAIN FOR MODELS

B11 THRU B15

CSD-1 GAS TRAIN FOR MODELS

SHUT-OFF

VALVE

TEST

COCK

COCK

TEST

SHUT-OFF

VALVE

NOTE: FOR PROPANE USE BLUE SPRING

A.S.M.E.

U.L. Listed

1 DRAFT HOOD - NOT SHOWN2 OUTER LID3 INNER LID4 COIL-FINNED COPPER - INCLUDES PARTS NO. 5, 6, 7, 85 MANIFOLD PIPE CONNECTION (2 REQ’D.)6 INNER JACKET - COIL SUPPORT & ENCLOSURE7 STAINLESS STEEL BAFFLE FOR COIL8 HOLD DOWN BRACKET - (COIL & BAFFLE) WITH J BOLT9 STAINLESS STEEL LOWER INNER JACKET

9A FIRE JACKET ASSEMBLY - PARTS 9, 9B, 129B INSULATION HIGH TEMPERATURE10 OUTER JACKET - MAIN BODY PORTION11 FRONT PANEL - OUTER JACKET12 OUTER FIRE JACKET WRAPPER & COIL JACKET SUPPORT13 FIRESHIELD - S.S.14 BASE RING WITH LEGS & REAR SKIRT15 BURNER TUBES (NUMBER VARIES)16 BURNER GAS RING & FLOOR SHIELD17 GAS PIPING SUPPORT BRACKET WITH U BOLT18 GAS JETS (ORIFICES) MAIN BURNER19 RADIATION SHIELD - BASE20 AQUASTAT WELL21 DRAIN COCK - 3/4"22 INSULATION HIGH TEMP. BLANKET - 2" (MINIBOND)23 INSULATION - FIBERGLASS - UPPER BLANKET

APPLICABLE FOR “D”, “E” OR “G” SERIES

BOTH MODEL AND SERIAL NUMBERS MUST BE FURNISHED TO OBTAIN CORRECT PARTS

PART NO. PART NAME

7

12

9B

9A

13

8 5 2

3

6

4

9

10

11

17

22

15

19

1618

21

23

4

14

20

5

20

“D”, “E” OR “G” SERIES ASSEMBLY

! THIS LIST COVERS PARTS EXCEPT THOSE IN GAS TRAIN OR IN CONTROL ASSEMBLY.CONSULT APPROPRIATE LIST FOR THESE ITEMS

! ALL REPAIR WORK SHOULD BE PERFORMED BY A QUALIFIED SERVICE ORGANIZATION.

NOT INCLUDING CONTROLS AND GAS TRAIN

GAS FIRED COPPER FIN CONE COIL WATER HEATERS • HEAVY DUTY INDUSTRIAL WATER HEATERS • “MINI-PACK” SEMI-INSTANTANEOUS WATER HEATERS • PACKAGED STORAGE WATER HEATERS • CLEAN STEAM BOILERS • ASME HOT WATER STORAGE TANKS

“Quality, Value and Service Since 1919”

ACE BOILER INC.

ACE BOILER INC. maintains a policy of continuous improvements and therefore reserves the right to change specifications without notice.

SECTION 275EFFECTIVE

DECEMBER 2002

SECTION 250CONTINUED

AJAX BOILER INC. - ACE BOILER INC.

FACTORY LIMITED WARRANTY POLICYThe Ajax Boiler Factory limited warranty provides assurance that all products are free from manufacuteres defects at the time of shipment and meet specifi cations and performance described in the product literature.

It is important to understand the difference between a factory warranty and an installed warranty. There are many factors that can occur to the products after they are shipped that the company has no control over and can not fully verify. These includes:

1. Hidden damage during the shipping. 2. Handling damage. 3. Damage during storage. 4. Installation conditions. 5. Other unknown variables in the system design: maintenance, pulsation and vibrations.

The installed warranty is the responsibility of the architech, specifying engineer, contractor and/or owner who jointly have control over the application, installation, location, operating and maintenance conditions.

The Ajax Boiler Inc. warranty excludes extended liabilities. Extended liability typically occurs when products are installed without proper drainage, fl ooding containment or when safety devices are not tested and repaired or replaced when needed.

Product problems are often caused by the condition of the water, the lack of water treatment and/or the improper treatment of the water, insuffi cient combustion air, improper draft conditions, bolts not re-tightened, pipes not fl ushed and cleaned of oil, metal chips, rags, vibration and pulsation etc. These are installation, operating and/or maintenance conditions that are beyond the seller’s responsibility and are not covered by the factory warranty, but may be covered by the installer’s warranty.

The factory warranty covering company products is based upon extensive product development and testing. Combustion products under go certifi cation testing and approvals to Underwriters Laboratory (UL) standards. Auditing of the production of combustion products is conducted by a nationally recognized testing laboratory.

Pressure vessel products are designed and manufactured to American Society of Mechanical Engineering (ASME) and National Board (NB) Design standards. Design reviews, factory product manufacturing quality inspections and testing are carried out by a third party National Board authorized inspection agency.

Ajax Boiler Inc. products have proven themselves in service for over 85 years which indicates that the company products perform exceedingly well when normal installation, operating and maintenance conditions exist.

The following is a review from the terms and conditions of sale. Also included in paragraph two, below, is the Ajax Boiler Inc. non-conformance policy.

1. Ajax Boiler Inc. warrants its products against defective material and/or workmanship only. The warranty does not apply to operational failures, electrical failures, gasket leaks, and/or other malfunctions caused by improper application, installation and/or maintenance.

2. It is the buyer’s responsibility to inspect and accept the product, when received, as conforming to their purchase order, specifi cations and approved drawings. All claims for non-conformance, errors, shortages, etc. must be made within 10 days after receipt of the shipment. 3. Ajax Boiler Inc. do not provide a warranty or guarantee, express or implied, in any manner, form, usage of trade, merchant -ability or fi tness which extend beyond the product description and quotation. 4. Ajax Boiler Inc. liability is limited to the factory repair or replacement of warranty failures, or non-conformance, upon the return of the product to the factory.

5. Ajax Boiler Inc. is not liable for any direct or consequential damages.

6. The Ajax Boiler Inc. warranty is based upon section 23161(2) of the uniform commercial code and is printed in the terms and conditions of sale which is referenced in every quotation, on the back of sales order acknowledgements and invoices. It is legally correct and is an industry standard policy.

February-2007

AJAX BOILER INC. - ACE BOILER INC.

WARRANTYLIMITED

THERMAL SHOCK In addition to our standard one (1) year warranty against defective parts and workmanship, Ajax Boiler Inc. provides the following guarantee with all commercial hot water, forced circulation, space heating boilers:

Ajax Boiler Inc. guarantees this new boiler pressure vessel for twenty (20) years after date of installation from damage due tothermal shock. Thermal shock occurs when cold makeup water, up to 150ºF less than the boiler water outlet temperature, is added directly into the boiler while the boiler is operating within the normal temperature range from 140ºF to 250ºF with a temperature rise from 20ºF to 40ºF. This guarantee shall cover damage to the boiler tubes, tube headers, and tube sheets when such damage is attributed to unequal expansion, poor circulation and/or other causes quite often described as “thermal shock”. This guarantee does not cover damage or failures that can be attributed to corrosion, condensation, scale, boiler treatment chemicals, dirt accumulation, low water conditions, or any other abnormal operating conditions.

The liability of Ajax Boiler Inc. is limited solely to the replacement of the complete pressure vessel, with tubes, if found by our inspection to be damaged by thermal shock. In no event shall Ajax Boiler Inc. be held liable for replacement labor charges or for freight or handling charges.

2701 South Harbor Blvd.Santa Ana, California 92704United StatesTel. (714) 437-9050Fax (714) 437-9060http://www.ajaxboiler.commail@ajaxboiler.com

June-2010

AJAX BOILER INC. - ACE BOILER INC.

LIMITED

WARRANTYAjax Boiler Inc. provides a limited warranty on its products against defective material and/or workmanship only. This limited warranty is not applicable to operational failures, electrical failures, gasket leaks, wear or malfunctions caused by improper application, installation, and/or maintenance.

Product Period - The following Limited Warranty period are from date of shipment: Boiler Pressure Vessels: One year. Carbon Steel Tank and Heat Exchanger Pressure Vessels: One year. Stainless Steel Tanks: Three years. Boiler Copper Fin Coils: Three years. Single-wall or Double-wall Tank/Exchanger Coils: One year. Single-wall or Double-wall Mini-Packs™: One year. Atlas Series Condensing Boiler: One year. Linings: (Pro-rated Warranty) In Section VIII Tanks: Glass 30" dia. and above (Five years). Glass 24" dia. and under (One year). Cement (Five years). Pre-Krete (Ten years). In Section IV Tanks: Glass (One year). Controls: Components manufactured by other than Ajax Boiler Inc. such as controls, instruments, forced draft burner, etc., provided with the boilers and packaged products are not covered by the Ajax Boiler Inc. Warranty. However, Ajax Boiler Inc. extends to the customer the same warranty provided by the manufacturer to Ajax Boiler Inc. The customer shall receive the full benefi ts of adjustments made to Ajax Boiler Inc. by the manufacturer.

Any claim for adjustment under this limited warranty must be made within the warranty period. Ajax Boiler Inc.’s liability shall be limited to factory repair or, at Ajax Boiler Inc.’s option, replacement of all parts which, upon test and examination by Ajax Boiler Inc., prove to be defective material and/or workmanship and within the above limited warranty. If required by Ajax Boiler Inc., parts which are claimed to be defective must be promptly delivered to the Ajax Boiler Inc. facility, transportation charges prepaid. This warranty does not cover the cost of labor, removal, or installation of the warranted item during the limited period.

This warranty is limited to the above and applies only for the period set forth. Ajax Boiler Inc. will not be liable for any loss damage, direct, incidental or consequential damages of any kind, whether based upon warranty, contract, negligence or strict liability and arising in connection with the sale, use or repair of the products. Ajax Boiler Inc.’s maximum liability shall exceed the contract price for the product’s merchantability or fitness for any particular purpose and in no event shall be held responsible for any consequential damages.

For complete Limited Warranty conditions see Section G and H under terms and condition of sale.

Ajax Boiler Inc., also doing business as Ace Boiler Inc., is referred to herein as Ajax Boiler Inc.

2701 South Harbor Blvd.Santa Ana, California 92704United StatesTel. (714) 437-9050Fax (714) 437-9060http://www.ajaxboiler.commail@ajaxboiler.com

February-2007

AJAX BOILER INC. - ACE BOILER INC.

WARNINGPRODUCT

SAFETY NOTICEAJAX BOILER AND WATER HEATER PRODUCTS OPERATE AT HIGH TEMPERATURE AND PRESSURES

• Before using this product, read and understand instructions. Save these instructions for future use.• Before servicing, to prevent serious burns or injury, the boiler and water heater products must be cooled to less than 80°F (27°C) and the pressure must be 0 psi (0 bar).• Turn off the electrical power before making electrical connections to prevent electrical shock.• These products must be placed in a controlled location where untrained or unqualifi ed personnel cannot access the operating or safety controls, must not be able to come in contact with high temperature or high pressure parts and must not perform maintenance or demolition work. • All work performed must be by qualifi ed properly equipped personnel trained in the proper application, installation, and maintenance or demolition of plumbing, steam, and electrical equipment and/or systems in accordance with all applicable codes and ordinances.• Ajax Boilers and Water Heaters are complete package units with safety and operating controls and are constructed with non ASBESTOS materials. Any replacement gaskets, refractory, insulation, etc used must not contain Asbestos. • No additional insulation is required on the Boilers and Water Heaters. • Additions or replacement of insulation on any connecting pipes or accessories to the Boilers and/or Water Heaters must be of “NON-ASBESTOS” and contain only non-hazardous materials.• Crystalline Silica, a material known to cause cancer, may be encapsulated in some refractory or insulation materials and must be handled only by authorized trained personnel. Crystalline Silica as used is encapsulated and is not harm full in this form. Care must be taken during removal or replacement of refractory or insulation to remove it in bulk form and avoid generation or inhalation of dust. Removal must be properly performed by trained, qualifi ed and equipped personnel. This is also true of Asbestos not contained in Ajax products but may be otherwise contained in replacement materials or parts, in connecting piping or other nearby products. • All safety and operating controls must be set within the specifi ed operating limits and tested periodically to assure proper operation. All limit and operating controls must be installed in series on the boiler.• Connect drain pipes to a safe drain to prevent serious personal injury from relief valve discharge and or from boiler blow down discharge.• After installation, check for proper operation of all limit and operating controls before leaving the site.• Perform scheduled and annual inspections including checking Controls for proper calibration and performance.

Failure to follow these warnings, to allow access by unauthorized persons and the use of non-properly trained and equipped personnel in the operation, service, modifi cation, removal or demolition of these products or replacement of parts with non-authorized factory non-asbestos materials could cause damage, personal injury or death.

2701 South Harbor Blvd.Santa Ana, California 92704United StatesTel. (714) 437-9050Fax (714) 437-9060http://www.ajaxboiler.commail@ajaxboiler.com

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uenc

y m

ust b

e de

term

ined

indi

vidu

ally

for

each

app

licat

ion.

Som

e co

nsid

erat

ions

are

:•

Cyc

ling

freq

uenc

y. A

pplia

nces

that

may

cyc

le m

ore

than

20,

000

times

ann

ually

sho

uld

be c

heck

edm

onth

ly.

•In

term

itten

t use

. App

lianc

es th

at a

re u

sed

seas

onal

lysh

ould

be

chec

ked

befo

re s

hutd

own

and

agai

n be

-fo

re th

e ne

xt u

se.

•C

onse

quen

ce o

f un

expe

cted

shu

tdow

n. W

here

the

cost

of a

n un

expe

cted

shu

tdow

n w

ould

be

high

, the

syst

em s

houl

d be

che

cked

mor

e of

ten.

•D

usty

, w

et,

or c

orro

sive

env

ironm

ent.

Sin

ce t

hese

envi

ronm

ents

can

cau

se t

he c

ontr

ols

to d

eter

iora

tem

ore

rapi

dly,

the

sys

tem

sho

uld

be c

heck

ed m

ore

ofte

n.A

ny c

ontr

ol s

houl

d be

rep

lace

d if

it do

es n

ot p

erfo

rmpr

oper

ly o

n ch

ecko

ut o

r tr

oubl

esho

otin

g. I

n ad

ditio

n, r

e-pl

ace

any

mod

ule

if it

is w

et o

r lo

oks

like

it ha

s ev

er b

een

wet

. Pro

tect

ive

encl

osur

es a

s ou

tline

d un

der “

Pla

nnin

g th

eIn

stal

latio

n” a

re re

com

men

ded

rega

rdle

ss o

f che

ckou

t fre

-qu

ency

.

MO

UN

T IG

NIT

ION

MO

DU

LE

Sel

ect a

loca

tion

clos

e en

ough

to th

e bu

rner

to a

llow

ash

ort

(3 f

t. [0

.9 m

] m

ax.)

, di

rect

cab

le r

oute

to

the

igni

ter.

Am

bien

t te

mpe

ratu

re a

t th

e m

odul

e m

ust

be w

ithin

the

rang

e lis

ted

unde

r A

PP

LIC

AT

ION

, pa

ge 1

. T

he m

odul

em

ust b

e pr

otec

ted

from

wat

er, m

oist

ure,

cor

rosi

ve c

hem

i-ca

ls, a

nd e

xces

sive

dus

t and

gre

ase.

We

reco

mm

end

mou

ntin

g th

e m

odul

e w

ith th

e te

rmin

als

dow

n to

pro

tect

them

from

drip

ping

wat

er a

nd d

ust.

It ca

nal

so b

e m

ount

ed w

ith th

e te

rmin

als

on e

ither

sid

e. D

O N

OT

MO

UN

T w

ith t

erm

inal

s po

intin

g up

. R

efer

to

Fig

. 1

for

mou

ntin

g re

com

men

datio

ns. F

aste

n se

cure

ly w

ith fo

ur N

o.6-

32 m

achi

ne o

r N

o. 8

she

etm

etal

scr

ews

(S86

10 a

ndS

8670

mou

ntin

g ho

le p

atte

rn is

the

sam

e as

the

S86

and

S89

mou

ntin

g ho

le p

atte

rn).

INS

TA

LL

AT

ION

WH

EN

INS

TA

LL

ING

TH

IS IG

NIT

ION

SY

ST

EM

…1.

Rea

d th

ese

inst

ruct

ions

car

eful

ly.

Fai

lure

to

follo

wth

em c

ould

dam

age

the

com

pone

nts

or c

ause

a h

azar

dous

cond

ition

.2.

Che

ck th

e ra

tings

giv

en in

the

inst

ruct

ions

and

on

the

com

pone

nts

to m

ake

sure

they

are

sui

tabl

e fo

r yo

ur a

ppli-

catio

n.3.

Inst

alle

r mus

t be

a tr

aine

d, e

xper

ienc

ed s

ervi

ce te

ch-

nici

an.

4.A

fter

inst

alla

tion

is c

ompl

ete,

che

ck o

ut c

ompo

nent

oper

atio

n as

pro

vide

d in

thes

e in

stru

ctio

ns.

WAR

NING

FIR

E O

R E

XP

LO

SIO

N H

AZ

AR

DM

AY

CA

US

E P

RO

PE

RT

Y D

AM

AG

E, S

EV

ER

EIN

JUR

Y, O

R D

EA

TH

1.T

he

ign

itio

n m

od

ule

can

mal

fun

ctio

n if

it g

ets

wet

, lea

din

g to

acc

um

ula

tio

n o

f exp

losi

ve g

as.

•N

ever

inst

all w

her

e w

ater

can

flo

od

, dri

p, o

rco

nd

ense

on

mo

du

le.

•N

ever

try

to

use

a m

od

ule

th

at h

as b

een

wet

—re

pla

ce it

.2.

Liq

uef

ied

pet

role

um

(L

P)

gas

is

hea

vier

th

anai

r an

d w

ill n

ot

ven

t u

pw

ard

nat

ura

lly.

•D

o n

ot

lig

ht

pil

ot

or

op

erat

e el

ectr

icsw

itch

es, l

igh

ts, o

r ap

plia

nce

s u

nti

l yo

u a

resu

re t

he

app

lian

ce a

rea

is f

ree

of

gas

.

CA

UT

ION

1.D

isco

nnec

t pow

er s

uppl

y be

fore

beg

inni

ng w

iring

to p

reve

nt e

lect

rical

sho

ck o

r equ

ipm

ent d

amag

e.2.

If a

new

gas

con

trol

is to

be

inst

alle

d, tu

rn o

ff ga

ssu

pply

bef

ore

star

ting

inst

alla

tion.

Con

duct

Gas

Leak

Tes

t ac

cord

ing

to g

as c

ontr

ol m

anuf

ac-

ture

r’s i

nstr

uctio

ns a

fter

the

gas

cont

rol

is i

n-st

alle

d.3.

If m

odul

e m

ust

be m

ount

ed n

ear

moi

stur

e or

wat

er, p

rovi

de s

uita

ble

wat

erpr

oof e

nclo

sure

.

PE

RF

OR

M P

RE

INS

TA

LL

AT

ION

SA

FE

TY

INS

PE

CT

ION

The

pre

inst

alla

tion

chec

ks d

escr

ibed

in A

NS

I Sta

ndar

dZ

21.7

1 on

pag

e 21

mus

t be

done

bef

ore

the

repl

acem

ent

mod

ule

is i

nsta

lled.

If

a co

nditi

on w

hich

cou

ld r

esul

t in

unsa

fe o

pera

tion

is d

etec

ted,

the

appl

ianc

e sh

ould

be

shut

off

and

the

owne

r ad

vise

d of

the

uns

afe

cond

ition

. A

nypo

tent

ially

uns

afe

cond

ition

mus

t be

corr

ecte

d be

fore

pro

-ce

edin

g w

ith th

e in

stal

latio

n.

Mai

nte

nan

ce R

equ

irem

ents

in S

ever

e E

nvi

ron

men

tsR

egul

ar p

reve

ntiv

e m

aint

enan

ce i

s im

port

ant

in a

nyap

plic

atio

n, b

ut e

spec

ially

so

in c

omm

erci

al c

ooki

ng,

agric

ultu

ral,

and

indu

stria

l app

licat

ions

bec

ause

:•

In m

any

such

app

licat

ions

, pa

rtic

ular

ly c

omm

erci

alco

okin

g, t

he e

quip

men

t op

erat

es 1

00,0

00-2

00,0

00cy

cles

per

yea

r. S

uch

heav

y cy

clin

g ca

n w

ear o

ut th

ega

s co

ntro

l in

one

to tw

o ye

ars.

A n

orm

al fo

rced

air

HE

AT

The

con

trol

s ca

n be

dam

aged

by

exce

ssiv

ely

high

tem

pera

ture

s. M

ake

sure

the

max

imum

am

bien

t tem

pera

-tu

re a

t the

con

trol

loca

tions

will

not

exc

eed

the

ratin

g of

the

cont

rol.

If th

e ap

plia

nce

norm

ally

ope

rate

s at

ver

y hi

ghte

mpe

ratu

res,

insu

latio

n, s

hiel

ding

, and

air

circ

ulat

ion

may

be n

eces

sary

to

prot

ect

the

cont

rols

. P

rope

r in

sula

tion

orsh

ield

ing

shou

ld b

e pr

ovid

ed b

y th

e ap

plia

nce

man

ufac

-tu

rer;

mak

e su

re a

dequ

ate

air

circ

ulat

ion

is m

aint

aine

dw

hen

the

appl

ianc

e is

inst

alle

d.

2

TA

BLE

1—

INT

ER

MIT

TE

NT

PIL

OT

IGN

ITIO

N M

OD

ULE

S.

IGN

ITE

R-

100

SE

NS

OR

TY

PE

PR

EP

UR

GE

PE

RC

EN

TLO

CK

OU

TIG

NIT

ION

MO

DE

LT

YP

EO

F G

AS

TIM

ING

SH

UT

OF

FT

IMIN

GS

EQ

UE

NC

Ea

S86

10A

Sep

arat

eN

atur

alN

one

No

No

Spa

rk o

n un

til p

ilot

light

off o

r m

anua

lS

8610

FC

ombi

natio

nsh

utof

f; pi

lot v

alve

open

unt

il m

anua

lsh

utdo

wn.

S86

10B

Sep

arat

eN

atur

alN

one

Yes

, at

15 o

r 90

Spa

rk o

n un

til p

ilot

or L

Plo

ckou

tse

c. m

ax.,

light

off o

r lo

ckou

t;S

8610

HC

ombi

natio

nas

ord

ered

pilo

t val

ve c

lose

son

lock

out.

S86

70D

Com

bina

tion

Nat

ural

45 s

ec.

Yes

, at

15 o

r 90

Igni

tion

tria

l fol

low

sor

LP

lock

out

sec.

max

.,pr

epur

ge; s

park

on

as o

rder

edun

til p

ilot l

ight

off o

rlo

ckou

t; pi

lot v

alve

clos

es o

n lo

ckou

t.a If

esta

blis

hed

flam

e is

lost

, all

mod

els

rest

art i

gniti

on tr

ial.

AP

PL

ICA

TIO

NT

hese

igni

tion

mod

ules

pro

vide

igni

tion

sequ

ence

, fla

me

mon

itorin

g, a

nd s

afet

y sh

utof

f for

inte

rmitt

ent p

ilot c

entr

alfu

rnac

es a

nd h

eatin

g ap

plia

nces

. S86

10 a

nd S

8670

mod

-el

s in

clud

e a

conn

ecto

r th

at c

onve

rts

the

exis

ting

igni

tion

cabl

e fr

om a

stu

d te

rmin

al r

ecep

tacl

e to

a 1

/4 in

ch fe

mal

equ

ick-

conn

ect.

S86

10 a

nd S

8670

pro

vide

up

to 1

.0 A

pilo

t

and

2.0

A m

ain

valv

e cu

rren

t ra

ting.

M

inim

um a

mbi

ent

tem

pera

ture

rat

ing

is -

40°

F [

-40°

C].

Max

imum

am

bien

tra

ting

is +

175°

F [+

79°

C] f

or S

8610

, S86

70 u

sed

with

1.0

A o

r le

ss m

ain

valv

e. M

axim

um a

mbi

ent r

atin

g fo

r S

8610

,S

8670

use

d w

ith 1

.0 to

2.0

A m

ain

valv

e is

+16

5° F

[+74

° C].

See

Tab

le 1

for

a s

umm

ary

of o

ther

diff

eren

ces

betw

een

mod

els.

S86

10A

,B,F

,H A

ND

S86

70D

INT

ER

MIT

TE

NT

PIL

OT

MO

DU

LE

PL

AN

NIN

G T

HE

INS

TA

LL

AT

ION

Inte

rmitt

ent p

ilot s

yste

ms

are

used

on

a w

ide

varie

ty o

fce

ntra

l hea

ting

equi

pmen

t and

on

heat

ing

appl

ianc

es s

uch

as c

omm

erci

al c

ooke

rs,

agric

ultu

ral e

quip

men

t, in

dust

rial

heat

ing

equi

pmen

t, an

d po

ol h

eate

rs. S

ome

of th

ese

appl

i-ca

tions

may

mak

e he

avy

dem

ands

on

the

cont

rols

, eith

erbe

caus

e of

freq

uent

cyc

ling

or b

ecau

se o

f moi

stur

e, c

orro

-si

ve c

hem

ical

s, d

ust,

or e

xces

sive

hea

t in

the

envi

ronm

ent.

In t

hese

situ

atio

ns,

spec

ial s

teps

may

be

requ

ired

to p

re-

vent

nui

sanc

e sh

utdo

wns

and

pre

mat

ure

cont

rol

failu

re.

The

se a

pplic

atio

ns re

quire

Hon

eyw

ell R

esid

entia

l and

Bui

ld-

ing

Con

trol

s E

ngin

eerin

g re

view

; co

ntac

t yo

ur H

oney

wel

lS

ales

Rep

rese

ntat

ive

for

assi

stan

ce.

FR

EQ

UE

NT

CY

CL

ING

The

se c

ontr

ols

are

desi

gned

for

use

on s

pace

hea

ting

appl

ianc

es th

at ty

pica

lly c

ycle

3 to

4 ti

mes

an

hour

dur

ing

the

heat

ing

seas

on a

nd n

ot a

t all

durin

g th

e co

olin

g se

ason

.In

an

appl

icat

ion

with

sig

nific

antly

gre

ater

cyc

ling

rate

s an

dcl

oser

to y

ear-

roun

d us

e, w

e re

com

men

d m

onth

ly c

heck

out

beca

use

the

cont

rols

may

wea

r ou

t mor

e qu

ickl

y.

WA

TE

R O

R S

TE

AM

CL

EA

NIN

GO

nce

a m

odul

e or

gas

con

trol

has

bee

n w

et,

it m

ayop

erat

e un

relia

bly

and

mus

t be

repl

aced

. If t

he a

pplia

nce

islik

ely

to b

e cl

eane

d w

ith w

ater

or

stea

m, t

he c

ontr

ols

and

asso

ciat

ed w

iring

sho

uld

be c

over

ed s

o w

ater

or s

team

flow

cann

ot r

each

the

m.

The

con

trol

s sh

ould

be

high

eno

ugh

abov

e th

e bo

ttom

of t

he c

abin

et s

o th

ey w

ill n

ot b

e su

bjec

tto

floo

ding

or s

plas

hing

dur

ing

norm

al c

lean

ing

proc

edur

es.

If ne

cess

ary,

shi

eld

the

cont

rols

to

prot

ect

them

fro

msp

lash

ing

wat

er. A

NE

MA

4 e

nclo

sure

is re

com

men

ded

for

the

igni

tion

mod

ule;

see

the

Ele

ctro

nic

Igni

tion

Ser

vice

Man

ual,

form

70-

6604

.

HIG

H H

UM

IDIT

Y O

R D

RIP

PIN

G W

AT

ER

Ove

r tim

e, d

rippi

ng w

ater

or

high

am

bien

t hum

idity

can

crea

te u

nwan

ted

elec

tric

al p

aths

on

the

mod

ule

circ

uit

boar

d, c

ausi

ng t

he m

odul

e to

fai

l. N

ever

in

stal

l an

appl

i-an

ce w

here

wat

er c

an d

rip o

n th

e co

ntro

ls.

In a

dditi

on,

high

am

bien

t hu

mid

ity c

an c

ause

the

gas

cont

rol t

o co

rrod

e, a

nd fi

nally

to fa

il.W

here

the

appl

ianc

e m

ay b

e in

stal

led

in a

hum

id a

tmos

-ph

ere,

mak

e su

re a

ir ci

rcul

atio

n ar

ound

the

mod

ule

and

gas

cont

rol i

s ad

equa

te t

o pr

even

t co

nden

satio

n. I

t’s a

lso

im-

port

ant

to r

egul

arly

che

ck o

ut t

he s

yste

m.

A N

EM

A 4

encl

osur

e m

ay b

e ne

eded

; se

e th

e E

lect

roni

c Ig

nitio

nS

ervi

ce M

anua

l, fo

rm 7

0-66

04.

CO

RR

OS

IVE

CH

EM

ICA

LS

Cor

rosi

ve c

hem

ical

s ca

n al

so a

ttack

the

mod

ule

and

gas

cont

rol

and

even

tual

ly c

ause

a f

ailu

re.

Whe

re c

hem

ical

sm

ay b

e us

ed ro

utin

ely

for c

lean

ing,

mak

e su

re th

e cl

eani

ngso

lutio

n ca

nnot

rea

ch t

he c

ontr

ols.

Whe

re c

hem

ical

s ar

elik

ely

to b

e su

spen

ded

in a

ir, a

s in

som

e in

dust

rial

and

agric

ultu

ral a

pplic

atio

ns,

prot

ect

the

igni

tion

mod

ule

from

expo

sure

with

a N

EM

A 4

enc

losu

re;

see

the

Ele

ctro

nic

Igni

tion

Ser

vice

Man

ual,

form

70-

6604

.

DU

ST

OR

GR

EA

SE

AC

CU

MU

LA

TIO

NH

eavy

acc

umul

atio

n of

dus

t or

gre

ase

may

cau

se t

heco

ntro

ls t

o m

alfu

nctio

n. W

here

dus

t or

gre

ase

may

be

apr

oble

m, p

rovi

de c

over

s fo

r the

mod

ule

and

the

gas

cont

rol

that

will

lim

it en

viro

nmen

tal

cont

amin

atio

n. A

NE

MA

4en

clos

ure

is re

com

men

ded

for t

he ig

nitio

n m

odul

e; s

ee th

eE

lect

roni

c Ig

nitio

n S

ervi

ce M

anua

l, fo

rm 7

0-66

04.

D.T

.F

orm

Num

ber

69-0

523

5-90

©H

oney

wel

l Inc

. 199

0

Co

nn

ect

Ign

itio

n C

able

Use

Hon

eyw

ell

igni

tion

cabl

e or

con

stru

ct a

n ig

nitio

nca

ble

that

con

form

s to

sui

tabl

e na

tiona

l sta

ndar

ds s

uch

asU

nder

writ

ers

Labo

rato

ries

Inc.

See

Tab

les

2 an

d 3.

NO

TE

: Whe

n us

ing

an S

8610

or S

8670

to re

plac

e an

S86

,us

e th

e en

clos

ed a

dapt

er t

o co

nver

t th

e S

86 i

gniti

onca

ble

to a

n S

8610

igni

tion

cabl

e. T

hen,

inst

all a

dapt

eran

d ca

ble

to th

e S

8610

igni

tion

mod

ule.

TA

BLE

2—

HO

NE

YW

ELL

PR

EA

SS

EM

BLE

D IG

NIT

ION

CA

BLE

S (

UL

ST

YLE

325

7).

CA

BLE

PA

RT

MO

DU

LE

IG

NIT

ER

NU

MB

ER

L

EN

GT

H E

ND

E

ND

3948

00-3

0 3

0 in

.

1

/4 in

. qui

ck

Raj

ah c

onne

c-co

nnec

t,

to

r re

cept

acle

,in

sula

ted

9

0 de

g. r

ubbe

r

bo

ot39

4801

-30

30

in.

1/4

in. q

uick

R

ajah

con

nec-

conn

ect,

tor

rece

ptac

le,

insu

late

d

str

aigh

t rub

ber

boot

TA

BLE

3—

RE

CO

MM

EN

DE

D IG

NIT

ION

CA

BLE

FO

RF

IELD

AS

SE

MB

LY.

TE

MP

ER

AT

UR

EC

AB

LE

VO

LTA

GE

RA

TIN

GT

YP

ER

AT

ING

(rm

s)

C

F

UL

Sty

le 3

217

10,0

00

150

302

UL

Sty

le 3

257

10,0

00

250

484

Cab

le m

ust b

e no

long

er th

an 3

6 in

. [0.

9 m

]. T

o co

nstr

uct

a ca

ble,

fit

one

end

of ig

nitio

n ca

ble

with

1/4

in.

diam

eter

Raj

ah c

onne

ctor

rec

epta

cle

and

the

othe

r w

ith a

1/4

in.

fem

ale

quic

k-co

nnec

t. P

rote

ct b

oth

ends

with

ins

ulat

edbo

ots.

NO

TE

: The

cab

le m

ust n

ot ru

n in

con

tinuo

us c

onta

ct w

ith a

met

al s

urfa

ce o

r sp

ark

volta

ge w

ill b

e gr

eatly

red

uced

.U

se c

eram

ic o

r pl

astic

sta

ndof

f ins

ulat

ors

as r

equi

red.

To

inst

all:

1.C

onne

ct o

ne e

nd o

f th

e ca

ble

to t

he m

ale

quic

kco

nnec

t SP

AR

K te

rmin

al o

n th

e ig

nitio

n m

odul

e.

2.C

onne

ct t

he o

ther

end

of

the

cabl

e to

the

igni

ter

orig

nite

r-se

nsor

stu

d on

the

pilo

t bur

ner/

igni

ter-

sens

or.

Co

nn

ect

Ven

t D

amp

erT

he D

80B

Ven

t D

ampe

r ca

n be

use

d w

ith a

ll ig

nitio

nm

odul

es, a

lthou

gh th

e M

olex

plu

g pr

ovid

ed o

n so

me

mod

-ul

es s

impl

ifies

wiri

ng c

onne

ctio

ns w

hen

used

with

the

D80

DP

lug-

In V

ent

Dam

per.

Onc

e a

mod

ule

with

ven

t da

mpe

rpl

ug h

as p

ower

ed a

ven

t dam

per c

ircui

t, it

cann

ot b

e us

edin

a g

as s

yste

m w

ithou

t a v

ent d

ampe

r . A

non

-rep

lace

able

fuse

in th

e m

odul

e bl

ows

on in

itial

pow

er-u

p. O

nce

this

fuse

has

blow

n, th

e m

odul

e w

on’t

wor

k un

less

the

vent

dam

per

is c

onne

cted

.

To

conn

ect t

he p

lug-

in m

odel

to D

80D

:

1.R

emov

e th

e pl

ug fr

om th

e te

rmin

al s

trip

on

the

igni

tion

mod

ule

case

and

dis

card

.

2.U

sing

the

wiri

ng h

arne

ss s

uppl

ied,

inse

rt th

e m

atch

ing

pin

plug

int

o re

cept

acle

on

case

and

oth

er e

nd t

o ve

ntda

mpe

r.

4

Gro

un

d C

on

tro

l Sys

tem

The

ign

iter,

fla

me

sens

or,

and

igni

tion

mod

ule

mus

tsh

are

a co

mm

on g

roun

d w

ith th

e m

ain

burn

er. U

se th

erm

o-pl

astic

ins

ulat

ed w

ire w

ith a

min

imum

rat

ing

of 1

05°

C[2

21°

F]

for

the

grou

nd w

ire;

asbe

stos

ins

ulat

ion

is n

otac

cept

able

. If

nece

ssar

y, u

se a

shi

eld

to p

rote

ct t

he w

irefr

om r

adia

nt h

eat

gene

rate

d by

the

bur

ner.

Con

nect

the

grou

nd w

ire a

s fo

llow

s:

1.F

it on

e en

d of

the

gro

und

wire

with

a f

emal

e 1/

4 in

.qu

ick-

conn

ect

term

inal

and

con

nect

it

to t

he m

ale

quic

k-co

nnec

t GN

D(B

UR

NE

R)

term

inal

on

the

igni

tion

mod

ule.

2.S

trip

the

othe

r en

d of

the

wire

and

fast

en it

und

er th

eig

nite

r br

acke

t mou

ntin

g sc

rew

. If n

eces

sary

, use

a s

hiel

dto

pro

tect

the

grou

nd w

ire fr

om r

adia

nt h

eat.

3.T

he b

urne

r ser

ves

as th

e co

mm

on g

roun

ding

are

a. If

ther

e is

not

goo

d m

etal

-to-

met

al c

onta

ct b

etw

een

the

burn

eran

d gr

ound

, run

a le

ad fr

om th

e bu

rner

to g

roun

d.

NO

TE

: “E

arth

” gr

ound

is n

ot r

equi

red.

To

conn

ect

the

D80

B,

follo

w t

he w

iring

dia

gram

s su

p-pl

ied

with

the

vent

dam

per o

r see

Fig

. 8 fo

r typ

ical

con

nec-

tions

.

Co

nn

ect

Ign

itio

n M

od

ule

1.C

onne

ct re

mai

ning

sys

tem

com

pone

nts

to th

e ig

nitio

nm

odul

e te

rmin

als

as s

how

n in

the

app

ropr

iate

wiri

ng d

ia-

gram

, Fig

s. 2

thro

ugh

11.

•F

ig. 2

is a

bas

ic c

ircui

t for

a h

eatin

g on

ly a

tmos

-ph

eric

bur

ner

with

S86

10F

,H o

r S

8670

D.

•F

ig. 3

sho

ws

S86

10F

,H w

ith v

ent d

ampe

r pl

ug in

a he

atin

g on

ly a

tmos

pher

ic b

urne

r sy

stem

with

D80

D V

ent D

ampe

r. N

ever

use

a v

ent d

ampe

r in

an L

P g

as s

yste

m o

r in

a fa

n-as

sist

ed c

ombu

stio

nsy

stem

.

•F

igs.

4 a

nd 5

sho

w S

8610

A,B

with

sep

arat

ese

nsor

and

ign

iter,

with

and

with

out

the

D80

DV

ent D

ampe

r.

•F

igs.

6 th

roug

h 11

sho

w S

8610

F,H

and

S86

70D

ina

varie

ty o

f sys

tem

s w

ith a

ltern

ate

conn

ectio

ns fo

rm

odul

es w

ith v

ent d

ampe

r plu

g. R

emem

ber,

how

-ev

er, t

hat a

ven

t dam

per s

houl

d no

t be

used

in a

nfa

n-as

sist

ed c

ombu

stio

n sy

stem

or

an L

P g

assy

stem

and

that

the

vent

dam

per p

lug

mus

t not

be

rem

oved

exc

ept t

o co

nnec

t the

mod

ule

to a

D80

Dw

ith t

he p

lug-

in c

able

. S

8610

A,B

can

be

subs

ti-tu

ted

in th

ese

draw

ings

by

sim

ply

conn

ectin

g th

eig

nite

r an

d se

nsor

as

show

n in

Fig

s. 4

and

5.

2.R

efer

to

heat

ing

appl

ianc

e m

anuf

actu

rer’s

ins

truc

-tio

ns fo

r w

iring

aux

iliar

y co

ntro

ls.

3.A

djus

t th

erm

osta

t he

at a

ntic

ipat

or t

o m

atch

sys

tem

curr

ent

draw

. T

he c

urre

nt d

raw

equ

als

the

tota

l cu

rren

tre

quire

d fo

r the

igni

tion

mod

ule

(0.2

A) p

lus

the

gas

cont

rol

and

any

othe

r au

xilia

ry e

quip

men

t in

the

cont

rol c

ircui

t.

Co

nn

ect

Gas

Co

ntr

ol

Use

No.

18

gaug

e so

lid o

r st

rand

ed w

ire.

Use

1/4

in.

fem

ale

quic

k-co

nnec

ts fo

r mod

ule

conn

ectio

ns. C

onne

ct to

gas

cont

rol t

erm

inal

s as

sho

wn

in w

iring

dia

gram

s, u

sing

term

inal

s ap

prop

riate

to th

e ga

s co

ntro

l.

369

-052

3

IMP

OR

TA

NT

1.A

s sh

own

in t

he w

iring

dia

gram

s, a

com

mon

grou

nd is

req

uire

d on

:a.

The

pilo

t bur

ner

mou

ntin

g br

acke

t, an

db.

The

GN

D(B

UR

NE

R)

term

inal

on

the

igni

tion

mod

ule.

Fai

lure

to u

se th

e G

ND

(BU

RN

ER

) ter

mi-

nal m

ay r

esul

t in

inte

rmitt

ent l

oss

of s

park

and

/or

loss

of f

lam

e cu

rren

t sen

sitiv

ity.

2.M

ake

sure

the

tran

sfor

mer

has

ade

quat

e V

A. T

heig

nitio

n m

odul

e re

quire

s at

leas

t 0.2

A a

t 24

Vac

.A

dd t

he c

urre

nt d

raw

s of

all

othe

r de

vice

s in

the

cont

rol c

ircui

t, in

clud

ing

the

pilo

t and

mai

n va

lves

in th

e ga

s co

ntro

l, an

d m

ultip

ly b

y 24

to d

eter

min

eth

e to

tal

VA

req

uire

men

t of

the

se c

ompo

nent

s.A

dd th

is to

tal t

o 4.

8 V

A (

for

the

igni

tion

mod

ule)

.T

he r

esul

t is

the

min

imum

tran

sfor

mer

VA

rat

ing.

Use

a C

lass

II

tran

sfor

mer

if

repl

acem

ent

is r

e-qu

ired.

MO

UN

T T

HE

SY

ST

EM

CO

NT

RO

LS

Mou

nt a

ny r

equi

red

cont

rols

, su

ch a

s th

e ga

s co

ntro

l,sp

ark

igni

ter,

fla

me

sens

or,

ther

mos

tat,

limit,

and

tra

ns-

form

er a

ccor

ding

to m

anuf

actu

rer’s

inst

ruct

ions

.

WIR

E T

HE

SY

ST

EM

CA

UT

ION

1.C

heck

the

wiri

ng d

iagr

am fu

rnis

hed

by th

e

ap-

plia

nce

man

ufac

ture

r, if

ava

ilabl

e, fo

r ci

rcui

ts d

if-fe

ring

from

the

wiri

ng h

ooku

ps s

how

n. C

aref

ully

follo

w a

ny s

peci

al in

stru

ctio

ns a

ffect

ing

the

gen-

eral

pro

cedu

res

outli

ned

belo

w.

2.D

isco

nnec

t th

e po

wer

sup

ply

befo

re m

akin

gw

iring

con

nect

ions

to p

reve

nt e

lect

rical

sho

ck o

req

uipm

ent d

amag

e.

FIG

. 1—

IGN

ITIO

N M

OD

UL

E M

OU

NT

ING

RE

CO

MM

EN

DA

TIO

NS

.

TE

RM

INA

LS F

AC

ING

DO

WN

TE

RM

INA

LS F

AC

ING

LE

FT

TE

RM

INA

LS F

AC

ING

RIG

HT

MO

UN

T T

HE

S86

10 O

R S

8670

IN A

NY

OF

TH

ES

E P

OS

ITIO

NS

:

DO

NO

T M

OU

NT

TH

E S

8610

OR

S86

70 W

ITH

TE

RM

INA

LS

FA

CIN

G U

P

M53

8

Fig

. 4—

S86

10A

,B i

n a

hea

tin

g s

yste

m w

ith

an

atm

osp

her

ic b

urn

er.

Fig

. 3—

S86

10F

,H w

ith

a v

ent d

amp

er p

lug

in a

hea

tin

g s

yste

m w

ith

an

atm

osp

her

ic b

urn

er a

nd

a D

80D

Ven

t Dam

per

.

6

Q34

5, Q

346,

Q34

8, Q

362,

Q38

1P

ILO

T B

UR

NE

R/

IGN

ITE

R-S

EN

SO

R

L1 (HO

T)

L2

TH

ER

MO

-S

TA

T

1

LIM

ITC

ON

TR

OLL

ER

2

4

MV

MV

/PV

PV

GN

D(B

UR

NE

R)

24V

GN

D24

VT

H-W

VE

NT

DA

MP

ER

PLU

GS

PA

RK

5

S86

10F

,H

3

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

ALT

ER

NA

TE

LIM

IT C

ON

TR

OLL

ER

LO

CA

TIO

N.

MA

XIM

UM

CA

BLE

LE

NG

TH

3 ft

[0.9

m].

CO

NT

RO

LS IN

24V

CIR

CU

IT M

US

T N

OT

BE

IN G

RO

UN

D L

EG

TO

TR

AN

SF

OR

ME

R.

RE

MO

VE

PLU

G O

NLY

IF U

SIN

G V

EN

T D

AM

PE

R.

FU

SE

BLO

WS

ON

ST

AR

TU

P W

HE

N P

LUG

IS R

EM

OV

ED

; T

HE

N M

OD

ULE

WIL

L O

PE

RA

TE

ON

LY W

HE

N V

EN

T D

AM

PE

R IS

CO

NN

EC

TE

D.

1 2 3 4 5

M54

0

WIR

ING

HA

RN

ES

S

D80

D V

EN

TD

AM

PE

R

2ND

OP

ER

AT

OR

1ST

OP

ER

AT

OR

PIL

OT

CO

MM

AIN

VA

LVE

DU

AL

VA

LVE

CO

MB

INA

TIO

NG

AS

CO

NT

RO

L

PIL

OT

BU

RN

ER

GR

OU

ND

PIL

OT

GA

SS

UP

PLY

MV

MV

/PV

PV

GN

D(B

UR

NE

R)

24V

GN

D24

VS

PA

RK

S86

10A

,B

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

ALT

ER

NA

TE

LIM

IT C

ON

TR

OLL

ER

LO

CA

TIO

N.

MA

XIM

UM

CA

BLE

LE

NG

TH

3 ft

[0.9

m].

CO

NT

RO

LS IN

24V

CIR

CU

IT M

US

T N

OT

BE

IN G

RO

UN

D L

EG

TO

TR

AN

SF

OR

ME

R.

FO

R M

OD

ULE

WIT

H T

H-W

TE

RM

INA

L A

ND

VE

NT

DA

MP

ER

PLU

G, C

ON

NE

CT

TH

ER

MO

ST

AT

TO

T

H-W

. LE

AV

E 2

4V O

PE

N. D

O N

OT

RE

MO

VE

VE

NT

DA

MP

ER

PLU

G.

1 2 3 4 5

M54

1

GR

OU

ND

PIL

OT

GA

SS

UP

PLY

2

4

3

SE

NS

OR

IGN

ITE

R

SE

NS

E

L1 (HO

T)

1 L2

LIM

IT

CO

NT

RO

LLE

R

TH

ER

MO

ST

AT

5

TH

-W(O

PT

)

VE

NT

DA

MP

ER

PLU

G (

OP

T)

5

2ND

OP

ER

AT

OR

1ST

OP

ER

AT

OR

PIL

OT

CO

MM

AIN

VA

LVE

DU

AL

VA

LVE

CO

MB

INA

TIO

NG

AS

CO

NT

RO

L

Fig

. 2—

S86

10F

,H;

S86

70D

in a

hea

tin

g s

yste

m w

ith

an

atm

osp

her

ic b

urn

er.

5

TA

BLE

4—

TE

RM

INA

L C

RO

SS

RE

FE

RE

NC

E.

TE

RM

INA

L O

NT

ER

MIN

AL

ON

OLD

MO

DU

LE:

NE

W M

OD

ULE

:25

V (

1)24

V (

GN

D)

TH

-W24

VM

VM

VM

V/P

VM

V/P

VP

VP

VG

ND

(B

urne

r)G

ND

(B

urne

r)

RE

PL

AC

ING

MO

DU

LE

WIT

H T

H-R

, TH

-W T

ER

MIN

AL

SO

n m

odul

es t

hat

do n

ot h

ave

a ve

nt d

ampe

r pl

ug,

the

ther

mos

tat

mus

t be

con

nect

ed b

etw

een

the

tran

sfor

mer

and

the

24V

ter

min

al o

n th

e m

odul

e. T

o ch

ange

out

am

odul

e w

ith T

H-R

, TH

-W te

rmin

als:

1.R

emov

e th

e w

ires

from

the

25V

(2)

and

TH

-R t

erm

i-na

ls o

n th

e ol

d m

odul

e. C

onne

ct t

hese

tw

o w

ires

with

aso

lder

less

con

nect

or.

2.T

ag a

nd r

emov

e th

e re

mai

ning

wire

s fr

om t

he o

ldm

odul

e.3.

Rem

ove

the

old

mod

ule

and

mou

nt th

e ne

w o

ne in

the

sam

e lo

catio

n.4.

Rec

onne

ct th

e re

mai

ning

wire

s as

sho

wn

in T

able

4.

5.In

crea

se th

e th

erm

osta

t ant

icip

ator

set

ting

by 0

.2 A

.

TH

ER

MO

ST

AT

L1 (HO

T)

L2 1

LIM

ITC

ON

TR

OLL

ER

2

4

5

MV

MV

/PV

PV

GN

D(B

UR

NE

R)

24V

GN

D24

VT

H-W

(OP

T)

VE

NT

DA

MP

ER

PLU

G (

OP

T)

SP

AR

K

5

S86

10F

,H; S

8670

D

2ND

OP

ER

AT

OR

1ST

OP

ER

AT

OR

PIL

OT

CO

MM

AIN

VA

LVE

DU

AL

VA

LVE

CO

MB

INA

TIO

NG

AS

CO

NT

RO

L

PIL

OT

BU

RN

ER

GR

OU

ND

PIL

OT

GA

SS

UP

PLY

Q34

5, Q

346,

Q34

8, Q

362,

Q38

1P

ILO

T B

UR

NE

R/

IGN

ITE

R-S

EN

SO

R

3

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

ALT

ER

NA

TE

LIM

IT C

ON

TR

OLL

ER

LO

CA

TIO

N.

MA

XIM

UM

CA

BLE

LE

NG

TH

3 ft

[0.9

m].

CO

NT

RO

LS IN

24V

CIR

CU

IT M

US

T N

OT

BE

IN G

RO

UN

D L

EG

TO

TR

AN

SF

OR

ME

R.

FO

R M

OD

ULE

WIT

H T

H-W

TE

RM

INA

L A

ND

VE

NT

DA

MP

ER

PLU

G, C

ON

NE

CT

TH

ER

MO

ST

AT

TO

TH

-W.

LEA

VE

24

V O

PE

N.

DO

NO

T R

EM

OV

E V

EN

T D

AM

PE

R P

LUG

.

1 2 3 4 5

M53

9

8

Fig

. 7—

S86

10F

,H;

S86

70D

in a

hea

tin

g s

yste

m w

ith

a t

wo

-sta

ge

gas

co

ntr

ol a

nd

po

wer

-ass

iste

d c

om

bu

stio

n.

5

MV

MV

/PV

PV

GN

D(B

UR

NE

R)

24V

GN

D24

VT

H-W

(OP

T)

VE

NT

DA

MP

ER

PLU

G (

OP

T)

SP

AR

K

5

S86

10F

,H; S

8670

D

PIL

OT

BU

RN

ER

GR

OU

ND

PIL

OT

GA

SS

UP

PLY

Q34

5, Q

346,

Q34

8, Q

362,

Q

381P

ILO

T

BU

RN

ER

/IG

NIT

ER

-S

EN

SO

R

3

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

ALT

ER

NA

TE

LIM

IT C

ON

TR

OLL

ER

LO

CA

TIO

N.

MA

XIM

UM

CA

BLE

LE

NG

TH

3 ft

[0.9

m].

CO

NT

RO

LS IN

24V

CIR

CU

IT M

US

T N

OT

BE

IN G

RO

UN

D L

EG

TO

TR

AN

SF

OR

ME

R.

FO

R M

OD

ULE

WIT

H T

H-W

TE

RM

INA

L A

ND

VE

NT

DA

MP

ER

PLU

G, C

ON

NE

CT

TH

ER

MO

ST

AT

TO

TH

-W.

LEA

VE

24

V O

PE

N.

DO

NO

T R

EM

OV

E V

EN

T D

AM

PE

R P

LUG

.

1 2 3 4 5M

544

AIR

PR

OV

ING

SW

ITC

H

CO

MB

US

TIO

NA

IR B

LOW

ER

R

ELA

Y

L1 (HO

T)L2

1

CO

MB

US

TIO

NA

IR B

LOW

ER

MO

TO

R

TH

ER

MO

ST

AT

L21

LIM

ITC

ON

TR

OLL

ER

L1 (HO

T)

2

RW

2W

12N

DO

PE

RA

TO

R1S

TO

PE

RA

TO

R

CO

M

MA

INV

ALV

E

ST

AG

E 1

TW

O S

TA

GE

DU

AL

VA

LVE

C

OM

BIN

AT

ION

GA

S C

ON

TR

OL

PIL

OT

GR

OU

ND

MA

INV

ALV

E

ST

AG

E 2 4

Fig

. 6—

S86

10F

,H;

S86

70D

in a

hea

tin

g s

yste

m w

ith

po

wer

-ass

iste

d c

om

bu

stio

n.

Fig

. 5—

S86

10A

,B w

ith

ven

t d

amp

erp

lug

in a

n a

tmo

sph

eric

bu

rne

r h

eati

ng

sys

tem

wit

h a

D80

D V

ent D

amp

er.

769

-052

3

MV

MV

/PV

PV

GN

D(B

UR

NE

R)

24V

GN

D24

VT

H-W

VE

NT

DA

MP

ER

PLU

GS

PA

RK

5

S86

10A

,B

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

ALT

ER

NA

TE

LIM

IT C

ON

TR

OLL

ER

LO

CA

TIO

N.

MA

XIM

UM

CA

BLE

LE

NG

TH

3 ft

[0.9

m].

CO

NT

RO

LS IN

24V

CIR

CU

IT M

US

T N

OT

BE

IN G

RO

UN

D L

EG

TO

TR

AN

SF

OR

ME

R.

RE

MO

VE

PLU

G O

NLY

IF U

SIN

G V

EN

T D

AM

PE

R.

1 2 3 4 5M

542

D80

D V

EN

T D

AM

PE

R

2

3

SE

NS

E

TH

ER

MO

ST

AT

2ND

OP

ER

AT

OR

1ST

OP

ER

AT

OR

PIL

OT

CO

MM

AIN

VA

LVE

DU

AL

VA

LVE

CO

MB

INA

TIO

NG

AS

CO

NT

RO

L

4L1 (H

OT

)

1 L2

LIM

IT

CO

NT

RO

LLE

RG

RO

UN

D

PIL

OT

GA

SS

UP

PLY

SE

NS

OR

IGN

ITE

R

TH

ER

MO

ST

AT

L1 (HO

T)

L2 1

LIM

ITC

ON

TR

OLL

ER

2

4

5

MV

MV

/PV

PV

GN

D(B

UR

NE

R)

24V

GN

D24

VT

H-W

(OP

T)

VE

NT

DA

MP

ER

PLU

G (

OP

T)

SP

AR

K

5

S86

10F

,H; S

8670

D

3

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

ALT

ER

NA

TE

LIM

IT C

ON

TR

OLL

ER

LO

CA

TIO

N.

MA

XIM

UM

CA

BLE

LE

NG

TH

3 ft

[0.9

m].

CO

NT

RO

LS IN

24V

CIR

CU

IT M

US

T N

OT

BE

IN G

RO

UN

D L

EG

TO

TR

AN

SF

OR

ME

R.

FO

R M

OD

ULE

WIT

H T

H-W

TE

RM

INA

L A

ND

VE

NT

DA

MP

ER

PLU

G, C

ON

NE

CT

TH

ER

MO

ST

AT

TO

T

H-W

. LE

AV

E 2

4V O

PE

N.

DO

NO

T R

EM

OV

E V

EN

T D

AM

PE

R P

LUG

.

1 2 3 4 5M

543

AIR

PR

OV

ING

SW

ITC

H

CO

MB

US

TIO

NA

IR B

LOW

ER

R

ELA

Y

L1 (HO

T)L2 1

CO

MB

US

TIO

NA

IR B

LOW

ER

MO

TO

R

2ND

OP

ER

AT

OR

1ST

OP

ER

AT

OR

PIL

OT

CO

MM

AIN

VA

LVE

DU

AL

VA

LVE

CO

MB

INA

TIO

NG

AS

CO

NT

RO

L

PIL

OT

B

UR

NE

RG

RO

UN

D

PIL

OT

GA

SS

UP

PLY

Q34

5, Q

346,

Q34

8, Q

362,

Q38

1P

ILO

T B

UR

NE

R/

IGN

ITE

R-S

EN

SO

R

10

Fig

. 9—

S86

10F

,H;

S86

70D

in a

hea

tin

g-c

oo

ling

sys

tem

wit

h p

ow

er-a

ssis

ted

co

mb

ust

ion

.

MV

MV

/PV

PV

GN

D(B

UR

NE

R)

24V

GN

D24

VT

H-W

(OP

T)

VE

NT

DA

MP

ER

PLU

G (

OP

T)

SP

AR

K

5

S86

10F

,H; S

8670

D

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

ALT

ER

NA

TE

LIM

IT C

ON

TR

OLL

ER

LO

CA

TIO

N.

MA

XIM

UM

CA

BLE

LE

NG

TH

3 ft

[0.9

m].

CO

NT

RO

LS IN

24V

CIR

CU

IT M

US

T N

OT

BE

IN G

RO

UN

D L

EG

TO

TR

AN

SF

OR

ME

R.

FO

R M

OD

ULE

WIT

H T

H-W

TE

RM

INA

L A

ND

VE

NT

DA

MP

ER

PLU

G, C

ON

NE

CT

TO

TH

-W.

LEA

VE

24V

O

PE

N.

DO

NO

T R

EM

OV

E V

EN

T D

AM

PE

R P

LUG

.

1 2 3 4 5M

546

Q34

5, Q

346,

Q34

8, Q

362,

Q

381P

ILO

T

BU

RN

ER

/IG

NIT

ER

-S

EN

SO

R

35

WG

Y

CO

IL

L1 (HO

T)

L21

AIR

PR

OV

ING

SW

ITC

H

PR

ES

SU

RE

CO

NT

RO

LLE

RC

OO

LIN

GC

ON

TR

OL

CO

MB

US

TIO

NA

IR B

LOW

ER

RE

LAY

CO

MB

US

TIO

NA

IR B

LOW

ER

MO

TO

R

2

L1 (HO

T)

L2

RC

R82

39F

AN

C

EN

TE

RLI

MIT

CO

N-

TR

OLL

ER

1

WY

RG

TH

ER

MO

ST

AT

CH

LF

AN

CO

NT

RO

L

FA

N

MO

TO

R

4

2ND

OP

ER

AT

OR

1ST

OP

ER

AT

OR

PIL

OT

CO

MM

AIN

VA

LVE

DU

AL

VA

LVE

CO

MB

INA

TIO

NG

AS

CO

NT

RO

L

PIL

OT

B

UR

NE

RG

RO

UN

D

PIL

OT

GA

SS

UP

PLY

969

-052

3

Fig

. 8—

S86

10F

,H;

S86

70D

in a

hea

tin

g s

yste

m w

ith

an

atm

osp

her

ic b

urn

er a

nd

a D

80B

Ven

t D

amp

er.

LIM

IT

CO

N-

TR

OLL

ER

5

MV

MV

/PV

PV

GN

D(B

UR

NE

R)

24V

GN

D24

VT

H-W

(OP

T)

VE

NT

DA

MP

ER

PLU

G (

OP

T)

SP

AR

K

5

S86

10F

,H; S

8670

D

3

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

ALT

ER

NA

TE

LIM

IT C

ON

TR

OLL

ER

LO

CA

TIO

N.

MA

XIM

UM

CA

BLE

LE

NG

TH

3 ft

[0.9

m].

CO

NT

RO

LS IN

24V

CIR

CU

IT M

US

T N

OT

BE

IN G

RO

UN

D L

EG

TO

TR

AN

SF

OR

ME

R.

FO

R M

OD

ULE

WIT

H T

H-W

TE

RM

INA

L A

ND

VE

NT

DA

MP

ER

PLU

G, C

ON

NE

CT

TO

TH

-W.

LEA

VE

24V

O

PE

N.

DO

NO

T R

EM

OV

E V

EN

T D

AM

PE

R P

LUG

.

CO

LOR

S R

EF

ER

TO

TH

E D

80B

WIR

E H

AR

NE

SS

, IF

US

ED

.

1 2 3 4 5

M54

5

L1 (HO

T)

L21

MOTOR

TH

ER

MO

ST

AT

OR

CO

NT

RO

LLE

R

LIM

ITC

ON

TR

OLL

ER

2

TR

AN

SF

OR

ME

RBLUE

YELLOW

RED

ORANGE

BLACK

6

D80

B

EN

D S

WIT

CH

N.O

.N

.C.

1K2

1K1

R

1K

12

34

5

1K3

4

6

2ND

OP

ER

AT

OR

1ST

OP

ER

AT

OR

PIL

OT

CO

MM

AIN

VA

LVE

DU

AL

VA

LVE

CO

MB

INA

TIO

NG

AS

CO

NT

RO

L

PIL

OT

B

UR

NE

RG

RO

UN

D

PIL

OT

GA

SS

UP

PLY

Q34

5, Q

346,

Q34

8, Q

362,

Q38

1P

ILO

T B

UR

NE

R/

IGN

ITE

R-S

EN

SO

R

12

Fig

. 11—

S86

10F

,H;

S86

70D

in a

co

mm

erci

al w

ater

hea

ter

con

tro

l sys

tem

.

CO

NT

RO

LLE

R

4

MV

MV

/PV

PV

GN

D(B

UR

NE

R)

24V

GN

D24

VT

H-W

(OP

T)

VE

NT

DA

MP

ER

PLU

G (

OP

T)

SP

AR

K

4

S86

10F

,H; S

8670

D

1

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

MA

XIM

UM

CA

BLE

LE

NG

TH

3 ft

[0.9

m].

CO

NT

RO

LS IN

24V

CIR

CU

IT M

US

T N

OT

BE

IN G

RO

UN

D L

EG

TO

TR

AN

SF

OR

ME

R.

FO

R M

OD

ULE

WIT

H T

H-W

TE

RM

INA

L A

ND

VE

NT

DA

MP

ER

PLU

G, C

ON

NE

CT

TH

ER

MO

ST

AT

TO

T

H-W

. LE

AV

E 2

4V O

PE

N.

DO

NO

T R

EM

OV

E V

EN

T D

AM

PE

R P

LUG

.

1 2 3 4M

548

PIL

OT

BU

RN

ER

GR

OU

ND

L1 (HO

T)

L2

3

L810

0

EC

O

2

2ND

OP

ER

AT

OR

1ST

OP

ER

AT

OR

PIL

OT

CO

MM

AIN

VA

LVE

DU

AL

VA

LVE

CO

MB

INA

TIO

NG

AS

CO

NT

RO

L

PIL

OT

GA

SS

UP

PLY

Q34

5, Q

346,

Q34

8, Q

362,

Q38

1P

ILO

T B

UR

NE

R/

IGN

ITE

R-S

EN

SO

R

1169

-052

3

Fig

. 10—

S86

10F

, H;

S86

70D

in

a h

ydro

nic

hea

tin

g s

yste

m w

ith

a D

80D

Ven

t D

amp

er.

2

MV

MV

/PV

PV

GN

D(B

UR

NE

R)

24V

GN

D24

VT

H-W

(OP

T)

VE

NT

DA

MP

ER

PLU

G (

OP

T)

SP

AR

K

4

S86

10F

,H; S

8670

D

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

CU

T P

LUG

OF

F M

OD

ULE

EN

D O

F D

80D

WIR

E H

AR

NE

SS

, CO

NN

EC

T L

EA

DW

IRE

CO

LOR

S A

S S

HO

WN

.

MA

XIM

UM

CA

BLE

LE

NG

TH

3 ft

[0.9

m].

FO

R M

OD

ULE

WIT

H T

H-W

TE

RM

INA

L A

ND

VE

NT

DA

MP

ER

PLU

G, C

ON

NE

CT

TO

TH

-W.

LEA

VE

24V

O

PE

N.

DO

NO

T R

EM

OV

E V

EN

T D

AM

PE

R P

LUG

.

LEA

VE

TP

-Z A

ND

Z-W

JU

MP

ER

S IN

PLA

CE

.

1 2 3 4 5M

547

Q34

5, Q

346,

Q34

8, Q

362,

Q

381P

ILO

T

BU

RN

ER

/IG

NIT

ER

-S

EN

SO

R

4

N.O

.

N.C

.1K

2

1K

12

34

1K3

D80

MO

TO

R

C.

1K1

1K1

BR

D80

D

CA

BLE

YE

LLO

WBLU

E

BLA

CK

OR

AN

GE

AU

TO

MA

NU

AL

SW

ITC

H

B1

Z

B3

WT

TP

1K1K3 T

V

TH

ER

MO

ST

AT

B2

C2

C1

L2L1G

L1 (HO

T)

L2

5

1

FA

NM

OT

OR

1K2

L814

8J

2ND

OP

ER

AT

OR

1ST

OP

ER

AT

OR

PIL

OT

CO

MM

AIN

VA

LVE

DU

AL

VA

LVE

CO

MB

INA

TIO

NG

AS

CO

NT

RO

L

3

PIL

OT

B

UR

NE

RG

RO

UN

D

PIL

OT

GA

SS

UP

PLY

14

OP

ER

AT

ION

Mod

ule

oper

atio

n ca

n be

con

veni

ently

div

ided

into

two

phas

es fo

r S

8610

and

thre

e fo

r S

8670

. The

pha

ses

are:

•P

repu

rge

(S86

70 o

nly)

•T

rial f

or ig

nitio

n (a

ll m

odel

s)•

Mai

n bu

rner

ope

ratio

n (a

ll m

odel

s)

Fig

s. 1

2 an

d 13

sum

mar

ize

the

norm

al o

pera

ting

se-

quen

ces

of th

e m

odul

es.

PR

EP

UR

GE

(S

8670

ON

LY

) O

n pr

oof

of a

irflo

w,

the

air

prov

ing

switc

h cl

oses

and

ener

gize

s th

e S

8670

. W

hen

the

mod

ule

is u

sed

in a

nat

mos

pher

ic s

yste

m, t

he c

all f

or h

eat e

nerg

izes

the

mod

ule.

In e

ither

cas

e, t

he m

odul

e fir

st i

nitia

tes

a 45

sec

ond.

dela

y to

allo

w s

yste

m p

repu

rge.

Afte

r pre

purg

e, th

e m

odul

est

arts

the

pilo

t ign

ition

seq

uenc

e.

Fig

. 12—

S86

10 n

orm

al o

per

atin

g s

equ

ence

.

ST

AR

TT

HE

RM

OS

TA

T (

CO

NT

RO

LL

ER

)C

AL

LS

FO

R H

EA

T

SP

AR

K G

EN

ER

AT

OR

PO

WE

RE

DF

irst v

alve

(pi

lot)

ope

rato

r op

ens

PIL

OT

BU

RN

ER

OP

ER

AT

ION

Pilo

t bur

ner

light

s.M

odul

e se

nses

flam

e cu

rren

t.

Pilo

t bur

ner

does

not

ligh

t.M

odul

e

Res

pons

e

S

huto

ff/lo

ckou

t tim

ing

is s

tam

ped

on m

odul

ea

Igni

tion

spar

k co

ntin

ues,

pilo

t va

lve

rem

ains

ope

n un

til s

yste

m

is r

eset

S86

10A

,F

S86

10B

,Ha

ST

AG

E 1

TR

IAL

FO

R

IGN

IITIO

N

ST

AG

E 2

MA

IN B

UR

NE

R

OP

ER

AT

ION

EN

D

MA

IN B

UR

NE

R O

PE

RA

TIO

NM

odul

e m

onito

rs p

ilot f

lam

e cu

rren

t.

TH

ER

MO

ST

AT

(C

ON

TR

OL

LE

R)

SA

TIS

FIE

DV

alve

s cl

ose,

pilo

t and

mai

n bu

rner

s ar

e of

f.

PO

WE

R IN

TE

RR

UP

TIO

NS

yste

m s

huts

off,

res

tart

s w

hen

pow

er is

re

stor

ed.

PIL

OT

FL

AM

E F

AIL

UR

EM

ain

valv

e cl

oses

.M

odul

e st

arts

tria

l for

igni

tion.

1

FL

AM

E C

UR

RE

NT

SE

NS

ED

Spa

rk g

ener

ator

off.

Sec

ond

valv

e op

erat

or (

mai

n)

open

s.

• •

2 3 4 5 61

OR

Afte

r 15

or

90 s

econ

ds

max

imum

sy

stem

lock

s ou

t; m

ust b

e m

anua

lly r

eset

.

M54

9

13

69-0

523

CH

EC

KO

UT

Che

ck o

ut th

e ga

s co

ntro

l sys

tem

:•

At i

nitia

l ins

talla

tion

of th

e ap

plia

nce.

•A

s pa

rt o

f reg

ular

mai

nten

ance

pro

cedu

res.

Mai

nte-

nanc

e in

terv

als

are

dete

rmin

ed b

y th

e ap

plic

atio

n.S

ee P

LAN

NIN

G T

HE

IN

ST

ALL

AT

ION

, pa

ge 1

, fo

rm

ore

info

rmat

ion.

•A

s th

e fir

st s

tep

in tr

oubl

esho

otin

g.•

Any

tim

e w

ork

is d

one

on th

e sy

stem

.

WAR

NING

FIR

E O

R E

XP

LO

SIO

N H

AZ

AR

DM

AY

CA

US

E P

RO

PE

RT

Y D

AM

AG

E, S

EV

ER

EIN

JUR

Y, O

R D

EA

TH

1.If

yo

u s

mel

l gas

or

susp

ect a

gas

leak

, tu

rn o

ffg

as a

t man

ual

ser

vice

val

ve a

nd

eva

cuat

e th

eb

uild

ing

. Do

no

t tr

y to

lig

ht

any

app

lian

ce, d

on

ot t

ou

ch a

ny

elec

tric

al s

wit

ch o

r tel

eph

on

e in

the

bu

ildin

g u

nti

l yo

u a

re s

ure

no

sp

illed

gas

rem

ain

s.2.

Gas

lea

k te

st m

ust

be

do

ne

as d

escr

ibed

in

Ste

ps

1 an

d 5

bel

ow

on

init

ial i

nst

alla

tio

n a

nd

any

tim

e w

ork

is

do

ne

invo

lvin

g t

he

gas

pip

-in

g.

ST

EP

3: R

eset

the

Mod

ule.

■T

urn

the

ther

mos

tat t

o its

low

est s

ettin

g.■

Wai

t one

min

ute.

As

you

do S

teps

4 a

nd 5

, wat

ch fo

r poi

nts

whe

re o

pera

tion

devi

ates

fro

m n

orm

al.

Ref

er t

o T

roub

lesh

ootin

g C

hart

to

corr

ect p

robl

em.

ST

EP

4: C

heck

Saf

ety

Shu

toff

Ope

ratio

n.T

his

step

app

lies

to lo

ckou

t and

con

tinuo

us r

etry

mod

ules

only

.■

Tur

n ga

s su

pply

off.

■S

et th

erm

osta

t or c

ontr

olle

r abo

ve ro

om te

mpe

ratu

re to

call

for

heat

.■

Wat

ch f

or s

park

at

pilo

t bu

rner

eith

er i

mm

edia

tely

or

follo

win

g pr

epur

ge. S

ee d

evic

e la

bel.

■T

ime

spar

k fr

om s

tart

to s

huto

ff. S

ee d

evic

e la

bel.

Igni

tion

sequ

ence

sho

uld

star

t ag

ain

follo

wed

by

shut

off

afte

r 90

sec

onds

max

imum

.■

Ope

n m

anua

l gas

con

trol

kno

b an

d m

ake

sure

no

gas

isflo

win

g to

pilo

t or

mai

n bu

rner

.■

Set

the

rmos

tat

belo

w r

oom

tem

pera

ture

and

wai

t on

em

inut

e be

fore

con

tinui

ng.

ST

EP

5: C

heck

Nor

mal

Ope

ratio

n.■

Set

ther

mos

tat o

r con

trol

ler a

bove

room

tem

pera

ture

toca

ll fo

r he

at.

■M

ake

sure

pilo

t lig

hts

smoo

thly

whe

n ga

s re

ache

s th

epi

lot b

urne

r.■

Mak

e su

re m

ain

burn

er l

ight

s sm

ooth

ly w

ithou

t fla

sh-

back

.■

Mak

e su

re b

urne

r op

erat

es s

moo

thly

with

out

float

ing,

liftin

g, o

r fla

me

rollo

ut t

o th

e fu

rnac

e ve

stib

ule

or h

eat

build

up in

the

vest

ibul

e.■

If ga

s lin

e ha

s be

en d

istu

rbed

, com

plet

e ga

s le

ak te

st.

GA

S L

EA

K T

ES

T: P

aint

gas

con

trol

gas

ket e

dges

and

all

pipe

con

nect

ions

dow

nstr

eam

of g

as c

ontr

ol, i

nclu

ding

pilo

t tub

ing

conn

ectio

ns, w

ith r

ich

soap

and

wat

er s

olu-

tion.

Bub

bles

ind

icat

e ga

s le

aks.

Tig

hten

joi

nts

and

scre

ws

or re

plac

e co

mpo

nent

to s

top

gas

leak

. Rec

heck

with

soa

p an

d w

ater

.

■T

urn

ther

mos

tat o

r co

ntro

ller

belo

w r

oom

tem

pera

ture

.M

ake

sure

mai

n bu

rner

and

pilo

t fla

mes

go

out.

ST

EP

1: P

erfo

rm V

isua

l Ins

pect

ion.

■W

ith p

ower

off,

mak

e su

re a

ll w

iring

con

nect

ions

are

clea

n an

d tig

ht.

■T

urn

on p

ower

to a

pplia

nce

and

igni

tion

mod

ule.

■O

pen

man

ual

shut

off

valv

es i

n th

e ga

s lin

e to

the

appl

ianc

e.■

Do

gas

leak

test

ahe

ad o

f gas

con

trol

if p

ipin

g ha

s be

endi

stur

bed.

GA

S L

EA

K T

ES

T: P

aint

gas

con

trol

gas

ket e

dges

and

all

pipe

con

nect

ions

dow

nstr

eam

of g

as c

ontr

ol, i

nclu

ding

pilo

t tub

ing

conn

ectio

ns, w

ith r

ich

soap

and

wat

er s

olu-

tion.

Bub

bles

ind

icat

e ga

s le

aks.

Tig

hten

joi

nts

and

scre

ws

or re

plac

e co

mpo

nent

to s

top

gas

leak

. Rec

heck

with

soa

p an

d w

ater

sol

utio

n.

ST

EP

2: R

evie

w N

orm

al O

pera

ting

Seq

uenc

e an

d M

odul

eS

peci

ficat

ions

.■

See

O

PE

RA

TIO

N,

pag

e 1

3,

and

AP

PLI

CA

TIO

N,

page

1.

WAR

NING

Wh

en p

erfo

rmin

g th

e fo

llow

ing

ste

ps,

do

no

t to

uch

stri

pp

ed e

nd

of

jum

per

or

SP

AR

K t

erm

inal

. T

he

ign

itio

n c

ircu

it g

ener

ates

ove

r 10

,000

vo

lts

and

elec

tric

al s

ho

ck c

an r

esu

lt.

■E

nerg

ize

the

mod

ule

and

imm

edia

tely

touc

h on

e en

d of

the

jum

per f

irmly

to th

e G

ND

term

inal

on

the

mod

ule.

Mov

eth

e fr

ee e

nd o

f th

e ju

mpe

r sl

owly

tow

ard

the

SP

AR

Kte

rmin

al u

ntil

a sp

ark

is e

stab

lishe

d.■

Pul

l the

jum

per s

low

ly a

way

from

the

term

inal

and

not

e th

ele

ngth

of t

he g

ap w

hen

spar

king

sto

ps. C

heck

tabl

e be

low

.

AR

C L

EN

GT

HA

CT

ION

No

arc

or a

rc le

ssC

heck

ext

erna

l fus

e, if

pro

vide

d.th

an 1

/8 in

ch [3

mm

]V

erify

pow

er a

t mod

ule

inpu

tte

rmin

al.

Rep

lace

mod

ule

if fu

se a

ndpo

wer

oka

y.A

rc 1

/8 in

ch [3

mm

]V

olta

ge o

utpu

t is

okay

.or

long

er.

ST

EP

4: C

heck

pilo

t and

mai

n bu

rner

ligh

toff.

■S

et th

e th

erm

osta

t to

call

for

heat

.■

Wat

ch th

e pi

lot b

urne

r dur

ing

the

igni

tion

sequ

ence

. See

if:•

Igni

tion

spar

k co

ntin

ues

afte

r th

e pi

lot i

s lit

.•

The

pilo

t lig

hts

and

the

spar

k st

ops,

but

mai

n bu

rner

does

not

ligh

t.•

S86

10B

,H; S

8670

D o

nly:

The

pilo

t lig

hts,

the

spar

k st

ops

and

mai

n bu

rner

ligh

ts, b

ut th

e sy

stem

shu

ts d

own.

■If

so, e

nsur

e ad

equa

te fl

ame

curr

ent a

s fo

llow

s.•

Tur

n of

f fur

nace

at c

ircui

t bre

aker

or

fuse

box

.•

Cle

an th

e fla

me

rod

with

em

ery

clot

h.

TR

OU

BL

ES

HO

OT

ING

IMP

OR

TA

NT

1.T

he fo

llow

ing

serv

ice

proc

edur

es a

re p

rovi

ded

asa

gene

ral g

uide

. Fol

low

app

lianc

e m

anuf

actu

rer’s

serv

ice

inst

ruct

ions

if a

vaila

ble.

2.O

n lo

ckou

t an

d re

try

mod

els,

met

er r

eadi

ngs

betw

een

gas

cont

rol a

nd ig

nitio

n m

odul

e m

ust b

eta

ken

with

in th

e tr

ial f

or ig

nitio

n pe

riod.

Onc

e th

eig

nitio

n m

odul

e sh

uts

off,

lock

out m

odel

s m

ust b

ere

set

by s

ettin

g th

e th

erm

osta

t do

wn

for

at le

ast

one

min

ute

befo

re c

ontin

uing

. O

n re

try

mod

els,

wai

t for

ret

ry o

r re

set a

t the

ther

mos

tat.

3.If

any

com

pone

nt d

oes

not

func

tion

prop

erly

,m

ake

sure

it is

cor

rect

ly in

stal

led

and

wire

d be

fore

repl

acin

g it.

4.T

he ig

nitio

n m

odul

e ca

nnot

be

repa

ired.

If it

mal

-fu

nctio

ns, i

t mus

t be

repl

aced

.

5.O

nly

trai

ned,

exp

erie

nced

ser

vice

tec

hnic

ians

shou

ld s

ervi

ce in

term

itten

t pilo

t sys

tem

s.

Per

form

the

che

ckou

t on

pag

e 12

as

the

first

ste

p in

trou

bles

hoot

ing.

The

n ch

eck

the

appr

opria

te tr

oubl

esho

ot-

ing

guid

e (F

ig. 1

5 or

16)

and

the

sche

mat

ic d

iagr

am (

Fig

.17

or

18)

to p

inpo

int

the

caus

e of

the

pro

blem

. If

trou

-bl

esho

otin

g in

dica

tes

an i

gniti

on p

robl

em,

see

Igni

tion

Sys

tem

Che

cks

belo

w to

isol

ate

and

corr

ect t

he p

robl

em.

Fol

low

ing

trou

bles

hoot

ing,

per

form

the

chec

kout

pro

ce-

dure

(pa

ge 1

2) a

gain

to

be s

ure

syst

em i

s op

erat

ing

norm

ally

.

IGN

ITIO

N S

YS

TE

M C

HE

CK

SS

TE

P 1

: Che

ck ig

nitio

n ca

ble.

Mak

e su

re:

■Ig

nitio

n ca

ble

does

not

run

in

cont

act

with

any

met

alsu

rfac

es.

■Ig

nitio

n ca

ble

is n

o m

ore

than

36

inch

es [

0.9

met

ers]

long

.■

Con

nect

ions

to th

e ig

nitio

n m

odul

e an

d to

the

igni

ter

orig

nite

r-se

nsor

are

cle

an a

nd ti

ght.

■Ig

nitio

n ca

ble

prov

ides

goo

d el

ectr

ical

con

tinui

ty.

ST

EP

2: C

heck

igni

tion

syst

em g

roun

ding

. Nui

sanc

e sh

ut-

dow

ns a

re o

ften

caus

ed b

y a

poor

or

erra

tic g

roun

d.■

A c

omm

on g

roun

d, u

sual

ly s

uppl

ied

by th

e pi

lot b

urne

rbr

acke

t, is

req

uire

d fo

r th

e m

odul

e an

d th

e pi

lot

burn

er/

igni

ter-

sens

or.

•C

heck

for

good

met

al-t

o-m

etal

con

tact

bet

wee

n th

epi

lot b

urne

r br

acke

t and

the

mai

n bu

rner

.•

Che

ck t

he g

roun

d le

ad f

rom

the

GN

D(B

UR

NE

R)

term

inal

on

the

mod

ule

to th

e pi

lot b

urne

r. M

ake

sure

conn

ectio

ns a

re c

lean

and

tig

ht.

If th

e w

ire is

dam

-ag

ed o

r de

terio

rate

d, r

epla

ce it

with

No.

14

thro

ugh

No.

18 g

auge

, moi

stur

e-re

sist

ant,

ther

mop

last

ic in

su-

late

d w

ire w

ith 1

05°

C [2

21°

F] m

inim

um r

atin

g.—

Che

ck th

e ce

ram

ic fl

ame

rod

insu

lato

r fo

r cr

acks

or e

vide

nce

of e

xpos

ure

to e

xtre

me

heat

, w

hich

can

perm

it le

akag

e to

gro

und.

Rep

lace

pilo

t bur

ner/

igni

ter-

sens

or a

nd p

rovi

de s

hiel

d if

nece

ssar

y.—

If fla

me

rod

or b

rack

et a

re b

ent

out

of p

ositi

on,

rest

ore

to c

orre

ct p

ositi

on.

ST

EP

3: C

heck

spa

rk ig

nitio

n ci

rcui

t. Y

ou w

ill n

eed

a sh

ort

jum

per

wire

mad

e fr

om i

gniti

on c

able

or

othe

r he

avily

insu

late

d w

ire.

■C

lose

the

man

ual g

as v

alve

.■

Dis

conn

ect t

he ig

nitio

n ca

ble

at th

e S

PA

RK

term

inal

on

the

mod

ule.

16F

ig. 1

4—E

xam

ple

s o

f u

nsa

tisf

acto

ry p

ilot

flam

es.

LAZY

YEL

LOW

FLA

ME

WAV

ING

BLU

E FL

AME

NO

ISY

LIFT

ING

BLO

WIN

G F

LAM

E

HAR

D S

HAR

P FL

AME

SMAL

L BL

UE

FLAM

EC

HE

CK

FO

R L

AC

K O

F G

AS

FR

OM

:

• C

LOG

GE

D O

RIF

ICE

FIL

TE

R

• C

LOG

GE

D P

ILO

T F

ILT

ER

• LO

W G

AS

SU

PP

LY P

RE

SS

UR

E

• P

ILO

T A

DJU

ST

ME

NT

AT

MIN

IMU

M

CH

EC

K F

OR

LA

CK

OF

AIR

FR

OM

:

• D

IRT

Y O

RIF

ICE

• D

IRT

Y L

INT

SC

RE

EN

, IF

US

ED

• D

IRT

Y P

RIM

AR

Y A

IR O

PE

NIN

G,

IF

TH

ER

E IS

ON

E

• P

ILO

T A

DJU

ST

ME

NT

AT

MIN

IMU

M

CH

EC

K F

OR

:

• E

XC

ES

SIV

E D

RA

FT

AT

PIL

OT

L

OC

AT

ION

• R

EC

IRC

ULA

TIN

G P

RO

DU

CT

S O

F C

OM

BU

ST

ION

CH

EC

K F

OR

:

• H

IGH

GA

S P

RE

SS

UR

E

TH

IS F

LAM

E IS

CH

AR

AC

TE

RIS

TIC

O

F M

AN

UF

AC

TU

RE

D G

AS

CH

EC

K F

OR

:

• H

IGH

GA

S P

RE

SS

UR

E

• O

RIF

ICE

TO

O S

MA

LL

M22

33A

AP

PE

AR

AN

CE

CA

US

E

TR

IAL

FO

R IG

NIT

ION

Pilo

t Ig

nit

ion

Fol

low

ing

prep

urge

tim

ing

(S86

70),

or o

n th

e ca

ll fo

r hea

t(S

8610

), th

e m

odul

e en

ergi

zes

the

first

mai

n va

lve

oper

a-to

r. T

he fi

rst m

ain

valv

e op

ens,

whi

ch a

llow

s ga

s to

flow

toth

e pi

lot

burn

er.

At

the

sam

e tim

e, t

he e

lect

roni

c sp

ark

gene

rato

r in

the

mod

ule

prod

uces

an

over

10,

000

volt

spar

kpu

lse

outp

ut. T

he v

olta

ge g

ener

ates

a s

park

at t

he ig

nite

r(S

8610

A,B

) or i

gnite

r-se

nsor

(S86

10F

,H; S

8670

) tha

t lig

hts

the

pilo

t.If

the

pilo

t doe

s no

t lig

ht, o

r the

pilo

t fla

me

curr

ent i

s no

tat

leas

t 1.0

µA

and

ste

ady,

the

mod

ule

will

not

ene

rgiz

e th

ese

cond

(m

ain)

val

ve a

nd t

he m

ain

burn

er w

ill n

ot l

ight

.S

8610

A,F

will

con

tinue

to s

park

as

long

as

the

ther

mos

tat

calls

for

heat

, or

until

the

pilo

t lig

hts.

Saf

ety

Lo

cko

ut

(S86

10B

,H;

S86

70D

)T

hese

mod

ules

pro

vide

100

per

cent

shu

toff

and

safe

tylo

ckou

t. A

tim

er in

thes

e m

odel

s st

arts

tim

ing

the

mom

ent

the

tria

l for

igni

tion

star

ts. I

gniti

on s

park

con

tinue

s on

ly u

ntil

the

timed

tria

l fo

r ig

nitio

n pe

riod

ends

. T

hen

the

mod

ule

goes

int

o sa

fety

loc

kout

. Lo

ckou

t de

-ene

rgiz

es t

he f

irst

mai

n va

lve

oper

ator

and

clo

ses

the

first

mai

n (p

ilot)

val

ve in

the

gas

cont

rol,

stop

ping

pilo

t gas

flow

. The

con

trol

sys

tem

mus

t be

res

et b

y se

tting

the

the

rmos

tat

belo

w r

oom

tem

-pe

ratu

re f

or o

ne m

inut

e or

by

turn

ing

off

pow

er t

o th

em

odul

e fo

r on

e m

inut

e.

MA

IN B

UR

NE

R O

PE

RA

TIO

NW

hen

the

pilo

t fla

me

is e

stab

lishe

d, a

flam

e re

ctifi

catio

nci

rcui

t is

com

plet

ed b

etw

een

the

sens

or a

nd b

urne

r gro

und.

The

flam

e se

nsin

g ci

rcui

t in

the

mod

ule

dete

cts

the

flam

ecu

rren

t, sh

uts

off

the

spar

k ge

nera

tor,

and

ene

rgiz

es t

hese

cond

mai

n va

lve

oper

ator

. The

sec

ond

mai

n va

lve

open

san

d ga

s flo

ws

to th

e m

ain

burn

er, w

here

it is

igni

ted

by th

epi

lot

burn

er.

On

lock

out

mod

els,

the

fla

me

curr

ent

also

hold

s th

e sa

fety

lock

out t

imer

in th

e re

set (

norm

al)

oper

at-

ing

cond

ition

.W

hen

the

call

for h

eat e

nds,

bot

h va

lve

oper

ator

s ar

e de

-en

ergi

zed,

and

bot

h va

lves

in th

e ga

s co

ntro

l clo

se.

Fig

. 13—

S86

70 n

orm

al o

per

atin

g s

equ

ence

.

6

9-05

23 1

5

M55

0

ST

AR

TT

HE

RM

OS

TA

T

PR

EP

UR

GE

SP

AR

K G

EN

ER

AT

OR

PO

WE

RE

D

PIL

OT

BU

RN

ER

OP

ER

AT

ION

OR

Pilo

t bur

ner

light

s.S

8670

sen

ses

flam

e cu

rren

t.P

ilot b

urne

r do

es n

ot li

ght.

Afte

r 15

or

90 s

ec

, sys

tem

lock

s ou

t; m

ust b

e m

anua

lly r

eset

.

Lo

ckou

t tim

ing

is

stam

ped

on m

odul

e.

a

a

ST

AG

E 1

PR

EP

UR

GE

ST

AG

E 2

TR

IAL

FO

R IG

NIT

ION

ST

AG

E 3

MA

IN B

UR

NE

R

OP

ER

AT

ION

EN

D

FL

AM

E C

UR

RE

NT

SE

NS

ED

MA

IN B

UR

NE

R O

PE

RA

TIO

NM

odul

e m

onito

rs p

ilot f

lam

e cu

rren

t.

TH

ER

MO

ST

AT

SA

TIS

FIE

DV

alve

s cl

ose,

pilo

t and

mai

n bu

rner

s ar

e of

f.

PO

WE

R IN

TE

RR

UP

TIO

NS

yste

m s

huts

off,

res

tart

s w

hen

pow

er is

re

stor

ed.

PIL

OT

FL

AM

E F

AIL

UR

EM

ain

valv

e cl

oses

.S

8670

sta

rts

tria

l for

igni

tion.

Spa

rk g

ener

ator

off.

Sec

ond

valv

e op

erat

or (

mai

n)

open

s.

• •

1 2 3 4 5 6 7

CA

LL

S F

OR

HE

AT

Com

bust

ion

air

blow

er s

tart

s.

Firs

t val

ve (

pilo

t) o

pera

tor

open

s.

Fig

. 16—

S86

70 t

rou

ble

sho

oti

ng

gu

ide.

18

• •

Che

ck c

ontin

uity

of i

gniti

on c

able

and

gro

und

wire

.N

OT

E: I

f gro

und

is p

oor

or e

rrat

ic, s

hutd

owns

may

occ

ur o

ccas

iona

lly e

ven

thou

gh o

pera

tion

is n

orm

al a

t the

tim

e of

che

ckou

t.If

chec

ks a

re o

kay,

rep

lace

mod

ule.

M11

73B

ST

AR

T

Che

ck li

ne v

olta

ge p

ower

, low

vol

tage

tran

sfor

mer

, lim

it co

ntro

ller,

ther

mos

tat a

nd w

iring

. A

lso,

che

ck a

ir pr

ovin

g sw

itch

on c

ombu

stio

n ai

r bl

ower

sys

tem

and

that

ven

t dam

per

(if u

sed)

is o

pen

and

end

switc

h is

m

ade.

NO

TE

: B

efor

e tr

oubl

esho

otin

g, fa

mili

ariz

e yo

urse

lf w

ith th

e st

artu

p an

d ch

ecko

ut p

roce

dure

.

NO

TU

RN

GA

S S

UP

PLY

OF

F.

TU

RN

TH

ER

MO

ST

AT

TO

C

ALL

FO

R H

EA

T

PO

WE

R T

O M

OD

ULE

(24V

NO

MIN

AL)

YE

S

Rep

lace

S86

70.

NO

45 S

EC

ON

DD

ELA

Y

YE

S

SP

AR

K A

CR

OS

SIG

NIT

ER

/SE

NS

OR

GA

PP

ull i

gniti

on le

ad a

nd c

heck

sp

ark

at S

8670

.R

epla

ce m

odul

e.

Spa

rk o

kay?

Che

ck ig

nitio

n ca

ble,

gro

und

wiri

ng, c

eram

ic in

sula

tor

and

gap,

and

cor

rect

.C

heck

boo

t of t

he ig

nitio

n ca

ble

for

sign

s of

mel

ting

or b

uckl

ing.

Tak

e pr

otec

tive

actio

n to

shi

eld

cabl

e an

d bo

ot fr

om e

xces

sive

tem

pera

ture

s.

YE

S

YE

S

Che

ck th

at a

ll m

anua

l gas

coc

ks a

re o

pen,

sup

ply

tubi

ng a

nd p

ress

ures

are

goo

d, a

nd p

ilot b

urne

r or

ifice

is

not b

lock

ed.

Che

ck e

lect

rical

con

nect

ions

bet

wee

n m

odul

e an

d pi

lot o

pera

tor

on g

as c

ontr

ol.

Che

ck fo

r 24

Vac

acr

oss

PV

-MV

/PV

term

inal

s on

mod

ule;

If v

olta

ge is

oka

y, r

epla

ce g

as c

ontr

ol; i

f no

volta

ge, r

epla

ce m

odul

e.

NO

TU

RN

GA

S S

UP

PLY

ON

YE

S

PIL

OT

BU

RN

ER

LIG

HT

S?

• • •

NO

SP

AR

K S

TO

PS

WH

EN

P

ILO

T IS

LIT

?

YE

S

• •

NO

TE

: If m

odul

e go

es in

to lo

ckou

t, re

set s

yste

m.

• • • • • • •

Che

ck c

ontin

uity

of i

gniti

on c

able

and

gro

und

wire

.C

lean

flam

e ro

d.C

heck

ele

ctric

al c

onne

ctio

ns b

etw

een

flam

e ro

d an

d m

odul

e.C

heck

for

crac

ked

cera

mic

flam

e ro

d in

sula

tor.

Che

ck th

at p

ilot f

lam

e co

vers

flam

e ro

d an

d is

ste

ady

and

blue

.A

djus

t pilo

t fla

me.

If ch

ecks

are

oka

y, r

epla

ce m

odul

e.

NO

MA

IN B

UR

NE

R L

IGH

TS

?

YE

S

Che

ck fo

r 24

Vac

(no

min

al)

acro

ss M

V-M

V/P

V te

rmin

als.

if n

o vo

ltage

, rep

lace

mod

ule.

Che

ck e

lect

rical

con

nect

ions

bet

wee

n m

odul

e an

d ga

s co

ntro

l. If

okay

, rep

lace

gas

con

trol

.

NO

SY

ST

EM

RU

NS

UN

TIL

C

ALL

FO

R H

EA

T E

ND

S?

YE

S

NO

TE

: If m

odul

e go

es in

to lo

ckou

t, re

set s

yste

m.

• •

Che

ck fo

r pr

oper

ther

mos

tat (

cont

rolle

r) o

pera

tion.

Rem

ove

MV

lead

at m

odul

e; if

val

ve c

lose

s, r

eche

ck te

mpe

ratu

re c

ontr

olle

r an

d w

iring

; if n

ot, r

epla

ce g

as

cont

rol.

NO

CA

LL F

OR

HE

AT

EN

DS

YE

S

SY

ST

EM

SH

UT

S O

FF

?• •

TR

OU

BLE

SH

OO

TIN

G

EN

DS

Rep

eat p

roce

dure

unt

il tr

oubl

efre

e op

erat

ion

is o

btai

ned.

NO

NO

•M

ake

sure

ele

ctric

al c

onne

ctio

ns a

re c

lean

and

tigh

t.R

epla

ce d

amag

ed w

ire w

ith m

oist

ure-

resi

stan

t N

o.18

wire

rat

ed f

or c

ontin

uous

dut

y up

to

105°

C[2

21°

F].

•C

heck

for c

rack

ed c

eram

ic in

sula

tor,

whi

ch c

an c

ause

shor

t to

grou

nd, a

nd re

plac

e ig

nite

r-se

nsor

if n

eces

-sa

ry.

•A

t the

gas

con

trol

, dis

conn

ect m

ain

valv

e w

ire fr

omth

e T

H o

r M

V te

rmin

al.

•T

urn

on p

ower

and

set

ther

mos

tat t

o ca

ll fo

r hea

t. T

hepi

lot s

houl

d lig

ht b

ut th

e m

ain

burn

er w

ill r

emai

n of

fbe

caus

e th

e m

ain

valv

e ac

tuat

or is

dis

conn

ecte

d.•

Che

ck th

e pi

lot f

lam

e. M

ake

sure

it is

blu

e, s

tead

y an

den

velo

ps 3

/8 to

1/2

inch

[10

to 1

3 m

m] o

f the

flam

ero

d. S

ee F

ig. 1

4 fo

r pos

sibl

e fla

me

prob

lem

s an

d th

eir

caus

es.

•If

nece

ssar

y, a

djus

t pi

lot

flam

e by

tur

ning

the

pilo

t

adju

stm

ent s

crew

on

the

gas

cont

rol c

lock

wis

eto

decr

ease

or c

ount

ercl

ockw

ise

to in

crea

se p

ilot

flam

e. F

ollo

win

g ad

just

men

t, al

way

s re

plac

e pi

lot

adju

stm

ent c

over

scr

ew a

nd ti

ghte

n fir

mly

to a

ssur

epr

oper

gas

con

trol

ope

ratio

n.•

Set

the

rmos

tat

belo

w r

oom

tem

pera

ture

to

end

call

for

heat

.■

Rec

heck

igni

tion

sequ

ence

as

follo

ws.

•R

econ

nect

mai

n va

lve

wire

.•

Set

ther

mos

tat t

o ca

ll fo

r he

at.

•W

atch

igni

tion

sequ

ence

at b

urne

r.•

If sp

ark

still

doe

sn’t

stop

afte

r pi

lot

light

s, r

epla

ceig

nitio

n m

odul

e.•

If m

ain

burn

er d

oesn

’t lig

ht o

r if m

ain

burn

er li

ghts

but

syst

em lo

cks

out,

chec

k m

odul

e, g

roun

d w

ire,

and

gas

cont

rol a

s de

scrib

ed in

app

ropr

iate

trou

bles

hoot

-in

g ch

art,

Fig

. 15

or 1

6.

Fig

. 15—

S86

10 t

rou

ble

sho

oti

ng

gu

ide.

1769

-052

3

Che

ck c

ontin

uity

of i

gniti

on c

able

and

gro

und

wire

.N

OT

E: I

f gro

und

is p

oor

or e

rrat

ic, s

hutd

owns

may

occ

ur o

ccas

iona

lly e

ven

thou

gh o

pera

tion

is n

orm

al a

t th

e tim

e of

che

ckou

t.C

heck

that

pilo

t fla

me

cove

rs fl

ame

rod

and

is s

tead

y an

d bl

ue.

If ch

ecks

are

oka

y, r

epla

ce m

odul

e.

M55

1

ST

AR

T

Che

ck li

ne v

olta

ge p

ower

, low

vol

tage

tran

sfor

mer

, lim

it co

ntro

ller,

ther

mos

tat

(con

trol

ler)

and

wiri

ng.

Als

o,

chec

k ai

r pr

ovin

g sw

itch

on c

ombu

stio

n ai

r bl

ower

sys

tem

(if

used

) an

d th

at v

ent d

ampe

r (if

use

d) is

ope

n an

d en

d sw

itch

is m

ade.

NO

TE

: B

efor

e tr

oubl

esho

otin

g, fa

mili

ariz

e yo

urse

lf w

ith th

e st

artu

p an

d ch

ecko

ut p

roce

dure

.

NO

TU

RN

GA

S S

UP

PLY

OF

F.

TU

RN

TH

ER

MO

ST

AT

(C

ON

TR

OLL

ER

) T

O C

ALL

F

OR

HE

AT

PO

WE

R T

O M

OD

ULE

(24V

NO

MIN

AL)

YE

S

SP

AR

K A

CR

OS

SIG

NIT

ER

/SE

NS

OR

GA

P

Pul

l ign

ition

lead

and

ch

eck

spar

k at

mod

ule.

NO

On

mod

els

with

ven

t dam

per

plug

, mak

e su

re v

ent d

ampe

r ha

s no

t bee

n in

stal

led,

then

rem

oved

. R

epla

ce v

ent d

ampe

r if

nece

ssar

y.O

n ot

her

mod

els,

rep

lace

mod

ule.

Spa

rk o

kay?

NO

Che

ck ig

nitio

n ca

ble,

gro

und

wiri

ng, c

eram

ic in

sula

tor

and

gap,

and

cor

rect

.C

heck

boo

t of t

he ig

nitio

n ca

ble

for

sign

s of

mel

ting

or b

uckl

ing.

Tak

e pr

otec

tive

actio

n to

shi

eld

cabl

e an

d bo

ot fr

om e

xces

sive

tem

pera

ture

s.

YE

S

YE

S

Che

ck th

at a

ll m

anua

l gas

val

ves

are

open

, sup

ply

tubi

ng a

nd p

ress

ures

are

goo

d, a

nd p

ilot b

urne

r or

ifice

is

not

blo

cked

.C

heck

ele

ctric

al c

onne

ctio

ns b

etw

een

mod

ule

and

pilo

t ope

rato

r on

gas

con

trol

.C

heck

for

24 V

ac a

cros

s P

V-M

V/P

V te

rmin

als

on m

odul

e. If

vol

tage

is o

kay,

rep

lace

gas

con

trol

; if n

ot,

repl

ace

mod

ule.

NO

TU

RN

GA

S S

UP

PLY

ON

YE

S

PIL

OT

BU

RN

ER

LIG

HT

S?

• • •

NO

SP

AR

K S

TO

PS

WH

EN

P

ILO

T IS

LIT

?

YE

S

• •

NO

TE

: If S

8610

B,H

goe

s in

to lo

ckou

t, re

set s

yste

m.

• • • • • • •

Che

ck c

ontin

uity

of i

gniti

on c

able

and

gro

und

wire

.C

lean

flam

e ro

d.C

heck

ele

ctric

al c

onne

ctio

ns b

etw

een

flam

e ro

d an

d m

odul

e.C

heck

for

crac

ked

cera

mic

flam

e ro

d in

sula

tor.

Che

ck th

at p

ilot f

lam

e co

vers

flam

e ro

d an

d is

ste

ady

and

blue

.A

djus

t pilo

t fla

me.

If pr

oble

m p

ersi

sts,

rep

lace

mod

ule.

NO

MA

IN B

UR

NE

R L

IGH

TS

?

YE

S

Che

ck fo

r 24

Vac

acr

oss

MV

-MV

/PV

term

inal

s. I

f no

volta

ge, r

epla

ce m

odul

e.C

heck

ele

ctric

al c

onne

ctio

ns b

etw

een

mod

ule

and

gas

cont

rol.

If ok

ay, r

epla

ce g

as c

ontr

ol o

r ga

s co

ntro

l op

erat

or.

• •

NO

SY

ST

EM

RU

NS

UN

TIL

C

ALL

FO

R H

EA

T E

ND

S?

YE

S

NO

TE

: If S

8610

B,H

goe

s in

to lo

ckou

t, re

set s

yste

m.

• • •

Che

ck fo

r pr

oper

ther

mos

tat (

cont

rolle

r) o

pera

tion.

Rem

ove

MV

lead

at m

odul

e; if

val

ve c

lose

s, r

eche

ck te

mpe

ratu

re c

ontr

olle

r an

d w

iring

; if n

ot, r

epla

ce g

as

cont

rol.

NO

CA

LL F

OR

HE

AT

EN

DS

YE

S

SY

ST

EM

SH

UT

S O

FF

?• •

TR

OU

BLE

SH

OO

TIN

G

EN

DS

Rep

eat p

roce

dure

unt

il tr

oubl

efre

e op

erat

ion

is o

btai

ned.

• •

Fig

. 18—

Rep

rese

nta

tive

sch

emat

ic f

or

S86

10A

,B. S

ee F

ig. 3

fo

r h

oo

kup

.

20

L1 (HO

T)

L21

24V

TR

AN

SF

OR

ME

R

LIM

ITC

ON

TR

OLL

ER

ON

-OF

FS

WIT

CH

24V

2

TH

ER

MO

ST

AT

OR

CO

NT

RO

LLE

R

24V

(GN

D)

1K1

1K2

3K2

2K2

3K1

GN

D(B

UR

-N

ER

)

MV

/P

VM

V

PV

IGN

ITE

R

BU

RN

ER

GR

OU

ND

1 2

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

DP

RO

TE

CT

ION

AS

RE

QU

IRE

D.

ALT

ER

NA

TE

LIM

IT C

ON

TR

OLL

ER

LO

CA

TIO

N.

3K R

ELA

Y O

N 1

00 P

ER

CE

NT

SH

UT

OF

F M

OD

ELS

ON

LY.

ON

NO

N-S

HU

TO

FF

MO

DE

LS, P

V A

ND

M

V W

IRE

D A

S F

OLL

OW

S.

INT

ER

NA

L W

IRIN

GE

XT

ER

NA

L W

IRIN

G

M11

66B

SP

AR

KD

RIV

EC

IRC

UIT

2K1

FLA

ME

DE

TE

CT

OR

CIR

CU

IT

RE

LAY

DR

IVE

RS

TIM

ING

CIR

CU

ITS

LOW

VO

LTA

GE

PO

WE

RS

UP

PLY

1K 2K 3K

HY

BR

ID C

IRC

UIT

AR

CG

AP

SP

AR

K

SE

NS

ES

EN

SO

R

MA

INV

ALV

E

PIL

OT

VA

LVE

1K1

1K2

2K2

MV

/P

VM

V

PV

MA

INV

ALV

E

PIL

OT

V

ALV

ETO

24V

(G

ND

)T

O 2

4V

3

3

Fig

. 17—

Rep

rese

nta

tive

sch

emat

ic f

or

S86

10F

,H. S

ee F

ig. 1

fo

r h

oo

kup

. S86

70 is

sim

ilar

exce

pt

the

tim

ing

cir

cuit

incl

ud

es a

pu

rge

tim

er. S

ee F

ig. 6

fo

r h

oo

kup

. 1969

-052

3

L1 (HO

T)

L21

24V

TR

AN

SF

OR

ME

R

LIM

ITC

ON

TR

OLL

ER

ON

-OF

FS

WIT

CH

24V

2

TH

ER

MO

ST

AT

OR

CO

NT

RO

LLE

R

24V

(GN

D)

SP

AR

KD

RIV

EC

IRC

UIT

2K1

FLA

ME

DE

TE

CT

OR

CIR

CU

IT

RE

LAY

DR

IVE

RS

TIM

ING

CIR

CU

ITS

LOW

VO

LTA

GE

PO

WE

RS

UP

PLY

1K 2K 3K

HY

BR

ID C

IRC

UIT

1K1

1K2

3K2

2K2

3K1

AR

CG

AP

SP

AR

KG

ND

(BU

R-

NE

R)

MV

/P

VM

V

PV

BU

RN

ER

GR

OU

ND

1 2

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

ALT

ER

NA

TE

LIM

IT C

ON

TR

OLL

ER

LO

CA

TIO

N.

3K R

ELA

Y O

N 1

00 P

ER

CE

NT

SH

UT

OF

F M

OD

ELS

ON

LY.

ON

NO

N-S

HU

TO

FF

MO

DE

LS, P

V A

ND

MV

W

IRE

D A

S F

OLL

OW

S.

INT

ER

NA

L W

IRIN

GE

XT

ER

NA

L W

IRIN

G

M11

65B

MA

INV

ALV

E

PIL

OT

V

ALV

E

IGN

ITE

RS

EN

SO

R

1K1

1K2

2K2

3

MV

/P

VM

V

PV

MA

INV

ALV

E

PIL

OT

V

ALV

ETO

24V

(G

ND

)T

O 2

4V

3

EX

HIB

IT B

PR

OC

ED

UR

E F

OR

INS

TA

LL

ING

AU

TO

MA

TIC

INT

ER

MIT

TE

NT

PIL

OT

SY

ST

EM

S

Prio

r to

beg

inni

ng t

his

proc

edur

e, a

pre

limin

ary

ex-

amin

atio

n of

the

appl

ianc

e an

d th

e au

tom

atic

inte

rmit-

tent

pilo

t sys

tem

sho

uld

be m

ade

to d

eter

min

e th

at th

eau

tom

atic

int

erm

itten

t pi

lot

syst

em c

an b

e pr

oper

lyap

plie

d to

the

appl

ianc

e.T

his

proc

edur

e is

inte

nded

as

a gu

ide

to a

id in

saf

ely

inst

allin

g a

liste

d au

tom

atic

inte

rmitt

ent p

ilot s

yste

m o

nan

exi

stin

g lis

ted

appl

ianc

e eq

uipp

ed w

ith a

n at

mos

-ph

eric

gas

bur

ner(

s) a

nd n

ot o

f the

dire

ct v

ent t

ype.

Thi

s pr

oced

ure

is b

ased

on

the

assu

mpt

ion

that

the

hist

ory

of th

e sp

ecifi

c in

stal

latio

n ha

s be

en o

ne o

f saf

ean

d sa

tisfa

ctor

y op

erat

ion.

Thi

s pr

oced

ure

is p

redi

cate

d on

cen

tral

furn

ace

and

boile

r in

stal

latio

ns,

and

it sh

ould

be

reco

gniz

ed t

hat

gene

raliz

ed p

roce

dure

s ca

nnot

ant

icip

ate

all s

ituat

ions

.A

ccor

ding

ly, i

n so

me

case

s, d

evia

tion

from

this

pro

ce-

dure

may

be

nece

ssar

y to

det

erm

ine

safe

ope

ratio

n of

the

equi

pmen

t.T

he fo

llow

ing

step

s sh

ould

be

follo

wed

in m

akin

g th

em

odifi

catio

ns:

1. P

erfo

rm a

saf

ety

insp

ectio

n of

the

exis

ting

appl

i-an

ce i

nsta

llatio

n. S

ee E

xhib

it A

for

a r

ecom

men

ded

proc

edur

e fo

r su

ch a

saf

ety

insp

ectio

n.

2. S

hut o

ff al

l gas

and

ele

ctric

ity to

the

appl

ianc

e. T

osh

ut o

ff ga

s, u

se th

e sh

utof

f val

ve in

the

supp

ly li

ne to

the

appl

ianc

e. D

o no

t us

e th

e sh

utof

f va

lve

whi

ch i

s pr

o-vi

ded

as p

art o

f a c

ombi

natio

n co

ntro

l.

3. I

nsta

ll th

e au

tom

atic

int

erm

itten

t pi

lot

syst

em i

nst

rict

acco

rdan

ce w

ith t

he m

anuf

actu

rer’s

ins

talla

tion

inst

ruct

ions

.

4. T

urn

on a

ll ga

s an

d el

ectr

icity

to th

e ap

plia

nce.

5. D

eter

min

e th

at t

he a

pplia

nce

tran

sfor

mer

has

adeq

uate

cap

acity

by

follo

win

g th

e st

eps

outli

ned

be-

low

: a.C

ompu

te th

e ap

prox

imat

e cu

rren

t dra

w b

y ad

ding

the

curr

ent

draw

of

the

auto

mat

ic i

nter

mitt

ent

pilo

tsy

stem

to

(1)

the

curr

ent

draw

of

the

asso

ciat

edva

lvin

g, a

nd (

2) t

he c

urre

nt d

raw

of

any

rela

ys o

rot

her

devi

ces

oper

ated

by

the

tran

sfor

mer

.b.

Mul

tiply

the

tota

l cur

rent

dra

w a

s co

mpu

ted

abov

eby

24

V t

o de

term

ine

the

tota

l V

A (

volt-

ampe

re)

requ

ired.

c.T

he t

otal

VA

(vo

lt-am

pere

) re

quire

d sh

ould

be

equa

l to

or le

ss th

an th

e V

A ra

ting

of th

e tr

ansf

orm

er.

d.If

the

tota

l V

A (

volt-

ampe

re)

requ

ired

is g

reat

erth

an th

e V

A ra

ting

of th

e tr

ansf

orm

er, t

he tr

ansf

orm

erm

ust

be r

epla

ced

with

a C

lass

2 t

rans

form

er o

fad

equa

te r

atin

g.

6. C

heck

the

heat

ant

icip

ator

in th

e co

mfo

rt th

erm

o-st

at to

det

erm

ine

if it

is p

rope

rly a

djus

ted

to th

e cu

rren

tdr

aw o

f th

e co

ntro

l sy

stem

. F

ollo

w t

he t

herm

osta

tm

anuf

actu

rer’s

inst

ruct

ions

.

7.M

ake

cert

ain

wiri

ng c

onne

ctio

ns a

re t

ight

and

wire

s ar

e po

sitio

ned

and

secu

red

so th

ey w

ill n

ot b

e ab

leto

con

tact

hig

h te

mpe

ratu

re lo

catio

ns.

8.C

ondu

ct a

Gas

Lea

kage

Tes

t of

the

app

lianc

epi

ping

and

con

trol

sys

tem

dow

nstr

eam

of

the

shut

off

valv

e in

the

supp

ly li

ne to

the

appl

ianc

e.

9.a.

Adj

ust

the

ther

mos

tat

to i

ts h

ighe

st t

empe

ra-

ture

set

ting,

and

test

man

ifold

pre

ssur

e an

d ad

just

the

pres

sure

reg

ulat

or t

o m

atch

orig

inal

inpu

t as

requ

ired

(ref

er to

Exh

ibit

A, s

tep

9b).

b.V

isua

lly d

eter

min

e th

at m

ain

burn

er is

bur

ning

prop

erly

; i.e

., no

floa

ting,

lifti

ng o

r fla

shba

ck. A

d-ju

st th

e pr

imar

y ai

r sh

utte

r(s)

as

requ

ired.

10.

If th

e ap

plia

nce

is e

quip

ped

with

hig

h an

d lo

wfla

me

cont

rol o

r fla

me

mod

ulat

ion,

che

ck fo

r pro

per m

ain

burn

er o

pera

tion

at b

oth

high

and

low

flam

e.

11.

Det

erm

ine

that

the

pilo

t is

ign

iting

and

bur

ning

prop

erly

and

that

mai

n bu

rner

igni

tion

is s

atis

fact

ory

byin

terr

uptin

g an

d re

-est

ablis

hing

the

ele

ctric

al s

uppl

y to

the

appl

ianc

e in

any

con

veni

ent

man

ner.

Mak

e th

isde

term

inat

ion

with

the

app

lianc

e bu

rner

bot

h co

ld a

ndho

t. P

erfo

rm th

is s

tep

as m

any

times

as

is n

eces

sary

tosa

tisfy

you

rsel

f tha

t the

aut

omat

ic in

term

itten

t pilo

t sys

-te

m is

ope

ratin

g pr

oper

ly.

12.

Tes

t the

pilo

t saf

ety

devi

ce (

1) to

det

erm

ine

if it

isop

erat

ing

prop

erly

, and

(2)

for

turn

dow

n ch

arac

teris

tics

acco

rdin

g to

the

man

ufac

ture

r’s in

stal

latio

n in

stru

ctio

ns.

No

adju

stm

ents

sho

uld

be m

ade

othe

r th

an t

hose

rec

-om

men

ded

by th

e sy

stem

man

ufac

ture

r.

13.

Seq

uenc

e th

e ap

plia

nce

thro

ugh

at l

east

thr

eeop

erat

ing

cycl

es.

14.

App

licab

le o

nly

to f

urna

ces.

Che

ck b

oth

the

limit

cont

rolle

r an

d th

e fa

n co

ntro

ller

for

prop

er o

pera

tion.

Lim

it co

ntro

l ope

ratio

n ca

n be

che

cked

by

bloc

king

the

circ

ulat

ing

air

inle

t or

tem

pora

rily

disc

onne

ctin

g th

eel

ectr

ical

sup

ply

to t

he b

low

er m

otor

and

det

erm

inin

gth

at t

he li

mit

cont

rolle

r ac

ts t

o sh

ut o

ff th

e m

ain

burn

erga

s. 15.

App

licab

le o

nly

to b

oile

rs.

a.D

eter

min

e th

at th

e ci

rcul

atin

g w

ater

pum

ps a

rein

ope

ratin

g co

nditi

on.

b.T

est

low

wat

er c

utof

fs,

auto

mat

ic f

eed

wat

erco

ntro

ls,

pres

sure

and

tem

pera

ture

lim

it co

ntro

l-le

rs a

nd r

elie

f va

lves

in

acco

rdan

ce w

ith t

hem

anuf

actu

rer’s

rec

omm

enda

tion

to d

eter

min

eth

ey a

re in

ope

ratin

g co

nditi

on.

16.

Add

the

labe

ls (

see

1.6.

1-n

and

-o)

on t

he a

ppli-

ance

.

EX

HIB

IT B

OF

AN

SI S

TA

ND

AR

D Z

21.7

1 F

OR

AU

TO

MA

TIC

INT

ER

MIT

TE

NT

PIL

OT

IGN

ITIO

N S

YS

TE

MS

FO

R F

IEL

DIN

ST

AL

LA

TIO

N.

22

EX

HIB

IT A

RE

CO

MM

EN

DE

D P

RO

CE

DU

RE

FO

R S

AF

ET

Y IN

SP

EC

TIO

N O

F A

N E

XIS

TIN

GA

PP

LIA

NC

E IN

ST

AL

LA

TIO

N A

S A

PR

EL

IMIN

AR

Y S

TE

P T

O A

PP

LY

ING

AN

AU

TO

MA

TIC

INT

ER

MIT

TE

NT

PIL

OT

SY

ST

EM

The

follo

win

g pr

oced

ure

is in

tend

ed a

s a

guid

e to

aid

in d

eter

min

ing

that

an

appl

ianc

e is

pro

perly

inst

alle

d an

dis

in a

saf

e co

nditi

on fo

r co

ntin

uing

use

.T

his

proc

edur

e is

pre

dica

ted

on c

entr

al fu

rnac

e an

dbo

iler

inst

alla

tions

equ

ippe

d w

ith a

n at

mos

pher

ic g

asbu

rner

(s)

and

not

of t

he d

irect

ven

t ty

pe.

It sh

ould

be

reco

gniz

ed t

hat

gene

raliz

ed t

est

proc

edur

es c

anno

tan

ticip

ate

all

situ

atio

ns.

Acc

ordi

ngly

, in

som

e ca

ses,

devi

atio

n fr

om t

his

proc

edur

e m

ay b

e ne

cess

ary

tode

term

ine

safe

ope

ratio

n of

the

equi

pmen

t.a.

Thi

s pr

oced

ure

shou

ld b

e pe

rfor

med

prio

r to

any

atte

mpt

at m

odifi

catio

n of

the

appl

ianc

e or

the

inst

al-

latio

n.b.

If it

is d

eter

min

ed th

ere

is a

con

ditio

n w

hich

cou

ldre

sult

in u

nsaf

e op

erat

ion,

the

app

lianc

e sh

ould

be

shut

off

and

the

owne

r ad

vise

d of

the

unsa

fe c

ondi

-tio

n.T

he fo

llow

ing

step

s sh

ould

be

follo

wed

in m

akin

g th

esa

fety

insp

ectio

n:

1. C

ondu

ct a

Gas

Lea

kage

Tes

t of

the

app

lianc

epi

ping

and

con

trol

sys

tem

dow

nstr

eam

of

the

shut

off

valv

e in

the

supp

ly li

ne to

the

appl

ianc

e.

2. V

isua

lly in

spec

t the

ven

ting

syst

em fo

r pro

per s

ize

and

horiz

onta

l pitc

h an

d de

term

ine

ther

e is

no

bloc

kage

or re

stric

tions

, lea

kage

or c

orro

sion

or o

ther

def

icie

ncie

sw

hich

cou

ld c

ause

an

unsa

fe c

ondi

tion.

3. S

hut

off

all g

as t

o th

e ap

plia

nce

and

shut

off

any

othe

r fue

l-bur

ning

app

lianc

e w

ithin

the

sam

e ro

om. U

seth

e sh

utof

f val

ve in

the

shut

off v

alve

in th

e su

pply

line

toea

ch a

pplia

nce.

4. In

spec

t bur

ners

and

cro

ssov

ers

for

bloc

kage

and

corr

osio

n.

5. A

pplic

able

onl

y to

war

m a

ir he

atin

g ap

plia

nces

.In

spec

t hea

t exc

hang

ers

for c

rack

s, o

peni

ngs

or e

xces

-si

ve c

orro

sion

.

6.A

pplic

able

onl

y to

boi

lers

. Ins

pect

for

evid

ence

of

wat

er o

r co

mbu

stio

n pr

oduc

t lea

ks.

7. In

sofa

r as

is p

ract

ical

, clo

se a

ll bu

ildin

g do

ors

and

win

dow

s an

d al

l doo

rs b

etw

een

the

spac

e in

whi

ch th

eap

plia

nce

is lo

cate

d an

d ot

her

spac

es o

f th

e bu

ildin

g.T

urn

on c

loth

es d

ryer

s. T

urn

on a

ny e

xhau

st fa

ns, s

uch

as r

ange

hoo

ds a

nd b

athr

oom

exh

aust

s, s

o th

ey w

ill

oper

ate

at m

axim

um s

peed

. Do

not o

pera

te a

sum

mer

exha

ust f

an. C

lose

fire

plac

e da

mpe

rs. I

f, af

ter

com

plet

-in

g st

eps

7 th

roug

h 12

, it i

s be

lieve

d su

ffici

ent c

ombu

s-tio

n ai

r is

not a

vaila

ble,

refe

r to

1.3.

4 of

the

Nat

iona

l Fue

lG

as C

ode

(Z22

3.1)

for

guid

ance

.

EX

HIB

IT A

OF

AN

SI S

TA

ND

AR

D Z

21.7

1 F

OR

AU

TO

MA

TIC

INT

ER

MIT

TE

NT

PIL

OT

IGN

ITIO

N S

YS

TE

MS

FO

R F

IEL

DIN

ST

AL

LA

TIO

N

8.P

lace

in o

pera

tion

the

appl

ianc

e be

ing

insp

ecte

d.F

ollo

w t

he l

ight

ing

inst

ruct

ions

. A

djus

t th

erm

osta

t so

appl

ianc

e w

ill o

pera

te c

ontin

uous

ly.

9.a.

Det

erm

ine

that

the

pilo

t is

burn

ing

prop

erly

and

that

mai

n bu

rner

igni

tion

is s

atis

fact

ory

by in

ter-

rupt

ing

and

re-e

stab

lishi

ng th

e el

ectr

ical

sup

ply

toth

e ap

plia

nce

in a

ny c

onve

nien

t man

ner.

b.D

eter

min

e m

anifo

ld p

ress

ure

in o

rder

to m

atch

inpu

t afte

r th

e ne

w c

ontr

ol is

inst

alle

d.

a.V

isua

lly d

eter

min

e th

at m

ain

burn

er g

as is

bur

n-in

g pr

oper

ly;

i.e.,

no f

loat

ing,

lifti

ng o

r fla

shba

ck.

Adj

ust t

he p

rimar

y ai

r sh

utte

r(s)

as

requ

ired.

b.If

appl

ianc

e is

equ

ippe

d w

ith h

igh

and

low

flam

eco

ntro

l or f

lam

e m

odul

atio

n, c

heck

for p

rope

r mai

nbu

rner

ope

ratio

n at

low

flam

e.

11.

Tes

t fo

r sp

illag

e at

the

dra

ft ho

od r

elie

f op

enin

gaf

ter

5 m

inut

es o

f m

ain

burn

er o

pera

tion.

Use

a d

raft

gaug

e, th

e fla

me

of a

mat

ch o

r can

dle,

or s

mok

e fr

om a

ciga

rette

, cig

ar o

r pi

pe.

12.

Ret

urn

door

s, w

indo

ws,

exh

aust

fan

s, f

irepl

ace

dam

pers

and

all

othe

r fu

el-b

urni

ng a

pplia

nces

to

thei

rpr

evio

us c

ondi

tions

of u

se.

13.

App

licab

le o

nly

to w

arm

air

heat

ing

appl

ianc

es.

Che

ck b

oth

limit

cont

rolle

r an

d fa

n co

ntro

ller

for

prop

erop

erat

ion.

Lim

it co

ntro

ller o

pera

tion

can

be c

heck

ed b

yte

mpo

raril

y di

scon

nect

ing

the

elec

tric

al s

uppl

y to

the

blow

er m

otor

and

det

erm

inin

g th

at th

e lim

it co

ntro

l act

sto

shu

t off

the

mai

n bu

rner

gas

.

14.

App

licab

le o

nly

to b

oile

rs:

a.D

eter

min

e th

at th

e ci

rcul

atin

g w

ater

pum

ps a

rein

ope

ratin

g co

nditi

on.

b.T

est

low

wat

er c

utof

fs,

auto

mat

ic f

eed

con-

trol

s, p

ress

ure

and

tem

pera

ture

lim

it co

ntro

ls a

ndre

lie

f va

lve

s in

a

cco

rda

nce

w

ith

th

em

anuf

actu

rer’s

rec

omm

enda

tions

and

ins

truc

-tio

ns to

det

erm

ine

they

are

in o

pera

ting

cond

ition

.

AN

SI S

TA

ND

AR

DS

2169

-052

3

PIL

OT

BU

RN

ER

/IGN

ITE

R-S

EN

SO

R

MU

ST

BE

RIG

IDLY

PO

SIT

ION

ED

R

ELA

TIV

E T

O M

AIN

BU

RN

ER

M32

71

G. S

. •

Rev

. 7-9

3 •

©H

oney

wel

l Inc

. 199

3 •

For

m N

umbe

r 60

-065

3—8

Q34

5A, Q

348A

, Q34

8B, Q

362A

,Q37

3Aan

d Q

381A

Pilo

t Bur

ner/

Igni

ter-

Sens

ors

App

licat

ion

The

se p

ilot

bur

ner/

igni

ter-

sens

ors

prov

ide

pilo

t fla

me

igni

tion

and

sen

sing

in

inte

rmit

tent

pil

ot s

yste

ms.

The

yco

nsis

t of

a t

arge

t ty

pe p

ilot

bur

ner

wit

h a

com

bina

tion

spar

k ig

nite

r an

d fl

ame

sens

or m

ount

ed i

n pl

ace

of t

heth

erm

ocou

ple.

Inst

alla

tion

WH

EN

IN

STA

LL

ING

TH

IS P

RO

DU

CT

…1.

Rea

d th

ese

inst

ruct

ions

car

eful

ly.

Fai

lure

to

foll

ow i

nstr

ucti

ons

can

dam

age

prod

uct

or c

ause

aha

zard

ous

cond

itio

n.2.

Che

ck r

atin

gs g

iven

in

inst

ruct

ions

and

on

prod

uct

to m

ake

sure

pro

duct

is

suit

able

for

you

rap

plic

atio

n.3.

Mak

e su

re i

nsta

ller

is

a tr

aine

d, e

xper

ienc

edse

rvic

e te

chni

cian

.4.

Aft

er

com

ple

tin

g

inst

alla

tio

n,

use

th

ese

inst

ruct

ions

to c

heck

out

pro

duct

ope

rati

on.

WA

RN

ING

FIR

E O

R E

XP

LO

SIO

N H

AZ

AR

DC

AN

CA

USE

PR

OP

ER

TY

DA

MA

GE

,SE

VE

RE

IN

JUR

Y, O

R D

EA

TH

.F

ollo

w th

ese

war

ning

s ex

actl

y:1.

Dis

conn

ect

pow

er s

uppl

y be

fore

wir

ing

to p

reve

nt e

lect

rica

l sh

ock

or e

quip

men

tda

mag

e.2.

To

avoi

d da

nger

ous

accu

mul

atio

n of

fue

lga

s, tu

rn o

ff g

as s

uppl

y at

app

lian

ce s

ervi

cev

alv

e b

efo

re

star

tin

g

inst

alla

tio

n

and

perf

orm

Gas

Lea

k T

est

afte

r co

mpl

etio

n of

inst

alla

tion

.3.

Do

not

bend

pil

ot t

ubin

g at

the

con

trol

or

pil

ot

afte

r co

mp

ress

ion

n

ut

has

b

een

tigh

tene

d. G

as le

akag

e at

the

conn

ecti

on m

ayre

sult

.

Fol

low

app

lian

ce m

anuf

actu

rer

inst

ruct

ions

if

avai

l-ab

le; o

ther

wis

e, u

se in

stru

ctio

ns p

rovi

ded

belo

w.

LO

CA

TIO

N1.

Pos

itio

n pi

lot

burn

er/i

gnit

er-s

enso

r fo

r ea

syac

cess

and

obs

erva

tion

. In

rep

lace

men

t ap

plic

atio

ns,

repl

ace

pilo

t bur

ner/

igni

ter-

sens

or w

ith

an id

enti

cal u

nit

and

posi

tion

new

pil

ot b

urne

r/ig

nite

r-se

nsor

in th

e sa

me

loca

tion

and

ori

enta

tion

as

the

orig

inal

one

.

Fig

. 1—

Mo

un

t p

ilot

bu

rner

/ign

iter

-sen

sor

on

mai

n b

urn

er.

PIL

OT

BU

RN

ER

/IG

NIT

ER

-S

EN

SO

RJU

ST

RIG

HT

PIL

OT

BU

RN

ER

/IG

NIT

ER

-S

EN

SO

RTO

O L

OW

PIL

OT

BU

RN

ER

/IG

NIT

ER

-S

EN

SO

RTO

O H

IGH

MA

IN B

UR

NE

R

FLA

ME

WIL

L IM

PIN

GE

ON

IGN

ITIO

N-

SE

NS

OR

IGN

ITIO

NFL

AM

E W

ILL

IMP

ING

E O

NM

AIN

BU

RN

ER

IGN

ITIO

N F

LAM

EJU

ST

MIS

SE

SM

AIN

BU

RN

ER

M32

73

Fig

. 2—

Lo

cati

on

of

pilo

t b

urn

er/ig

nit

er-s

enso

r.

2.M

ount

pil

ot b

urne

r/ig

nite

r-se

nsor

on

mai

n bu

rner

.M

ount

ing

surf

aces

oth

er th

an th

e m

ain

burn

er m

ay s

hift

,be

nd,

or w

arp

as f

urna

ce e

xpan

ds a

nd c

ontr

acts

whi

leop

erat

ing.

See

Fig

. 1.

3.M

ount

pil

ot b

urne

r/ig

nite

r-se

nsor

so

the

pilo

t fla

me

rem

ains

pro

perl

y po

siti

oned

wit

h re

spec

t to

the

mai

nbu

rner

fla

me.

See

Fig

. 2.

4.S

uppl

y pi

lot

flam

e w

ith

ampl

e ai

r fr

ee o

fco

mbu

stio

n pr

oduc

ts.

5.D

o no

t im

ping

e pi

lot

flam

e on

adj

acen

t pa

rts.

Do

not

impi

nge

mai

n bu

rner

fla

me

on p

ilot

bur

ner/

igni

ter-

sens

or.

6.D

o no

t ex

pose

pil

ot f

lam

e to

fal

ling

sca

le,

whi

chco

uld

impa

ir m

ain

burn

er ig

niti

on.

7.D

o no

t exp

ose

pilo

t bur

ner/

igni

ter-

sens

or to

mai

nbu

rner

rol

lout

whi

le ig

niti

ng o

r ex

ting

uish

ing.

8.D

o no

t ex

pose

pil

ot f

lam

e to

dra

fts

that

pus

h or

pull

pil

ot f

lam

e aw

ay f

rom

the

ign

iter

-sen

sor.

NO

TE

: T

he Q

381A

Pil

ot B

urne

r/Ig

nite

r-S

enso

r is

for

hori

zont

al m

ount

ing

only

. M

ount

ing

brac

ket

mus

tre

mai

n ve

rtic

al.

!

2

CO

NN

EC

T P

ILO

T G

AS

TU

BIN

G1.

Cut

tubi

ng to

des

ired

leng

th a

nd b

end

as n

eces

sary

for

rout

ing

to p

ilot

bur

ner/

igni

ter-

sens

or.

Do

not

mak

esh

arp

bend

s or

def

orm

tub

ing.

Do

not

bend

tub

ing

atco

ntro

l af

ter

com

pres

sion

nut

has

bee

n ti

ghte

ned

beca

use

this

can

res

ult i

n ga

s le

akag

e at

con

nect

ion.

2.S

quar

e of

f an

d re

mov

e bu

rrs

from

end

of

tubi

ng.

3.P

ush

tubi

ng i

nto

com

pres

sion

nut

cle

aran

ce h

ole

unti

l tub

ing

bott

oms.

NO

TE

:

Wh

en

rep

laci

ng

a

con

tro

l,

cut

off

o

ldco

mp

ress

ion

fi

ttin

g

and

re

pla

ce

wit

h

new

com

pre

ssio

n

fitt

ing

p

rov

ided

w

ith

n

ew

pil

ot

burn

er. N

ever

use

old

com

pres

sion

fit

ting

bec

ause

it

may

not

pro

vide

a g

as-t

ight

sea

l. S

ee F

ig. 3

.

2.C

onne

ct o

ne e

nd o

f th

e ig

niti

on c

able

to

stud

term

inal

on

igni

ter-

sens

or u

sing

1/4

in.

[6

mm

] di

am-

eter

sna

p-sp

ring

or

cage

-cli

ps o

n ca

ble

ends

.3.

Con

nect

the

oth

er e

nd o

f th

e ig

niti

on c

able

to

the

igni

ter

term

inal

on

igni

tion

mod

ule.

4.U

se c

eram

ic o

r pl

asti

c st

ando

ff i

nsul

ator

s as

nec

-es

sary

to p

reve

nt c

able

fro

m c

onta

ctin

g m

etal

sur

face

s.

INST

AL

L B

LE

ED

GA

S T

UB

E (

opti

onal

)1.

Rou

te b

leed

tube

fro

m b

leed

tap

on g

as c

ontr

ol to

the

pilo

t bur

ner/

igni

ter-

sens

or.

2.P

ush

clip

into

pla

ce. S

ee F

ig. 4

.3.

Inse

rt b

leed

gas

tub

e un

til

3/8

in.

[10

mm

] to

tubi

ng is

abo

ve p

ilot

bur

ner/

igni

ter-

sens

or b

rack

et. T

ipof

ble

ed g

as t

ube

mus

t no

t ex

tend

int

o pi

lot

flam

e.

Fig

. 3—

Alw

ays

use

new

co

mp

ress

ion

fit

tin

g.

PIL

OT

BU

RN

ER

BO

DY

O

N B

RA

CK

ET

OF

PIL

OT

B

UR

NE

R/IG

NIT

ER

-SE

NS

OR

TIG

HT

EN

NU

T O

NE

TU

RN

B

EY

ON

D F

ING

ER

TIG

HT

CO

MP

RE

SS

ION

FIT

TIN

G

BR

EA

KS

OF

F A

ND

CLI

NC

HE

S

TU

BIN

G A

S N

UT

IS T

IGH

TE

NE

D

TO

GA

S C

ON

TR

OL

M32

96

4.W

hile

hol

ding

tubi

ng a

ll th

e w

ay in

, eng

age

thre

ads

and

turn

unt

il f

inge

r ti

ght.

5.U

sing

a w

renc

h, t

urn

com

pres

sion

nut

one

tur

nbe

yond

fin

ger

tigh

t. D

o no

t ov

erti

ghte

n.6.

Con

nect

oth

er e

nd o

f tu

bing

to

gas

cont

rol

acco

rdin

g to

gas

con

trol

man

ufac

ture

r in

stru

ctio

ns.

WIR

E I

GN

ITE

R-S

EN

SOR

The

ign

iter

-sen

sor

mus

t be

mou

nted

on

the

burn

er.

Con

nect

the

con

trol

mod

ule

grou

nd w

ire

to o

ne o

f th

eig

nite

r-se

nsor

mou

ntin

g sc

rew

s to

com

plet

e th

e sy

stem

grou

ndin

g.C

onne

ct g

roun

d w

ire

as f

ollo

ws:

1.U

se 2

21°

F [

105°

C]

min

imum

the

rmop

last

ic-

insu

late

d w

ire

for

the

grou

nd l

eadw

ire

(asb

esto

sin

sula

tion

is n

ot a

ccep

tabl

e).

2.A

mal

e 1/

4 in

. [6

mm

] qu

ick-

conn

ect

term

inal

is

prov

ided

on

Hon

eyw

ell i

gnit

ion

mod

ules

. Fas

ten

fem

ale

quic

k-co

nnec

t to

wir

e en

d at

igni

tion

mod

ule.

3.S

trip

oth

er e

nd a

nd f

aste

n un

der

igni

ter-

sens

orm

ount

ing

scre

w.

4.If

nec

essa

ry, u

se s

hiel

d to

pro

tect

lea

d fr

om r

adi-

ant h

eat o

f bu

rner

.5.

The

pil

ot b

urne

r se

rves

as

the

grou

ndin

g ar

ea f

orth

e fl

ame

sign

al.

Run

lea

d fr

om p

ilot

bur

ner

to t

heco

mm

on g

roun

d se

lect

ed.

Con

nect

the

igni

tion

cab

le a

s fo

llow

s:1.

The

hig

h te

nsio

n ig

niti

on c

able

mus

t co

nfor

m t

oap

plic

able

loca

l or

nati

onal

sta

ndar

ds.

!Fig

. 4—

Inst

all b

leed

gas

tu

be.

TH

IS D

IME

NS

ION

SH

OU

LD

BE

MA

XIM

UM

OF

3/8

INC

H

[9.5

mm

] WH

EN

BLE

ED

T

UB

E IS

IN F

INA

L P

OS

ITIO

N.

BLE

ED

TU

BE

CLI

P

M12

61

1/8

IN. S

TE

EL

TU

BIN

G

Star

tup

and

Che

ckou

tP

ER

FO

RM

GA

S L

EA

K T

EST

WA

RN

ING

FIR

E O

R E

XP

LO

SIO

N H

AZ

AR

DC

AN

CA

USE

PR

OP

ER

TY

DA

MA

GE

,SE

VE

RE

IN

JUR

Y, O

R D

EA

TH

.C

heck

for

gas

leak

s w

ith

soap

and

wat

er s

olu-

tion

any

tim

e w

ork

is d

one

on a

gas

sys

tem

.

Gas

Lea

k T

est:

1.E

nsur

e th

at g

as s

uppl

y is

turn

ed o

n at

the

appl

ianc

ese

rvic

e va

lve.

2.P

aint

pip

e co

nnec

tion

s up

stre

am o

f pi

lot

burn

erw

ith

rich

soa

p an

d w

ater

sol

utio

n. B

ubbl

es i

ndic

ate

gas

leak

. 3.If

leak

is d

etec

ted,

tigh

ten

pipe

con

nect

ions

.4.

Set

ther

mos

tat t

o ca

ll fo

r hea

t to

ligh

t mai

n bu

rner

.5.

Wit

h m

ain

burn

er i

n op

erat

ion,

pai

nt p

ipe

join

ts(i

nclu

ding

ada

pter

s) a

nd g

as c

ontr

ol in

let a

nd o

utle

t wit

hri

ch s

oap

and

wat

er s

olut

ion.

6.If

ano

ther

leak

is d

etec

ted,

tigh

ten

adap

ter

scre

ws,

join

ts, a

nd p

ipe

conn

ecti

ons.

7.R

epla

ce p

art i

f le

ak c

anno

t be

stop

ped.

360

-065

3—8

Fig

. 5—

Ign

iter

-sen

sor

tip

mu

st b

e in

pilo

t fl

ame.

Fig

. 6—

Pro

per

sh

ield

ing

of

pilo

t fl

ame.

M12

73T

YP

ICA

LS

HIE

LD

■■S

et th

e th

erm

osta

t to

call

for

hea

t.■■

Wat

ch th

e pi

lot b

urne

r du

ring

the

igni

tion

seq

uenc

e.S

ee if

:•

Igni

tion

spa

rk c

onti

nues

aft

er th

e pi

lot i

s li

t.•

The

pil

ot l

ight

s an

d th

e sp

ark

stop

s, b

ut m

ain

burn

er d

oes

not l

ight

.•

S860

0B,H

; S8

6H o

nly:

The

pilo

t lig

hts,

the

spa

rkst

ops

and

mai

n bu

rner

ligh

ts, b

ut th

e sy

stem

lock

sou

t.■■

If s

o, a

ssur

e ad

equa

te f

lam

e cu

rren

t as

foll

ows:

•T

urn

off

furn

ace

at c

ircu

it b

reak

er o

r fu

se b

ox.

•C

lean

the

flam

e ro

d w

ith

emer

y cl

oth.

•M

ake

sure

ele

ctri

cal c

onne

ctio

ns a

re c

lean

and

tigh

t.R

epla

ce d

amag

ed w

ire

wit

h m

oist

ure-

resi

stan

tno

. 18

wir

e ra

ted

for

con

tinu

ous

duty

up

to22

1° F

[10

5° C

].•

Che

ck f

or c

rack

ed c

eram

ic i

nsul

ator

, w

hich

can

caus

e sh

ort

to g

roun

d, a

nd r

epla

ce p

ilot

bur

ner/

igni

ter-

sens

or if

nec

essa

ry.

•A

t th

e ga

s co

ntro

l, di

scon

nect

mai

n va

lve

wir

efr

om th

e T

H o

r M

V te

rmin

al.

•T

urn

on p

ower

and

set

the

rmos

tat

to c

all

for

heat

.T

he p

ilot

sho

uld

ligh

t bu

t th

e m

ain

burn

er w

ill

rem

ain

off

beca

use

the

mai

n va

lve

actu

ator

is

dis-

conn

ecte

d.•

Che

ck th

e pi

lot f

lam

e. M

ake

sure

it is

blu

e, s

tead

yan

d en

velo

ps 3

/8 t

o 1/

2 in

. [1

0 to

13

mm

] of

the

flam

e ro

d. S

ee F

ig. 7

for

pos

sibl

e fl

ame

prob

lem

san

d th

eir

caus

es.

•If

nec

essa

ry, a

djus

t pil

ot fl

ame

by tu

rnin

g th

e pi

lot

adju

stm

ent

scre

w o

n th

e ga

s co

ntro

l cl

ockw

ise

tode

crea

se o

r co

unte

rclo

ckw

ise

to i

ncre

ase

pilo

tfl

ame.

Aft

er a

djus

tmen

t, a

lway

s re

plac

e pi

lot

adju

stm

ent

cove

r sc

rew

and

tig

hten

fir

mly

to

assu

re p

rope

r ga

s co

ntro

l ope

rati

on.

•S

et th

erm

osta

t bel

ow ro

om te

mpe

ratu

re to

end

cal

lfo

r he

at.

■■R

eche

ck ig

niti

on s

eque

nce

as f

ollo

ws:

•R

econ

nect

mai

n va

lve

wir

e.•

Set

ther

mos

tat t

o ca

ll f

or h

eat.

•W

atch

igni

tion

seq

uenc

e at

bur

ner.

•If

spa

rk s

till

doe

s no

t sto

p af

ter p

ilot

ligh

ts, r

epla

ceig

niti

on m

odul

e.•

If m

ain

burn

er d

oes

not

ligh

t or

if

mai

n bu

rner

ligh

ts b

ut s

yste

m lo

cks

out,

che

ck m

odul

e, g

roun

dw

ire,

and

gas

con

trol

as

desc

ribe

d in

con

trol

mod

ule

inst

ruct

ions

.

3/8

TO

1/2

INC

H[1

0 T

O 1

3 m

m]

PR

OP

ER

FLA

ME

AD

JUS

TM

EN

T

IGN

ITE

R-S

EN

SO

R

3/8

TO

1/2

INC

H[1

0 T

O 1

3 m

m]

PR

OP

ER

FLA

ME

AD

JUS

TM

EN

T

IGN

ITE

R-S

EN

SO

R

M37

77

Q37

3A

Q34

5A, Q

348A

-B, Q

362A

AN

D Q

381

A

AD

JUST

PIL

OT

FL

AM

ET

he p

ilot

fla

me

shou

ld e

nvel

op 3

/8 t

o 1/

2 in

.[1

0 to

13

mm

] of

the

ign

iter

-sen

sor

tip.

See

Fig

. 5.

To

adju

st p

ilot

fla

me:

1.T

urn

off

syst

em b

y se

ttin

g th

erm

osta

t be

low

tem

pera

ture

to c

all f

or h

eat.

2.D

isco

nnec

t lea

d to

MV

term

inal

on

gas

cont

rol.

3.L

ight

pil

ot b

y se

ttin

g th

erm

osta

t to

call

for

hea

t.4.

Rem

ove

pilo

t ad

just

men

t co

ver

scre

w f

rom

gas

cont

rol.

5. T

urn

inne

r pi

lot

adju

stm

ent

scre

w c

lock

wis

e to

decr

ease

or

coun

terc

lock

wis

e to

incr

ease

pil

ot f

lam

e.6.

Alw

ays

repl

ace

pilo

t ad

just

men

t co

ver

scre

w a

ndti

ghte

n fi

rmly

aft

er c

ompl

etin

g ad

just

men

t to

ass

ure

pro-

per

oper

atio

n.

Serv

ice

WA

RN

ING

FIR

E O

R E

XP

LO

SIO

N H

AZ

AR

DC

AN

CA

USE

PR

OP

ER

TY

DA

MA

GE

,SE

VE

RE

IN

JUR

Y, O

R D

EA

TH

.P

erfo

rm G

as L

eak

Tes

t any

tim

e w

ork

is d

one

toth

e sy

stem

.

PIL

OT

OU

TA

GE

1.If

pil

ot f

lam

e go

es o

ut d

urin

g ig

niti

on,

but

ispr

o-pe

rly

adju

sted

, re

chec

k m

ount

ing

and

loca

tion

inst

ruct

ions

in L

ocat

ion

sect

ion.

2.R

efer

to

igni

tion

mod

ule

inst

ruct

ions

to

chec

kw

irin

g be

twee

n ig

nite

r-se

nsor

and

ign

itio

n m

odul

e or

betw

een

gas

cont

rol a

nd ig

niti

on m

odul

e.3.

If a

ll m

ount

ing

and

loca

tion

ins

truc

tion

s ar

e fo

l-lo

wed

but

pil

ot c

onti

nues

to

go o

ut, c

onst

ruct

shi

eldi

ngto

pro

tect

pil

ot f

lam

e fr

om m

ain

burn

er i

gnit

ion

and

exti

ncti

on a

nd d

raft

s. S

ee F

ig. 6

.4.

Che

ck p

ilot

and

mai

n bu

rner

ligh

toff

.

!

Hom

e an

d B

uild

ing

Con

trol

Hom

e an

d B

uild

ing

Con

trol

Hel

ping

You

Con

trol

You

r W

orld

Hon

eyw

ell I

nc.

Hon

eyw

ell L

imite

d—H

oney

wel

l Lim

itée

1985

Dou

glas

Dri

ve N

orth

740

Elle

smer

e R

oad

Gol

den

Val

ley,

Min

neso

ta 5

5422

Scar

boro

ugh,

Ont

ario

M1P

2V

9

Prin

ted

in U

.S.A

.

QU

AL

ITY

IS

KE

Y

Fig

. 7—

Exa

mp

le o

f u

nsa

tisf

acto

ry p

ilot

flam

es.

CH

EC

K I

GN

ITIO

N C

AB

LE

1.A

ssur

e th

at i

gnit

ion

cabl

e is

not

in

cont

act

wit

hm

etal

sur

face

s.2.

Ass

ure

that

ign

itio

n ca

ble

is n

ot m

ore

than

3 fe

et [1

m] l

ong.

3.A

ssur

e co

nnec

tion

s to

the

ign

itio

n m

odul

e st

udte

rmin

al a

nd th

e ig

nite

r-se

nsor

are

cle

an a

nd ti

ght.

4.C

heck

ele

ctri

cal c

onti

nuit

y of

igni

tion

cab

le.

CH

EC

K G

RO

UN

DIN

G1.

If g

roun

d is

poo

r or

err

atic

, sa

fety

shu

tdow

n w

ill

oc-c

ur.

The

refo

re,

if n

uisa

nce

shut

dow

ns a

re r

epor

ted,

chec

k th

e gr

ound

pre

caut

ions

in

Wir

e Ig

nite

r-S

enso

rse

ctio

n.

2.If

lea

dwir

e is

dam

aged

or

dete

rior

ated

, us

eno

. 14

to

18 g

auge

, m

oist

ure-

resi

stan

t, th

erm

opla

stic

,in

sula

ted

wir

e w

ith

221°

F [

105°

C]

min

imum

rat

ing

asre

plac

emen

t.3.

Exc

essi

ve t

empe

ratu

re a

t th

e ce

ram

ic f

lam

e ro

din

sula

tor

wil

l per

mit

ele

ctri

cal l

eaka

ge to

gro

und.

a.If

bra

cket

is

bent

, be

nd i

t ba

ck t

o co

rrec

tpo

siti

on.

b.If

ins

ulat

or i

s cr

acke

d, r

epla

ce p

ilot

bur

ner/

igni

ter-

sens

or.

TE

ST S

AF

ET

Y L

OC

KO

UT

Ref

er t

o ap

plia

nce

man

ufac

ture

r in

stru

ctio

ns t

o te

stfo

r pr

oper

saf

ety

lock

out t

imes

.

LAZY

YELL

OW

FLAM

E

WAV

ING

BLU

EFL

AME

NO

ISY

LIFT

ING

BLO

WIN

GFL

AME

HAR

DSH

ARP

FLAM

E

SMAL

LBL

UE

FLAM

EC

HE

CK

FO

R L

AC

K O

F G

AS

FR

OM

:

• C

LOG

GE

D O

RIF

ICE

FIL

TE

R

• C

LOG

GE

D P

ILO

T F

ILT

ER

• LO

W G

AS

SU

PP

LY P

RE

SS

UR

E

• P

ILO

T A

DJU

ST

ME

NT

AT

MIN

IMU

M

CH

EC

K F

OR

LA

CK

OF

AIR

FR

OM

:

• D

IRT

Y O

RIF

ICE

• D

IRT

Y L

INT

SC

RE

EN

, IF

US

ED

• D

IRT

Y P

RIM

AR

Y A

IR O

PE

NIN

G,

IF

TH

ER

E IS

ON

E

• P

ILO

T A

DJU

ST

ME

NT

AT

MIN

IMU

M

CH

EC

K F

OR

:

• E

XC

ES

SIV

E D

RA

FT

AT

PIL

OT

L

OC

AT

ION

• R

EC

IRC

ULA

TIN

G P

RO

DU

CT

S O

F C

OM

BU

ST

ION

CH

EC

K F

OR

:

• H

IGH

GA

S P

RE

SS

UR

E

TH

IS F

LAM

E IS

CH

AR

AC

TE

RIS

TIC

O

F M

AN

UF

AC

TU

RE

D G

AS

CH

EC

K F

OR

:

• H

IGH

GA

S P

RE

SS

UR

E

• O

RIF

ICE

TO

O S

MA

LL

M37

78

AP

PE

AR

AN

CE

CA

US

E

NO

ISY

LIFT

ING

BLO

WIN

GFL

AME

LAZY

YELL

OW

FLAM

E

WAV

ING

BLU

EFL

AME

HAR

DSH

ARP

FLAM

E

SMAL

LBL

UE

FLAM

E

AP

PE

AR

AN

CE

Lis

tin

gs/

Ap

pro

vals

:•

UL

Gui

de (

NK

PZ

) fo

r in

dust

rial

cont

rol

equi

pmen

t per

UL

Sta

ndar

d 50

8 In

dust

rial

Con

trol

Equ

ipm

ent

•U

L G

uide

(M

FH

X)

for

heat

ing/

cool

ing

ap-

plia

nce

switc

h pe

r U

L S

tand

ard

353

Lim

itC

ontr

ols

•C

SA

Cla

ss (

3211

06)

for

indu

stria

l co

ntro

leq

uipm

ent

per

CS

A S

tand

ard

C22

.2 N

o.14

-M I

ndus

tria

l Con

trol

Equ

ipm

ent

Max

imu

m S

ervi

ce P

ress

ure

: 25

0 P

SI

En

clo

sure

:N

EM

A T

ype

1 (F

or in

door

use

onl

y)F

orm

ed s

heet

met

al w

ith p

owde

rcoa

t fin

ish.

Not

for

use

in h

azar

dous

loca

tions

.C

on

tact

s:IF

S01

: O

ne S

PD

T (

For

m C

) sw

itch

IFS

02: T

wo

sets

of S

PD

T (

For

m C

) sw

itche

sto

pro

vide

ver

satil

ity i

n w

iring

tw

o se

para

teci

rcui

ts.

15 A

mps

at

125/

250V

AC

.5 A

mps

at

125V

DC

.25

Am

ps a

t 25

0VD

CM

oto

r R

atin

gs

:

120V

AC

240V

AC

Ho

rsep

ow

er :

1/8

1/4

AC

F.L

.A. :

3.8

2.9

AC

L.R

.A. :

22.8

17.4

Pilo

t D

uty

Rat

ing

:12

5 V

A12

0/24

0 V

AC

IFS

H1/

2 C

on

tact

s:IF

SH

1: O

ne S

PD

T (

For

m C

) sw

itch

IFS

H2:

Tw

o se

ts o

f SP

DT

(F

orm

C)

switc

hes

to p

rovi

de v

ersa

tility

in

wiri

ng t

wo

sepa

rate

circ

uits

.22

Am

ps a

t 12

5/25

0VA

CM

oto

r R

atin

gs

:12

0VA

C24

0VA

CH

ors

epo

wer

:1/

21

AC

F.L

.A. :

9.8

8.0

AC

L.R

.A. :

58.8

48.0

Pilo

t D

uty

Rat

ing

:12

5 V

A12

0/24

0 V

AC

Am

bie

nt

Tem

per

atu

re R

ang

e:32

°F/1

76°F

(0°

C/8

0°C

)M

edia

Tem

per

atu

re R

ang

e:32

°F/2

50°F

(0°

C/1

21°C

)P

ipe

Co

nn

ecti

on

s:1"

NP

T B

rass

on

mod

els

IFS

xxB

1" N

PT

316

Sta

inle

ss S

teel

on

mod

els

IFS

xxS

Co

nd

uit

En

tran

ce:

Tw

o op

enin

gs fo

r 1/2

" co

ndui

tU

sag

e:F

or p

ipe

size

s 1"

- 8

"C

auti

on

:Thi

s de

vice

is

not

inte

nded

for

app

lica-

tions

in

expl

osiv

e en

viro

nmen

ts.

No

te:

IFS

W S

erie

s av

aila

ble

with

NE

MA

4 e

nclo

-su

re

for

ou

tdo

or

use

. (S

ee

b

ulle

tin

s#1

02-0

26 &

#10

2-02

7 or

Cat

alog

100

-8.2

).

GE

NE

RA

L

The

Mod

el I

FS

is

a flo

w s

witc

h us

ed i

n liq

uid

flow

lin

es c

arry

ing

wat

er o

r an

y flu

id n

ot h

arm

ful

to b

rass

, st

ainl

ess

stee

l, E

PD

M o

r flu

oros

ilico

ne,

and

not

clas

sifie

d as

a h

azar

dous

flu

id.

Thi

s sw

itch

can

serv

e as

a w

ay t

o st

art

and

stop

elec

tric

ally

ope

rate

d eq

uipm

ent

whe

n a

flow

or

noflo

w c

ondi

tion

occu

rs in

a v

arie

ty o

f ap

plic

atio

ns.

Thi

s de

vice

is d

esig

ned

for

use

only

as

an o

pera

t-in

g co

ntro

l. W

here

an

oper

atin

g co

ntro

l fa

ilure

wou

ld r

esul

t in

pers

onal

inju

ry a

nd/o

r lo

ss o

f pro

p-er

ty,

it is

the

res

pons

ibili

ty o

f th

e in

stal

ler

to a

ddde

vice

s (s

afet

y, li

mit

cont

rols

) th

at p

rote

ct a

gain

st,

or s

yste

ms

(ala

rm, s

uper

viso

ry s

yste

ms)

that

war

nof

con

trol

fai

lure

.

Inst

ruct

ion

Sh

eet

Ind

ust

rial

Flo

w S

wit

chS

UP

ER

CE

DE

S: 1

02-1

22 D

AT

ED

Jan

uary

1, 2

002

# 54

0111

0-R

EV

E

EF

FE

CT

IVE

: Mar

ch 1

7, 2

004

102-

022

(IF

S01

&IF

S02

ON

LY)

MO

UN

TIN

G A

ND

INS

TA

LL

AT

ION

The

Mod

el I

FS

may

be

mou

nted

in a

hor

izon

tal

pipe

line

or

a ve

rtic

al p

ipe

line

with

upw

ard

liqui

dflo

w.

It is

not

rec

omm

ende

d fo

r in

stal

latio

nsw

here

flo

w i

s do

wnw

ard.

Whe

n m

ount

ed i

n a

horiz

onta

l pip

e lin

e th

e sw

itch

will

trip

at

a lo

wer

flow

rat

e th

an s

how

n in

Fig

. 7.

Mou

nt th

e de

vice

in a

sec

tion

of p

ipe

whe

re th

ere

is a

str

aigh

t ru

n of

at

leas

t 5

pipe

dia

met

ers

onea

ch s

ide

of th

e flo

w s

witc

h. D

o no

t loc

ate

adja

-ce

nt t

o va

lves

, el

bow

s or

orif

ices

. T

he s

witc

hsh

ould

be

mou

nted

so

the

term

inal

s or

wire

lead

sar

e ea

sily

acc

essi

ble

for

wiri

ng.

IFS

mod

els

with

fle

xibl

e pa

ddle

s ar

e fu

rnis

hed

with

4 p

addl

es.

Rig

id p

addl

e m

odel

s ar

e fu

r-ni

shed

with

2 p

addl

es.

For

pip

e si

zes

1", 2

", 3

" or

6", u

se th

e pa

ddle

s pr

ovid

ed.

Inte

rmed

iate

siz

esm

ay b

e tr

imm

ed f

rom

the

app

ropr

iate

pad

dle

usin

g th

e pa

ddle

tem

plat

e in

Fig

. 5.

The

pad

dle

mus

t no

t to

uch

the

insi

de o

f th

e pi

pe o

r bi

nd in

any

way

. P

addl

es s

mal

ler

than

the

act

ual p

ipe

size

sho

uld

be u

sed

for a

dded

sup

port

and

hig

her

sens

itivi

ty, s

ee F

ig. 3

. The

pad

dles

mus

t be

prop

-er

ly a

ttach

ed a

nd th

e sc

rew

that

hol

ds th

e pa

ddle

mus

t be

secu

rely

tigh

tene

d.

For

a 1

" pip

e ap

plic

atio

n m

ount

in a

sta

ndar

d 1"

x1"

x 1

" te

e. U

se a

redu

cing

tee

for l

arge

r siz

es o

fpi

pe to

kee

p flo

w s

witc

h cl

ose

to p

ipe

and

prov

ide

adeq

uate

pad

dle

leng

th in

the

flow

str

eam

.

Exa

mpl

e: U

se a

2"

x 2"

x 1

" te

e fo

r 2"

pip

e. A

wel

dole

t may

als

o be

use

d. S

crew

the

devi

ce in

toth

e te

e fit

ting

as s

how

n in

Fig

. 4.

The

fla

t of

the

padd

le m

ust

be a

t a

right

ang

le t

o th

e flo

w.

The

arro

w o

n th

e si

de o

f the

bus

hing

mus

t poi

nt in

the

dire

ctio

n of

flow

, see

Fig

. 1.

FIG

. 1

Sen

siti

vity

Ad

just

men

t No

te:

Tur

n sc

rew

clo

ckw

ise

to in

crea

se th

e flo

w r

ate

requ

ired

to a

ctiv

ate

the

switc

h.T

urn

scre

w c

ount

er-c

lock

wis

e to

dec

reas

e th

eflo

w r

ate

requ

ired

to a

ctiv

ate

the

switc

h.

FIG

. 2

FIG

. 4

CA

UT

ION

:S

crew

the

dev

ice

into

the

TE

E f

ittin

g as

sho

wn.

Car

e m

ust b

e ta

ken

to p

rope

rly o

rient

the

devi

ce fo

rth

e di

rect

ion

of th

e flo

w. D

o no

t tig

hten

by

gras

ping

the

switc

h en

clos

ure.

Use

the

wre

nchi

ng fl

ats

on th

ebu

shin

g on

ly. T

urni

ng r

adiu

s re

quire

d fo

r m

ount

ing

the

IFS

is 3

".

FIG

. 5

Use

the

draw

ing

atrig

ht a

s a

tem

plat

ean

d tr

im a

t the

dot

-te

d ar

c w

hen

trim

-m

ing

the

appr

opri-

ate

padd

le f

or i

n-te

rme

dia

te

pip

esi

zes.

CA

UT

ION

:T

he p

addl

e m

ust

not

touc

h th

e in

-si

de o

f the

pip

e or

bind

in a

ny w

ay.

FIG

. 3

Typ

ical

pad

dle

arra

ngem

ent

for 6

" to

8" p

ipe,

usi

ng s

mal

ler

flexi

ble

padd

les

for

adde

dsu

ppor

t an

d hi

gher

sen

sitiv

-ity

.

NO

TE

:W

he

n

inst

alli

ng

rig

id p

add

les,

do

not s

tack

pad

dles

.O

nly

inst

all

ON

Epa

ddle

tha

t be

stfit

s th

e pi

pe.

WIR

ING

Use

pro

perly

rat

ed te

mpe

ratu

re s

uppl

y w

ire fo

rth

e an

ticip

ated

ser

vice

tem

pera

ture

.

Mak

e al

l el

ectr

ical

con

nect

ions

in

acco

rdan

cew

ith th

e N

atio

nal E

lect

rical

Cod

e an

d lo

cal r

egu-

latio

ns.

See

Fig

s. 6

A a

nd 6

B f

or d

iagr

ams

illus

trat

ing

switc

h ac

tion.

AD

JUS

TM

EN

TR

emov

e sw

itch

cove

r an

d tu

rn t

he s

ensi

tivity

adju

stin

g sc

rew

clo

ckw

ise

to in

crea

se t

he f

low

rate

req

uire

d to

act

uate

the

sw

itch.

T

urn

the

sens

itivi

ty a

djus

ting

scre

w c

ount

er-c

lock

wis

e to

decr

ease

the

flo

w r

ate

requ

ired

to a

ctua

te t

hesw

itch.

(S

ee F

ig.

1.)

Be

sure

to

repl

ace

the

cove

r up

on c

ompl

etio

n of

the

ins

talla

tion

and

adju

stm

ent.

CA

UT

ION

: C

heck

the

inst

alla

tion

for

"no-

flow

"sw

itch

oper

atio

n. M

ake

appr

opria

te a

djus

tmen

tsto

the

sens

itivi

ty a

djus

tmen

t scr

ew to

be

sure

the

switc

h re

stor

es f

ully

at

the

desi

red

flow

rat

e.

NO

TE

S:

1.T

ypic

al fl

ow r

ates

for

1" to

1 1

/2"

pipe

siz

esar

e av

erag

es w

hich

may

var

y ap

prox

imat

ely

±1

GP

M w

ith t

he u

se o

f a

bron

ze r

educ

ing

tee.

2.T

ypic

al fl

ow r

ates

for

2" to

8"

pipe

siz

es a

reav

erag

es w

hich

may

var

y ±

10%

with

the

use

of a

1"

wel

dole

t.(*

) Flo

w ra

tes

for t

hese

siz

es a

re c

alcu

late

d.

IFS

01 /

IFS

02S

WIT

CH

INF

OR

MA

TIO

NIF

SH

1 / I

FS

H2

SW

ITC

H IN

FO

RM

AT

ION

FIG

. 6B

SN

OIT

ACI

FIC

EP

S

hctiw

Setautc

Aot

deriuqeR

MP

G-

setaR

wolFlacipyT

)snoitallatsniepiplacitrev

roF(

)sehc

ni(ezi

Se

piP

14/1

12/1

12

2/12

34

5*6

8*

mumini

Mtne

mtsujdA

wolF

esaercnI5.4

5.46

5.75.31

8153

0507

012

wolF

esaerceD

5.35.3

55.5

5.931

5204

06091

mumixa

Mtne

mtsujdA

wolF

esaercnI5.9

015.31

0292

0507

021081

014

wolF

esaerceD

75.8

5.015.81

6254

56501

061083

Do

it O

nce

. Do

it R

igh

t.T

AC

O, I

NC

., 11

60 C

rans

ton

Str

eet,

Cra

nsto

n, R

I 02

920

T

elep

hone

: (4

01)

942-

8000

F

AX

: (4

01)

942-

2360

.T

AC

O (

Can

ada)

, Ltd

., 61

80 O

rdan

Driv

e, M

issi

ssau

ga,

Ont

ario

L5T

2B

3.

Tel

epho

ne:

905/

564-

9422

.

FA

X:

905/

564-

9436

.M

anuf

actu

red

by P

OT

TE

R E

LE

CT

RIC

SIG

NA

L C

O.,

St.

Loui

s, M

O

Vis

it o

ur

web

sit

e at

: ht

tp://

ww

w.ta

co-h

vac.

com

Prin

ted

in U

SA

Cop

yrig

ht 2

002

TA

CO

, Inc

.

FIG

. 6A

FIG

. 7

SCH

EMA

TIC

SKET

CHSH

OW

SAR

RAN

GEM

ENT

OF

THER

MO

STAT

SAN

DU

NIT

ROL

7000

BGO

IN

TYPI

CAL

FRYE

RAP

PLIC

ATIO

N

Info

rmat

ion

subj

ect t

o ch

ange

with

out n

otic

e.

7

/99

Ref

er t

o ap

plia

nce

man

ufac

ture

r’s

inst

ruct

ions

for

prop

er s

yste

m o

pera

tion.

The

7000

“D” s

erie

s co

ntro

ls c

onta

in d

ual

auto

mat

ic v

alve

s (s

olen

oid

and

diap

hrag

m) i

nac

cord

ance

with

AN

SI s

tand

ards

. Th

ese

valv

es a

re fo

r use

in a

24V

AC s

yste

m fo

rei

ther

dire

ct ig

nitio

n or

pilo

t ign

ition

sys

tem

s.

PIL

OT

BU

RN

ER

AD

JU

ST

ME

NT

� R

emov

e th

e pi

lot a

djus

tmen

t cap

(do

not

lose

the

gask

et).

�Ad

just

the

pilo

t key

to p

rovi

de p

rope

r fla

me.

� R

e-as

sem

ble

the

gask

et a

nd c

ap.

� L

eak

test

per

war

ning

not

e 13

.

WA

RN

ING

!

� I

nsta

llatio

n an

d se

rvic

ing

of g

as a

pplia

nces

and

con

trols

mus

t onl

y be

perfo

rmed

by

qual

ified

per

sonn

el. A

fter i

nsta

llatio

n or

ser

vici

ng; t

est m

anua

lva

lve,

ope

ratin

g va

lves

, pre

ssur

e re

gula

tion,

and

aut

omat

ic s

afet

y sh

utt o

ffva

lve

for p

rope

r ope

rtatio

n.�

DO

NO

Tus

e th

is c

ontro

l if i

t has

bee

n ex

pose

d to

wat

er c

orro

sion

thro

ugh

imm

ersi

on, d

rippi

ng, e

tc.

It m

ay b

e da

mag

e an

d m

ust b

e re

plac

ed.

� S

hut o

ff ga

s an

d el

ectri

city

bef

ore

star

ting

inst

alla

tion

or s

ervi

ce. T

urn

back

on

to te

st o

r ope

rate

.�

DO

NO

Tco

nnec

t app

lianc

e be

fore

pre

ssur

e te

stin

g ga

s pi

ping

. Dam

age

to g

as v

alve

may

resu

lt.�

DO

NO

Tin

sert

any

obje

ct o

ther

than

sui

tabl

e pi

pe o

r tub

ing

in th

e in

let o

rou

tlet o

f the

gas

val

ve. I

nter

nal d

amag

e m

ay o

ccur

and

resu

lt in

a h

azar

dous

cond

ition

.�

DO

NO

Tgr

ip g

as v

alve

bod

y w

ith a

pip

e w

renc

h or

vis

e. D

amag

e m

ayre

sult

caus

ing

gas

leak

age.

Use

inle

t or o

utle

t bos

ses

or a

spe

cial

bod

yw

renc

h.�

DO

NO

Tsh

ort t

he g

as v

alve

term

inal

s. T

he th

erm

osta

t or t

he fu

se w

ill be

dam

aged

.�

DO

NO

Tal

low

any

flam

e to

impi

nge

on th

e re

gula

tor

vent

tubi

ng if

sup

-pl

ied.

It m

ay c

log

and

caus

e ga

s va

lve

mal

func

tion.

D

ON

OT

use

the

gas

cock

to a

djus

t gas

flow

.�

In

cas

e of

failu

re o

f mai

n bu

rner

to s

hut o

ff; tu

rn o

ff ga

s su

pply.

Allo

wfa

n, if

so

equi

pped

, to

run

until

hea

ting

unit

has

cool

ed o

ff.�

� K

eep

all c

ombu

stib

le m

ater

ials

aw

ay fr

om g

as a

pplia

nces

. DO

NO

T

allo

w li

nt o

r dus

t to

colle

ct in

bur

ner a

rea.

��

Dia

ls m

ust o

nly

be o

pera

ted

by h

and.

Nev

er u

se p

liers

, wre

nch

or o

ther

tool

s to

turn

dia

ls.

��

Leas

test

with

soa

p so

lutio

n af

ter i

nsta

llatio

n or

ser

vice

with

the

mai

n

burn

er o

n. C

oat p

ipe

and

tubi

ng jo

ints

, gas

kets

, etc

. Bub

bles

indi

cate

leak

s

95-5

971—

22

L400

8A,B

,E,L

; L6

008A

,G,H

REM

OTE

BU

LB A

QU

AST

AT®

CO

NTR

OLL

ERS

The

Aqu

asta

t® c

ontr

olle

r ca

n be

rem

otel

y m

ount

ed—

eith

er v

ertic

ally

on

a w

all o

r pa

nel,

or d

irect

ly o

n th

e bo

iler,

tank

, or

vess

el.

If th

e sy

stem

is fi

lled,

dra

in th

e sy

stem

to a

poi

nt b

elow

the

boile

r ta

ppin

g, o

r to

whe

reve

r th

e se

nsin

g bu

lb is

to b

ein

stal

led.

Mou

ntin

g th

e Ca

se�

Rem

ove

the

cove

r an

d fa

sten

the

case

to th

e w

all o

rpa

nel u

sing

the

thre

e m

ount

ing

hole

s in

the

back

of

the

case

.�

Whe

n m

ount

ing

the

rem

ote

bulb

, if d

esira

ble,

rou

teth

e tu

bing

to r

un th

roug

h an

y of

the

othe

r th

ree

corn

er n

otch

es in

the

case

. Be

care

ful n

ot to

kin

k or

bend

tubi

ng s

harp

ly. B

e su

re b

ends

hav

e at

leas

t 1 in

.(2

5.4

mm

) rad

ius.

Inst

allin

g Re

mot

e Bu

lb w

ith Im

mer

sion

Wel

lF

it w

ell,

if us

ed, t

o se

nsin

g bu

lb s

nugl

y fo

r go

od th

erm

alre

spon

se. I

nser

t bul

b un

til it

res

ts a

gain

st th

e bo

ttom

of t

hew

ell;

then

hol

d it

ther

e w

hile

tigh

teni

ng th

e tu

bing

cla

mp.

�S

crew

the

wel

l int

o th

e bo

iler,

tank

or

pipe

tapp

ing.

�In

sert

the

bulb

into

the

wel

l, pu

shin

g th

e tu

bing

unt

ilth

e bu

lb b

otto

ms

in th

e w

ell.

�A

ttach

the

reta

iner

cla

mp

to th

e en

d of

the

wel

l spu

d.Lo

osen

the

draw

nut

and

spr

ead

the

jaw

s of

the

clam

p w

ith th

e sc

rew

driv

er if

nec

essa

ry.

�W

ith th

e re

tain

er c

lam

p at

tach

ed to

the

wel

l spu

d (b

esu

re ja

ws

of c

lam

p ho

ok o

ver r

idge

at e

nd o

f the

spud

, as

show

n in

Fig

. 2, p

oint

s A

). A

djus

t tub

ing

to fi

tth

roug

h re

tain

er c

lam

p gr

oove

, as

show

n at

poi

nt B

.�

Tig

hten

the

draw

nut

so

the

reta

iner

cla

mp

is fi

rmly

atta

ched

to th

e w

ell s

pud

and

the

tubi

ng is

hel

d by

the

clam

p.

Mou

ntin

g w

ith B

ulb

Com

pres

sion

Fitt

ing

�S

crew

the

fittin

g in

to th

e bo

iler

or p

ipe

tapp

ing.

�S

lide

seal

ing

was

her

onto

the

bulb

.�

Inse

rt th

e bu

lb in

to th

e fit

ting

until

bul

b bo

ttom

s.�

Slid

e sp

lit s

leev

e in

to fi

tting

.�

Pla

ce c

lam

ps A

and

B o

n as

sem

bly

so th

at s

leev

e is

draw

n in

to fi

tting

whe

n sc

rew

s ar

e tig

hten

ed.

NO

TE

:M

ake

sure

that

the

nub

on c

lam

p A

enga

ges

spac

e be

twee

n sl

eeve

and

cla

mp.

�T

ight

en c

lam

p sc

rew

s ev

enly

.

M87

77

WE

LLB

ULB

SP

UD

MO

UN

TIN

GC

LAM

P

A

DR

AW

N

UT

TU

BIN

G

B

INS

ER

T—

MO

UN

TIN

G C

LA

MP

SC

RE

WD

RIV

ER

SP

RE

AD

JA

WS

TO

FIT

OV

ER

RID

GE

ON

W

ELL

SP

UD

JAW

S

Fig

. 2.

Im

mer

sion

wel

l fit

ting.

IMP

OR

TA

NT

Do

not s

ecur

e dr

aw n

ut s

o tig

htly

that

reta

iner

clam

p co

uld

cut o

r col

laps

e tu

bing

.

M88

15

CLA

MP

B

CLA

MP

AC

LAM

P S

CR

EW

S (

2)

BU

LB

CO

MP

RE

SS

ION

F

ITT

ING

SE

ALI

NG

W

AS

HE

RBU

LB

INS

ER

TIO

N L

EN

GT

HA

PP

RO

X. 3

-3/1

6 IN

. (81

MM

)S

PLI

T S

LEE

VE Fig

. 3.

Bul

b co

mpr

essi

on f

ittin

g.

Mou

ntin

g w

ith C

apill

ary

Com

pres

sion

Fitti

ng�

Scr

ew fi

tting

into

the

boile

r or

pip

e ta

ppin

g.�

Pla

ce p

acki

ng n

ut o

n tu

bing

.�

Slid

e bu

lb c

ompl

etel

y th

roug

h fit

ting.

�P

lace

com

posi

tion

disc

and

4 s

lotte

d br

ass

was

hers

on tu

bing

in th

e or

der

show

n in

Fig

. 4. T

urn

bras

sw

ashe

rs s

o th

at s

lots

are

180

deg

rees

to e

ach

othe

r.�

Slid

e se

al a

ssem

bly

into

fitti

ng a

nd ti

ghte

n pa

ckin

g nu

t.

CO

MP

OS

ITIO

N D

ISK

(SLO

TT

ED

)

BO

ILE

R P

LUG

CA

PIL

LAR

Y T

UB

ING

EX

AM

PLE

OF

SLO

TT

ED

WA

SH

ER

S

AS

SE

MB

LED

IN

PA

IRS

:P

AC

KIN

G N

UT

M88

16

IMM

ER

SIO

NB

ULB

Fig

. 4.

Cap

illar

y co

mpr

essi

on f

ittin

g.

WIR

ING

All

wiri

ng m

ust a

gree

with

app

licab

le c

odes

and

ord

inan

ces

and

regu

latio

ns in

suc

h m

atte

rs a

s w

ire s

ize,

type

of

insu

latio

n, a

nd e

nclo

sure

. The

con

trol

lers

are

pro

vide

dw

ith c

ondu

it kn

ocko

uts

in th

e to

p an

d bo

ttom

of c

ase.

Ref

er to

Fig

. 5 o

r 6

for

a ty

pica

l con

nect

ion

diag

ram

.

X-X

X U

L

INST

ALLA

TIO

N IN

STRU

CTIO

NS

®U

.S. R

egis

tere

d T

rade

mar

kC

opyr

ight

© 1

995

Hon

eyw

ell I

nc.

• A

ll R

ight

s R

eser

vedL4

008A

,B,E

,L; L

6008

A,G,

HAq

uast

at® C

ontro

llers

APPL

ICAT

ION

The

se re

mot

e bu

lb (s

ee F

ig. 7

), im

mer

sion

type

(see

Fig

. 1)

cont

rolle

rs o

pera

te in

res

pons

e to

tem

pera

ture

cha

nges

inhy

dron

ic h

eatin

g sy

stem

s an

d ot

her

heat

ed li

quid

s.

Ele

ctric

al R

atin

gs:

Sw

itch

ratin

gs a

re s

how

n on

the

insi

de c

over

of e

ach

devi

ce. T

he e

lect

rical

requ

irem

ents

on

cont

rolle

d eq

uipm

ent

mus

t not

exc

eed

this

ratin

g.L4

008A

—br

eaks

the

burn

er c

ircui

t on

a ris

e in

wat

erte

mpe

ratu

re. I

t is

norm

ally

use

d as

a li

mit

cont

rolle

r.W

hen

used

as

an o

pera

ting

cont

rolle

r or

low

lim

it, a

sepa

rate

hig

h lim

it co

ntro

l mus

t be

used

.L4

008B

—m

akes

a c

ontr

ol c

ircui

t on

a ris

e in

wat

erte

mpe

ratu

re. I

t is

norm

ally

use

d as

a c

ircul

ator

cont

rolle

r to

pre

vent

circ

ulat

or o

pera

tion

until

boi

ler

wat

er te

mpe

ratu

re is

at o

r ab

ove

the

cont

rol s

ettin

g.L4

008E

—br

eaks

the

burn

er c

ircui

t and

lock

s ou

t on

aris

e in

wat

er te

mpe

ratu

re. I

t is

used

as

a hi

gh li

mit

cont

rolle

r w

here

man

ual r

eset

is d

esira

ble.

L400

8L—

is u

sed

as a

2-s

tage

Aqu

asta

t® c

ontr

olle

r.L6

008A

—m

akes

the

burn

er c

ircui

t on

a dr

op in

wat

erte

mpe

ratu

re. I

t is

norm

ally

use

d as

a c

ircul

ator

and

low

lim

it co

olin

g co

ntro

ller.

L600

8G—

is u

sed

as a

2-s

tage

Aqu

asta

t® c

ontr

olle

r to

cycl

e 2-

stag

e ga

s va

lve.

L600

8H—

is u

sed

as a

low

fire

Aqu

asta

t® c

ontr

olle

r.

If im

mer

sion

wel

l or

capi

llary

com

pres

sion

fitti

ng m

ust b

eor

dere

d, r

efer

to fo

rm 6

8-00

40, W

ells

and

Fitt

ings

for

Tem

pera

ture

Con

trol

lers

, for

par

t num

bers

and

ord

erin

gin

form

atio

n.

INST

ALLA

TIO

N

Whe

n In

stal

ling

this

Pro

duct

…1.

Rea

d th

ese

inst

ruct

ions

car

eful

ly. F

ailu

re to

follo

wth

em c

ould

dam

age

the

prod

uct o

r ca

use

a ha

zard

-ou

s co

nditi

on.

2.C

heck

the

ratin

gs g

iven

in th

e in

stru

ctio

ns a

nd o

nth

e pr

oduc

t to

mak

e su

re th

e pr

oduc

t is

suita

ble

for

your

app

licat

ion.

3.In

stal

ler

mus

t be

a tr

aine

d, e

xper

ienc

ed s

ervi

cete

chni

cian

.4.

Afte

r in

stal

latio

n is

com

plet

e, c

heck

out

pro

duct

oper

atio

n as

pro

vide

d in

thes

e in

stru

ctio

ns.

CA

UT

ION

Dis

conn

ect p

ower

sup

ply

befo

re in

stal

latio

n to

prev

ent e

lect

rical

sho

ck o

r eq

uipm

ent d

amag

e.

Dep

endi

ng o

n m

odel

and

inst

alla

tion

requ

irem

ents

, ins

tall

the

tem

pera

ture

sen

sing

bul

b ei

ther

in a

n im

mer

sion

wel

l(s

ee F

ig. 2

) th

at e

xten

ds in

to th

e bo

iler

or ta

nk, o

r di

rect

lyim

mer

se th

e te

mpe

ratu

re s

ensi

ng b

ulb

in th

e liq

uid.

For

inst

alla

tions

not

usi

ng a

wel

l, se

cure

the

bulb

with

a b

ulb

com

pres

sion

fitti

ng (s

ee F

ig. 3

), or

a c

apill

ary

com

pres

sion

fittin

g (s

ee F

ig. 4

). O

rder

the

wel

l or

the

fittin

g se

para

tely

.

The

boi

ler

man

ufac

ture

r ge

nera

lly p

rovi

des

a ta

ppin

g fo

rin

sert

ing

the

Aqu

asta

t® c

ontr

olle

r se

nsin

g el

emen

t. Lo

cate

this

tapp

ing

in a

rep

rese

ntat

ive

poin

t whe

re ty

pica

l wat

erte

mpe

ratu

re c

an b

e m

easu

red.

Nev

er lo

cate

the

bulb

or

prot

ectin

g im

mer

sion

wel

l clo

se to

a h

ot o

r co

ld w

ater

inle

tor

ste

am c

oil.

Inst

all t

he b

ulb

in th

e su

pply

line

of a

nin

dire

ct w

ater

hea

ter,

in th

e in

dire

ct w

ater

hea

ter

itsel

f, or

in th

e fe

ed r

iser

abo

ut 6

in. (

152

mm

) ab

ove

the

boile

r. If

the

riser

is v

alve

d, in

stal

l the

bul

b be

twee

n th

e bo

iler

and

the

valv

e.

95-5

971-

2

Fig

. 1.

Int

erna

l vi

ew.

M88

06

SE

TP

OIN

TIN

DIC

AT

ING

DIA

L

DIF

FE

RE

NT

IAL

AD

JUS

TM

EN

TW

HE

EL

AD

AP

TE

R C

LAM

PS

CR

EW

S

INS

ER

TIO

NE

LEM

EN

T

WIT

H V

ER

TIC

AL

MO

UN

TIN

G O

F IM

ME

RS

ION

WE

LL,

ELE

ME

NT

IS A

TT

AC

HE

D T

O B

OT

TO

M O

F T

HE

CA

SE

.

SE

LEC

T M

OD

ELS

HA

VE

SC

RE

W T

ER

MIN

AL,

NO

T T

AB

T

ER

MIN

AL.

1 2

2

1

95-5

971—

24

L400

8A,B

,E,L

; L6

008A

,G,H

REM

OTE

BU

LB A

QU

AST

AT®

CO

NTR

OLL

ERS

Hom

e an

d B

uild

ing

Con

trol

Hon

eyw

ell L

imite

d-H

oney

wel

l Lim

itée

740

Elle

smer

e R

oad

Scar

boro

ugh,

Ont

ario

M1P

2V

9

Hel

ping

You

Con

trol

You

r W

orld

95-5

971—

2 J

.H.

Rev

. 9-9

5 P

rinte

d in

U.S

.A

QU

AL

ITY

IS

KE

Y

Hom

e an

d B

uild

ing

Con

trol

Hon

eyw

ell I

nc.

1985

Dou

glas

Dri

ve N

orth

Gol

den

Val

ley,

MN

554

22

Adju

stin

g L6

008G

Inte

rsta

ge D

iffer

entia

lT

he L

6008

G C

ontr

olle

r ha

s an

adj

usta

ble

inte

rsta

gedi

ffere

ntia

l. T

he s

etpo

int a

djus

tmen

t kno

b de

term

ines

the

tem

pera

ture

at w

hich

the

right

sw

itch

oper

ates

. The

left

switc

h ca

n be

adj

uste

d to

ope

rate

from

3°

to 1

0°F

(1.

7° to

5.6°

C)

abov

e th

e po

int o

f ope

ratio

n of

the

right

sw

itch.

The

Inte

rsta

ge d

iffer

entia

l is

adju

sted

by

turn

ing

the

star

whe

elw

ith a

nar

row

scr

ewdr

iver

inse

rted

into

the

rect

angu

lar

hole

in th

e ch

assi

s. S

ee F

ig. 8

CHEC

KOUT

WA

RN

ING

CA

N C

AU

SE

PR

OP

ER

TY

DA

MA

GE

, SE

VE

RE

INJU

RY

OR

DE

AT

H.

Thi

s pr

oduc

t is

inte

nded

for

use

only

in s

yste

ms

with

a p

ress

ure

relie

f val

ve.

Che

ck to

be

sure

the

Aqu

asta

t® c

ontr

olle

r is

pro

perly

inst

alle

d an

d ad

just

ed. P

ut th

e sy

stem

into

ope

ratio

n an

dob

serv

e th

e ac

tion

of th

e co

ntro

l thr

ough

sev

eral

cyc

les

tom

ake

sure

that

it p

rovi

des

prop

er c

ontr

ol o

f the

sys

tem

as

desc

ribed

in th

e O

pera

tion

sect

ion.

Mak

e an

y ad

ditio

nal

adju

stm

ents

nec

essa

ry to

ass

ure

com

fort

req

uire

men

ts.

M89

72

RIG

HT

SW

ITC

H

LEF

T S

WIT

CH

ST

AR

WH

EE

L (I

NT

ER

ST

AG

ED

IFF

ER

EN

TIA

L A

DJU

ST

ME

NT

)

1

1

SE

LEC

T M

OD

ELS

HA

VE

FO

UR

TE

RM

INA

LS.

Fig

. 8.

Int

erst

age

diffe

rent

ial

adju

stm

ent

on a

n L4

008L

or L

6008

G.

95-5

971—

23

L400

8A,B

,E,L

; L6

008A

,G,H

REM

OTE

BU

LB A

QU

AST

AT®

CO

NTR

OLL

ERS

L1

(HO

T)

L2 1

1 2

2

PO

WE

R S

UP

PLY

. PR

OV

IDE

DIS

CO

NN

EC

T M

EA

NS

AN

D

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

SE

LEC

T M

OD

ELS

HA

VE

1/4

IN. T

AB

TE

RM

INA

L F

OR

WT

ER

MIN

AL.

L400

8A O

R E

HIG

H L

IMIT

C

ON

TR

OLL

ER

L600

8AC

IRC

ULA

TO

RLO

W L

IMIT

C

ON

TR

OLL

ERR

WB

CIR

CU

LAT

OR

IGN

ITIO

NT

RA

NS

FO

RM

ER

RA

89A

RE

LAY

RA

817A

PR

OT

EC

TO

RE

LAY

®C

ON

TR

OLB

UR

NE

R M

OT

OR

24V

TH

ER

MO

ST

AT

21

34

TT

1 2

3 4

M87

85

Fig

. 5.

Typ

ical

oil-

fired

hyd

roni

c he

atin

g sy

stem

with

dom

estic

hot

wat

er.

SETT

ING

Con

trol

Poi

nt:

Inse

rt a

scr

ewdr

iver

in th

e sl

otte

d he

ad v

isib

le th

roug

h th

eco

ver,

and

turn

the

indi

catin

g di

al to

the

cont

rol p

oint

.T

empe

ratu

re s

ettin

gs s

houl

d be

acc

ordi

ng to

boi

ler

man

ufac

ture

r’s r

ecom

men

datio

ns.

Diff

eren

tial

(on

adju

stab

le d

iffer

entia

l m

odel

s):

Rem

ove

cove

r an

d m

ove

the

diffe

rent

ial a

djus

tmen

t whe

el(F

ig. 1

or

7) to

a p

oint

on

the

scal

e co

rres

pond

ing

to th

ede

sire

d di

ffere

ntia

l. R

epla

ce c

over

.

Man

ual

Res

et (

L400

8E):

Afte

r bo

iler

wat

er te

mpe

ratu

re h

as d

ropp

ed to

a p

oint

belo

w th

e hi

gh li

mit

setti

ng, l

ess

diffe

rent

ial,

the

rese

tbu

tton

at th

e fr

ont o

f the

cas

e m

ust b

e pu

shed

bef

ore

the

burn

er c

an o

pera

te.

ADJU

STM

ENTS

Adju

stin

g Di

ffere

ntia

lS

et th

e di

ffere

ntia

l to

corr

espo

nd w

ith th

e bo

iler m

anuf

actu

rer

reco

mm

enda

tions

. To

adju

st m

odel

s w

ith a

djus

tabl

edi

ffere

ntia

l, ro

tate

the

whe

el o

n th

e ba

ck o

f the

sna

psw

itch,

see

Fig

. 7, u

ntil

the

desi

red

read

ing

is a

ligne

d w

ithth

e V

not

ch in

the

fram

e. T

he w

heel

pro

vide

s as

adj

ustm

ent

from

5°

to 3

0°F

(3°

to 1

7°C

). R

epla

ce th

e co

ver

on th

eA

quas

tat®

con

trol

ler.

L1

(HO

T)

L2

1

1P

OW

ER

SU

PP

LY. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D

PR

OT

EC

TIO

N A

S R

EQ

UIR

ED

.

JUM

PE

R

M89

68

HE

AT

ING

LO

AD

NO

. 2

HE

AT

ING

LO

AD

NO

. 1

RR

BB

WW

21

L600

8G

Fig

. 6.

Typ

ical

oil

burn

er i

nsta

llatio

n us

ing

L400

8Lor

L60

08G

.

L1

(HO

T)

L2

1

1P

OW

ER

SU

PP

LY. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D

PR

OT

EC

TIO

N A

S R

EQ

UIR

ED

.

L400

8L

HL

TE

MP

RA

890F

65

T

4T

3

F1 2

2G NC

NO

CO

M

PIL

OT

VA

LVE

IGN

ITIO

N

MA

INV

ALV

E(S

)

M46

72

M89

69

DIF

FE

RE

NT

IAL

WH

EE

L

NO

TC

H IN

FR

AM

E

SN

AP

SW

ITC

H

SE

LEC

T M

OD

ELS

HA

VE

A S

CR

EW

TE

RM

INA

L IN

ST

EA

D

OF

TA

B T

ER

MIN

AL.

1

1

Fig

. 7.

Adj

ustin

g th

e di

ffere

ntia

l.

Adj

ust t

he c

ontr

ol p

oint

to c

orre

spon

d w

ith th

e bo

iler

man

ufac

ture

r re

com

men

datio

ns. T

o ad

just

, ins

ert a

scre

wdr

iver

in th

e sl

otte

d sc

rew

type

hea

d lo

cate

d be

neat

hth

e w

indo

w in

the

cove

r. T

urn

the

scal

e to

the

desi

red

cont

rol p

oint

.

VR

8104

, VR

8204

AN

D V

R83

04 IN

TE

RM

ITT

EN

T P

ILO

T C

OM

BIN

ATIO

N G

AS

CO

NT

RO

LS

69-1

225—

42

a A

vaila

ble

only

on

CE

VR

8204

mod

els. Ta

ble

4. V

R82

04A

,H/V

R83

04A

,H,U

CE

.

a T

he V

R82

04U

use

s st

anda

rd U

.S. c

onst

ruct

ion.

Inle

t and

out

let p

orts

are

1/2

in. N

PT,

and

the

pilo

t con

nect

ion

is th

e st

anda

rd 7

/16

in. t

hrea

d fo

r a

1/4

in. p

ilot t

ube.

Eur

opea

n-st

yle

inle

t and

out

let p

ress

ure

taps

are

ava

ilabl

e.

CA

UT

ION

Eq

uip

men

t D

amag

e H

azar

d.

Imp

rop

er u

se c

an d

amag

e eq

uip

men

t.R

ead

the

inst

ruct

ions

bef

ore

use.

Thi

s co

ntro

l m

ust b

e in

stal

led

in a

ccor

danc

e w

ith th

e ru

les

in fo

rce.

Tab

le 3

. Mo

del

Nu

mb

er S

uff

ix L

ette

r D

esig

nat

ion

.

Mo

del

No

. S

uff

ix L

ette

r

Am

bie

nt

Tem

per

atu

re

Ran

ge

Pre

ssu

re

Reg

ula

tor

Typ

e

A0°

F to

175

°F

(-18

°C to

+79

°C)

Sta

ndar

d

CS

tep-

open

ing

HS

low

-ope

ning

Ua

Non

regu

latin

g (o

n-of

f)

K-4

0°F

to +

175°

F

(-40

°C to

+79

°C)

Slo

w-o

peni

ng

MS

tand

ard

PS

tep-

open

ing

QTw

o-S

tage

RC

onve

rtib

le

Sp

ecif

icat

ion

sV

R82

04A

,H (

CE

Mo

del

On

ly)

VR

8304

A,H

(C

E M

od

el O

nly

)

Mai

n va

lve

conn

ectio

ns (

If N

PT,

th

e va

lves

mus

t be

serv

iced

by

the

appl

ianc

e m

anuf

actu

rer.

1/2

in. I

SO

, 7/1

inte

rnal

thre

ad (

BS

P,

NP

T.1/

2 in

., 3/

4 in

. IS

O, 7

/1 in

tern

al th

read

(B

SP,

P

L) o

r 1/

2 in

., 3/

4 in

. NP

T.

Val

ve C

lass

ifica

tion

B +

DC

+ D

Cap

acity

(1k

W =

3.4

1BT

UH

)29

kW

at 2

.5 m

Bar

43 k

W a

t 5.0

mB

arfo

r 1/

2 in

., 70

kW

at 2

.5 m

Bar

99 k

W a

t 5.0

mB

ar.

For

3/4

in.,

87 k

W a

t 2.5

mB

ar:

121

kW a

t 5.0

mB

ar.

Sup

ply

Vol

tage

24 V

ac, 5

0/60

Hz.

Fla

nges

Non

e.

Clo

sing

tim

eLe

ss th

an 1

sec

ond.

Ope

ning

Tim

eS

tand

ard

open

ing

(A):

less

than

2 s

econ

ds.

Slo

w o

peni

ng (

H):

less

than

6 s

econ

ds.

Spe

cial

fast

ope

ning

(U

): le

ss th

an 1

sec

ond.

Sui

ted

for

gas

fam

ilies

2H, 2

L, a

nd 3

.

Out

let P

ress

Ran

ge(E

xcep

t unr

egul

ated

mod

els)

Nat

ural

gas

: 7.5

to 1

2.5

mB

ar (

3 to

5 in

. wc)

.N

atur

al g

as: 1

2.5

to 1

7.5

mB

ar (

5 to

7 in

. wc)

.LP

gas

: 20

to 3

0 m

Bar

(8

to 1

2 in

. wc)

.

Man

ually

ope

rate

d va

lve

oper

atio

ns10

,000

cyc

les

for

man

ual v

alve

s; 2

00,0

00 c

ycle

s fo

r au

tom

atic

val

ves.

Am

bien

t tem

pera

ture

ran

ge-2

0°C

to +

70°C

(-4

°F to

+15

8°F

).

Max

imum

inle

t pre

ssur

e60

mB

ar (

24 in

. wc)

.

Scr

een

Fin

e m

esh

on in

let.

Pilo

t con

nect

iona

M11

x 1

for

6 m

m o

utsi

de d

iam

eter

tube

.

Gro

und

term

inal

a6.

3 m

m.

Pre

ssur

e ta

psa

9 m

m O

D fo

r bo

th in

let a

nd o

utle

t.

App

rova

lC

E-0

063A

U12

15.

® U

.S. R

egis

tere

d Tr

adem

ark

Cop

yrig

ht ©

200

0 H

oney

wel

l Inc

. A

ll R

ight

s R

eser

ved

INST

ALLA

TION

INST

RUCT

IONS

69-1

225-

4

VR81

04, V

R820

4, a

nd V

R830

4In

term

itten

t Pilo

t Com

bina

tion

Gas

Con

trols

APPL

ICAT

ION

Thes

e in

term

itten

t pilo

t gas

con

trols

are

use

d in

gas

-fire

d ap

plia

nces

with

up

to 4

15 ft

3/hr

cap

acity

at 1

in. w

c pr

essu

re d

rop

(8.5

m3/

hr a

t 0.2

5 kP

a) o

n na

tura

l gas

. Th

ey in

clud

e sa

fety

shu

toff,

a m

anua

l val

ve, t

wo

auto

mat

ic o

pera

tors

, a p

ress

ure

regu

lato

r and

a p

ilot

adju

stm

ent.

Thes

e ga

s co

ntro

ls a

re a

vaila

ble

in a

rang

e of

val

ve

capa

citie

s, s

ee T

able

1. (

Tabl

e 2

prov

ides

gas

cap

acity

co

nver

sion

fact

ors.

) The

suf

fix le

tter i

ndic

ates

te

mpe

ratu

re ra

nge

and

regu

lato

r typ

e, s

ee T

able

3.

For C

E-a

ppro

ved

mod

els,

the

rele

vant

sec

tions

of t

hese

in

stru

ctio

ns a

nd T

able

4 a

re a

pplic

able

.

Tabl

e 1.

Val

ve C

apac

itya

aC

apac

ity b

ased

on

1000

Btu

/ft3 , 0

.64

sp g

r nat

ural

gas

at 1

in. w

c pr

essu

re d

rop

(37.

3 M

J/m

3 , 0.6

4 sp

gr n

atur

al g

as

at 0

.25

kPa

pres

sure

dro

p).

bC

apac

ity is

redu

ced

by 5

per

cent

whe

n us

ing

an o

utle

t scr

een.

cVa

lves

are

gua

rant

eed

at o

nly

77 p

erce

nt o

f the

ratin

g.d

Min

imum

regu

latio

n fo

r LP

gas

is 1

5,00

0 B

tuh.

eM

inim

um re

gula

tion

for L

P g

as is

40,

000

Btu

h.f

Min

imum

regu

latio

n fo

r LP

gas

is 5

0,00

0 B

tuh.

Tabl

e 2.

Gas

Cap

acity

Con

vers

ion

Fact

or.

CE-O

nly

Mod

els

Thes

e ga

s co

ntro

ls a

re u

sed

in a

pplia

nces

up

to 1

21kW

or

415

kB

TUH

on

natu

ral g

as a

nd a

ppro

ved

on E

N12

6,

whi

ch c

onsi

sts

of o

ne a

utom

atic

saf

ety

shut

off v

alve

, C

lass

B o

r C, o

ne s

ervo

-ope

rate

d sh

utof

f val

ve, C

lass

D,

pres

sure

gov

erno

r, C

lass

C, m

anua

lly-o

pera

ted

valv

e,

with

or w

ithou

t pilo

t out

let.

Onl

y th

e A

, H a

nd U

mod

els

are

avai

labl

e C

E-a

ppro

ved.

Tabl

e 4

show

s th

e ad

ditio

nal s

peci

ficat

ions

for t

he

CE

-onl

y m

odel

s.

Mod

el

Siz

e In

let-

Out

let

(in.)

AG

A C

ertif

ied

Cap

acity

for

Nat

ural

Gas

AG

A C

ertif

ied

Min

imum

R

egul

atio

n fo

r N

atur

al G

as

AG

A C

ertif

ied

Max

imum

R

egul

atio

n fo

r N

atur

al G

as

ft3 /h

rm

3 /hr

ft3 /h

rm

3 /hr

ft3 /h

rm

3 /hr

VR

8104

1/2

x 1/

285

2.3

10d

0.4

120

3.4

VR

8204

150

4.2

20e

0.6

200

5.7

VR

8304

b,c

240

6.8

30f

0.8

340

9.6

VR

8304

b,c

1/2

x 3/

427

07.

637

01.

05

VR

8304

b,c

3/4

x 3/

430

08.

541

511

.8

Gas

Spe

cific

Gra

vity

Mul

tiply

Lis

ted

Cap

acity

By

Man

ufac

ture

d0.

600.

516

Mix

ed0.

700.

765

Pro

pane

1.53

1.62

VR

8104

, VR

8204

AN

D V

R83

04 IN

TE

RM

ITT

EN

T P

ILO

T C

OM

BIN

ATIO

N G

AS

CO

NT

RO

LS

69-1

225—

44

Corr

osiv

e C

he

mic

als

Cor

rosi

ve c

hem

ical

s ca

n at

tack

the

cont

rol,

even

tual

ly

caus

ing

a fa

ilure

. If c

hem

ical

s ar

e us

ed fo

r ro

utin

e cl

eani

ng, a

void

con

tact

with

the

cont

rol.

Whe

re

chem

ical

s ar

e su

spen

ded

in a

ir, a

s in

som

e in

dust

rial o

r ag

ricul

tura

l app

licat

ions

, pro

tect

the

cont

rol w

ith a

n en

clos

ure.

Dust

or

Gre

ase

Accu

mu

latio

nH

eavy

acc

umul

atio

ns o

f dus

t or

grea

se c

an c

ause

the

cont

rol t

o m

alfu

nctio

n. W

here

dus

t or

grea

se c

an b

e a

prob

lem

, pro

vide

cov

ers

for

the

cont

rol t

o lim

it co

ntam

inat

ion.

Hea

tE

xces

sive

ly h

igh

tem

pera

ture

s ca

n da

mag

e th

e co

ntro

l. M

ake

sure

the

max

imum

am

bien

t tem

pera

ture

at t

he

cont

rol d

oes

not e

xcee

d th

e ra

ting

of th

e co

ntro

l. If

the

appl

ianc

e op

erat

es a

t ver

y hi

gh te

mpe

ratu

res,

use

in

sula

tion,

shi

eldi

ng, a

nd a

ir ci

rcul

atio

n, a

s ne

cess

ary,

to

prot

ect t

he c

ontr

ol. P

rope

r in

sula

tion

or s

hiel

ding

sho

uld

be p

rovi

ded

by th

e ap

plia

nce

man

ufac

ture

r; v

erify

pro

per

air

circ

ulat

ion

is m

aint

aine

d w

hen

the

appl

ianc

e is

in

stal

led.

INS

TA

LLA

TIO

N

Wh

en

In

sta

llin

g t

his

Pro

duct.

..1.

Rea

d th

ese

inst

ruct

ions

car

eful

ly. F

ailu

re to

follo

w

them

cou

ld d

amag

e th

e pr

oduc

t or

caus

e a

haza

rdou

s co

nditi

on.

2.C

heck

the

ratin

gs g

iven

in th

e in

stru

ctio

ns a

nd o

n th

e pr

oduc

t to

mak

e su

re th

e pr

oduc

t is

suita

ble

for

your

app

licat

ion.

3.In

stal

ler

mus

t be

a tr

aine

d, e

xper

ienc

ed s

ervi

ce

tech

nici

an.

4.A

fter

inst

alla

tion

is c

ompl

ete,

che

ck o

ut p

rodu

ct

oper

atio

n as

pro

vide

d in

thes

e in

stru

ctio

ns.

WA

RN

ING

Fir

e o

r E

xplo

sio

n H

azar

d.

Can

cau

se p

rop

erty

dam

age,

sev

ere

inju

ry

or

dea

th.

Fol

low

thes

e w

arni

ngs

exac

tly:

1.D

isco

nnec

t pow

er s

uppl

y be

fore

wiri

ng to

pr

even

t ele

ctric

al s

hock

or

equi

pmen

t dam

age.

2.To

avo

id d

ange

rous

acc

umul

atio

n of

fuel

gas

, tu

rn o

ff th

e ga

s su

pply

at t

he a

pplia

nce

serv

ice

valv

e be

fore

sta

rtin

g in

stal

latio

n, a

nd p

erfo

rm

Gas

Lea

k Te

st a

fter

inst

alla

tion

is c

ompl

ete.

3.D

o no

t ben

d pi

lot t

ubin

g at

gas

con

trol

or

pilo

t bu

rner

afte

r com

pres

sion

fitti

ng is

tigh

tene

d, o

r ga

s le

akag

e at

the

conn

ectio

n ca

n re

sult.

4.A

lway

s in

stal

l a s

edim

ent t

rap

in th

e ga

s su

pply

line

to p

reve

nt c

onta

min

atio

n of

the

gas

cont

rol.

5.D

o no

t for

ce th

e ga

s co

ntro

l kno

b. U

se o

nly

your

han

d to

turn

the

gas

cont

rol k

nob.

Nev

er

use

any

tool

s. If

the

gas

cont

rol k

nob

will

not

op

erat

e by

han

d, th

e ga

s co

ntro

l sho

uld

be

repl

aced

by

a qu

alifi

ed s

ervi

ce te

chni

cian

. F

orce

or

atte

mpt

ed r

epai

r m

ay r

esul

t in

fire

or

expl

osio

n.

CA

UT

ION

Eq

uip

men

t D

amag

e.C

an b

urn

ou

t va

lve

coil

term

inal

s.N

ever

app

ly a

jum

per

acro

ss (

or s

hort

) th

e va

lve

coil

term

inal

s, e

ven

tem

pora

rily.

Fol

low

the

appl

ianc

e m

anuf

actu

rers

inst

ruct

ions

if

avai

labl

e; o

ther

wis

e, u

se th

ese

inst

ruct

ions

as

a gu

ide.

IMP

OR

TAN

TT

hese

gas

con

trol

s ar

e sh

ippe

d w

ith p

rote

ctiv

e se

als

over

the

inle

t and

out

let t

appi

ngs.

Do

not

rem

ove

the

seal

s un

til r

eady

to in

stal

l ada

pter

s or

con

nect

the

pipi

ng.

Co

nve

rtin

g G

as C

on

trol f

rom

Na

tura

l Ga

s

to L

P G

as (

or

LP

Ga

s to

Na

tura

l G

as)

WA

RN

ING

Fir

e O

r E

xplo

sio

n H

azar

d.

Can

cau

se p

rop

erty

dam

age,

sev

ere

inju

ry

or

dea

th.

1.D

o no

t atte

mpt

to c

onve

rt s

tep-

open

ing

mod

els

(suf

fix le

tter

P).

2.

Alw

ays

chan

ge th

e m

ain

and

pilo

t bur

ner

orifi

ces

whe

n co

nver

ting

from

nat

ural

to L

P g

as

or fr

om L

P to

nat

ural

gas

. Car

eful

ly fo

llow

ap

plia

nce

man

ufac

ture

r sp

ecifi

catio

ns a

nd

inst

ruct

ions

to a

ssur

e pr

oper

app

lianc

e co

nver

sion

.3.

Gas

con

trol

s ar

e fa

ctor

y-se

t for

nat

ural

(an

d m

anuf

actu

red)

or

LP g

as. D

o no

t atte

mpt

to

use

a ga

s co

ntro

l set

for

natu

ral

(man

ufac

ture

d) g

as o

n LP

gas

, or a

gas

con

trol

se

t for

LP

gas

on

natu

ral (

man

ufac

ture

d) g

as.

Con

trol

s w

ith s

tand

ard,

slo

w-o

peni

ng, a

nd tw

o-st

age

regu

lato

rs (

mod

el n

umbe

rs w

ith s

uffix

H, K

, M, o

r Q

) ca

n be

con

vert

ed fr

om o

ne g

as to

the

othe

r w

ith a

con

vers

ion

kit (

orde

red

sepa

rate

ly).

See

Tab

le 4

for

the

corr

ect

conv

ersi

on k

it.

Con

vert

ible

Pre

ssure

Reg

ula

tors

Con

trol

s w

ith s

uffix

lette

r R

are

con

vert

ible

pre

ssur

e re

gula

tor

mod

els.

The

y ca

n be

con

vert

ed fr

om n

atur

al

gas

to L

P g

as o

r fr

om L

P g

as to

nat

ural

gas

with

out a

co

nver

sion

kit.

Bef

ore

conv

ertin

g th

e co

ntro

l fro

m o

ne g

as to

ano

ther

, ch

eck

the

cont

rol l

abel

and

the

appl

ianc

e m

anuf

actu

rer’s

ra

ting

plat

e to

det

erm

ine

if th

e pr

essu

re r

egul

ator

set

ting

(fac

tory

set

) w

ill m

eet t

he a

pplia

nce

man

ifold

re

quire

men

ts a

fter

conv

ersi

on.

NO

TE

:C

onve

rtib

le p

ress

ure

regu

lato

r m

odel

s (s

uffix

le

tter

R)

do n

ot h

ave

field

-adj

usta

ble

regu

lato

rs.

If th

e fa

ctor

y pr

essu

re r

egul

ator

set

ting

mee

ts th

e ap

plia

nce

man

ifold

req

uire

men

t, co

nver

t the

con

trol

as

follo

ws:

1.R

emov

e th

e pr

essu

re r

egul

ator

cap

, Fig

. 1.

2.In

vert

the

cap

so th

at th

e le

tters

app

ear

that

re

pres

ent t

he g

as ty

pe a

ppro

pria

te fo

r th

e ap

plia

nce.

NA

T fo

r na

tura

l man

ufac

ture

d ga

s, L

P

for

liqui

d pe

trol

eum

gas

.3.

Rep

lace

the

cap

and

tight

en fi

rmly

.

VR

8104

, VR

8204

AN

D V

R83

04 IN

TE

RM

ITT

EN

T P

ILO

T C

OM

BIN

AT

ION

GA

S C

ON

TR

OLS

369

-122

5—4

SP

EC

IFIC

AT

ION

S

Bo

dy

Pat

tern

: S

trai

ght t

hrou

gh; s

ee T

able

1 fo

r in

let a

nd

outle

t siz

e.

Ele

ctri

cal R

atin

gs:

Vol

tage

and

Fre

quen

cy: 2

4 V

ac, 6

0 H

z.C

urre

nt D

raw

: 0.5

A w

ith b

oth

oper

ator

s en

ergi

zed.

Cap

acit

y: S

ee T

able

1.

Co

nve

rsio

n:

Use

con

vers

ion

fact

ors

in T

able

2 to

con

-ve

rt c

apac

ities

for

othe

r ga

ses.

Reg

ula

tio

n R

ang

e: S

ee T

able

1.

Nat

ura

l-L

P G

as C

on

vers

ion

Kit

s: S

ee T

able

5.

Tab

le 5

. N

atu

ral-

LP

Gas

Co

nve

rsio

n K

its.

Pip

e A

dap

ters

:A

ngle

and

str

aigh

t ada

pter

s av

aila

ble

for

3/8-

, 1/2

- an

d 3/

4-in

. pip

e. S

ee T

able

6. F

lang

e ki

ts in

clud

e on

e fla

nge

with

atta

ched

O-r

ing,

four

mou

ntin

g sc

rew

s, a

9/

64 in

. hex

wre

nch

and

inst

ruct

ions

.

Ap

pro

vals

:A

mer

ican

Gas

Ass

ocia

tion

Des

ign

Cer

tific

ate:

L20

2500

6.C

anad

ian

Gas

Ass

ocia

tion

Des

ign

Cer

tific

ate:

L20

2500

6.A

ustr

alia

n G

as A

ssoc

iatio

n D

esig

n C

ertif

icat

e: 4

214.

App

rove

d fo

r D

elta

C a

pplic

atio

ns.

Eur

opea

n C

omm

unity

(C

E)

Cer

tific

ate:

Pen

ding

.

PL

AN

NIN

G T

HE

IN

ST

ALLA

TIO

N

WA

RN

ING

Fir

e o

r E

xplo

sio

n H

azar

d.

Can

cau

se p

rop

erty

dam

age,

sev

ere

inju

ry,

or

dea

th.

Fol

low

thes

e w

arni

ngs

exac

tly:

1.P

lan

the

inst

alla

tion

as o

utlin

ed b

elow

.2.

Pla

n fo

r fr

eque

nt m

aint

enan

ce a

s de

scrib

ed in

th

e M

aint

enan

ce s

ectio

n.

Tab

le 6

. Fla

ng

e A

dap

ter

Par

t N

um

ber

s.

aF

lang

e ki

ts in

clud

e on

e fla

nge,

one

O-r

ing

and

four

m

ount

ing

scre

ws.

bD

o no

t use

flan

ges

on c

ontr

ol m

odel

s w

ith 3

/4 in

. inl

et

and

3/4

in. o

utle

t. O

n m

odel

s w

ith 1

/2 in

. inl

et a

nd

3/4

in. o

utle

t, us

e fla

nges

onl

y on

the

1/2

in. i

nlet

sid

e.

Hea

vy d

eman

ds a

re m

ade

on th

e co

ntro

ls w

hen

inte

rmitt

ent p

ilot s

yste

ms

are

used

on

cent

ral h

eatin

g eq

uipm

ent i

n ba

rns,

gre

enho

uses

, and

com

mer

cial

pr

oper

ties

and

on h

eatin

g ap

plia

nces

suc

h as

co

mm

erci

al c

ooke

rs, a

gric

ultu

ral e

quip

men

t, in

dust

rial

heat

ing

equi

pmen

t and

poo

l hea

ters

.

Spe

cial

ste

ps m

ay b

e re

quire

d to

pre

vent

nui

sanc

e sh

utdo

wns

and

con

trol

failu

re d

ue to

freq

uent

cyc

ling,

se

vere

env

ironm

enta

l con

ditio

ns r

elat

ed to

moi

stur

e,

corr

osiv

e ch

emic

als,

dus

t or

exce

ssiv

e he

at. T

hese

ap

plic

atio

ns r

equi

re H

oney

wel

l Hom

e an

d B

uild

ing

Con

trol

Eng

inee

ring

revi

ew; c

onta

ct y

our

Hon

eyw

ell

Sal

es R

epre

sent

ativ

e fo

r as

sist

ance

.

Rev

iew

the

follo

win

g co

nditi

ons

that

can

app

ly to

you

r sp

ecifi

c in

stal

latio

n an

d fo

llow

the

prec

autio

ns

sugg

este

d.

Fre

que

nt

Cycl

ing

Thi

s co

ntro

l is

desi

gned

for

use

on a

pplia

nces

that

ty

pica

lly c

ycle

thre

e to

four

tim

es a

n ho

ur o

nly

durin

g th

e he

atin

g se

ason

. In

year

-aro

und

appl

icat

ions

with

gre

ater

cy

clin

g ra

tes,

the

cont

rol c

an w

ear

out m

ore

quic

kly.

P

erfo

rm a

mon

thly

che

ckou

t.

Wa

ter

or

Ste

am

Cle

anin

gIf

a co

ntro

l get

s w

et, r

epla

ce it

. If t

he a

pplia

nce

is li

kely

to

be c

lean

ed w

ith w

ater

or

stea

m, p

rote

ct (

cove

r) th

e co

ntro

l and

wiri

ng fr

om w

ater

or

stea

m fl

ow. M

ount

the

cont

rol h

igh

enou

gh a

bove

the

botto

m o

f the

cab

inet

so

it do

es n

ot g

et w

et d

urin

g no

rmal

cle

anin

g pr

oced

ures

.

Hig

h H

um

idity

or

Drip

pin

g W

ate

rD

rippi

ng w

ater

can

cau

se th

e co

ntro

l to

fail.

Nev

er in

stal

l an

app

lianc

e w

here

wat

er c

an d

rip o

n th

e co

ntro

l. In

ad

ditio

n, h

igh

ambi

ent h

umid

ity c

an c

ause

the

cont

rol t

o co

rrod

e an

d fa

il. If

the

appl

ianc

e is

in a

hum

id

atm

osph

ere,

mak

e su

re a

ir ci

rcul

atio

n ar

ound

the

cont

rol

is a

dequ

ate

to p

reve

nt c

onde

nsat

ion.

Als

o, r

egul

arly

ch

eck

out t

he s

yste

m.

Mo

del

No

. S

uff

ix L

ette

rK

it t

o C

on

vert

N

atu

ral G

as t

o L

PK

it t

o C

on

vert

LP

to

Nat

ura

l Gas

H, K

, M39

3691

3945

88

PN

ot fi

eld

conv

ertib

le.

Not

fiel

d co

nver

tible

.

Q39

6021

3960

25

RN

ot r

equi

red,

co

nver

tible

val

ve.

Not

req

uire

d,

conv

ertib

le v

alve

.

Inle

t/O

utl

et

Pip

e S

ize

(in

. NP

T)

Fla

ng

e Ty

pe

Par

t N

um

ber

a,b

Wit

ho

ut

Hex

W

ren

chW

ith

Hex

W

ren

ch

3/8

Str

aigh

t39

3690

-139

3690

-11

3/8

Elb

ow39

3690

-239

3690

-12

1/2

Str

aigh

t39

3690

-639

3690

-16

1/2

Elb

ow39

3690

-339

3690

-13

3/4

Str

aigh

t39

3690

-439

3690

-14

3/4

Elb

ow39

3690

-539

3690

-15

VR

8104

, VR

8204

AN

D V

R83

04 IN

TE

RM

ITT

EN

T P

ILO

T C

OM

BIN

ATIO

N G

AS

CO

NT

RO

LS

69-1

225—

46

Fig

. 3. S

edim

ent

trap

inst

alla

tio

n.

Inst

all

Co

ntr

ol

1.M

ount

ed 0

to 9

0 de

gree

s in

any

dire

ctio

n, in

clud

ing

vert

ical

ly, f

rom

the

uprig

ht p

ositi

on o

f the

gas

co

ntro

l kno

b.2.

Mou

nt s

o th

e ga

s flo

w is

in th

e di

rect

ion

of th

e ar

row

on

the

botto

m o

f the

con

trol

.3.

Thr

ead

the

pipe

the

amou

nt s

how

n in

Tab

le 7

for

inse

rtio

n in

to c

ontr

ol o

r ad

apte

rs. D

o no

t thr

ead

pipe

too

far.

Val

ve d

isto

rtio

n or

mal

func

tion

can

resu

lt if

the

pipe

is in

sert

ed to

o de

eply

.

Tab

le 7

. N

PT

Pip

e T

hre

ad L

eng

th (

in.)

.

4. A

pply

a m

oder

ate

amou

nt o

f goo

d qu

ality

pip

e co

mpo

und

(do

not u

se T

eflo

n ta

pe)

only

to th

e pi

pe, l

eavi

ng tw

o en

d th

read

s ba

re. O

n LP

in

stal

latio

ns, u

se a

com

poun

d re

sist

ant t

o LP

gas

. S

ee F

ig. 4

.5.

Rem

ove

the

seal

s ov

er th

e co

ntro

l inl

et a

nd o

utle

t if

nece

ssar

y.6.

Con

nect

the

pipe

to th

e co

ntro

l inl

et a

nd o

utle

t. U

se

a w

renc

h on

the

squa

re e

nds

of th

e co

ntro

l. If

a fla

nge

is u

sed,

pla

ce th

e w

renc

h on

the

flang

e ra

ther

than

on

the

gas

cont

rol.

Ref

er to

Fig

. 5

and

6.

Con

nect P

ilot G

as T

ubin

g1.

Cut

tubi

ng to

the

desi

red

leng

th a

nd b

end

as

nece

ssar

y fo

r ro

utin

g to

the

pilo

t bur

ner.

Do

not

mak

e sh

arp

bend

s or

def

orm

the

tubi

ng. D

o no

t be

nd th

e tu

bing

at t

he g

as c

ontr

ol a

fter

the

com

pres

sion

nut

is ti

ghte

ned,

bec

ause

this

can

re

sult

in g

as le

akag

e at

the

conn

ectio

n.2.

Squ

are

off a

nd r

emov

e bu

rrs

from

the

end

of th

e tu

bing

.3.

Uns

crew

the

bras

s co

mpr

essi

on fi

tting

from

the

pilo

t out

let (

Fig

. 6).

Slip

the

fittin

g ov

er th

e tu

bing

an

d sl

ide

out o

f the

way

. See

Fig

. 7.

NO

TE

:W

hen

repl

acin

g a

cont

rol,

cut o

ff th

e ol

d co

mpr

essi

on fi

tting

and

rep

lace

with

the

com

pres

sion

fitti

ng p

rovi

ded

on th

e co

mbi

natio

n ga

s co

ntro

l. N

ever

use

the

old

com

pres

sion

fit

ting

beca

use

it m

ay n

ot p

rovi

de a

gas

-tig

ht

seal

.

4.P

ush

the

tubi

ng in

to th

e pi

lot g

as ta

ppin

g on

the

outle

t end

of t

he c

ontr

ol u

ntil

it bo

ttom

s. W

hile

ho

ldin

g th

e tu

bing

all

the

way

in, s

lide

the

fittin

g in

to p

lace

and

eng

age

the

thre

ads;

then

turn

unt

il fin

ger

tight

. Tig

hten

one

mor

e tu

rn w

ith a

wre

nch,

bu

t do

not o

vert

ight

en.

5.C

onne

ct th

e ot

her

end

of th

e tu

bing

to th

e pi

lot

burn

er a

ccor

ding

to th

e pi

lot b

urne

r man

ufac

ture

r’s

inst

ruct

ions

.

Fig

. 4.

Use

mo

der

ate

amo

un

t o

f p

ipe

com

po

un

d.

Pip

e S

ize

Th

read

Pip

e th

is A

mo

un

tM

axim

um

Dep

th P

ipe

can

b

e In

sert

ed in

to C

on

tro

l

3/8

9/16

3/8

1/2

3/4

1/2

3/4

13/1

63/

4

GA

SC

ON

TR

OL

GA

SC

ON

TR

OL

HO

RIZ

ON

TA

LDR

OP

PIP

ED

GA

SS

UP

PL

Y

PIP

ED

GA

SS

UP

PL

Y3

IN.

(76

MM

)M

INIM

UM

3 IN

.(7

6 M

M)

MIN

IMU

M

RIS

ER

GA

SC

ON

TR

OL

TU

BIN

GG

AS

SU

PP

LY

HO

RIZ

ON

TA

LDR

OP

3 IN

.(7

6 M

M)

MIN

IMU

M

RIS

ER

M30

77

21

2

2

1 2

ALL

BE

ND

S IN

ME

TA

LLIC

TU

BIN

G S

HO

ULD

BE

SM

OO

TH

.

CA

UT

ION

: S

HU

T O

FF

TH

E M

AIN

GA

S S

UP

PLY

BE

FO

RE

RE

MO

VIN

GE

ND

CA

P T

O P

RE

VE

NT

GA

S F

RO

M F

ILLI

NG

TH

E W

OR

K A

RE

A.

TE

ST

F

OR

GA

S L

EA

KA

GE

WH

EN

INS

TA

LLA

TIO

N IS

CO

MP

LET

E.

TW

O IM

PE

RF

EC

T

TH

RE

AD

SG

AS

CO

NT

RO

L

TH

RE

AD

PIP

E T

HE

AM

OU

NT

S

HO

WN

IN T

AB

LE F

OR

IN

SE

RT

ION

INT

O G

AS

CO

NT

RO

L

AP

PLY

A M

OD

ER

AT

E A

MO

UN

T O

FP

IPE

CO

MP

OU

ND

TO

PIP

E O

NLY

(LE

AV

E T

WO

EN

D T

HR

EA

DS

BA

RE

).M

3075

B

PIP

E

VR

8104

, VR

8204

AN

D V

R83

04 IN

TE

RM

ITT

EN

T P

ILO

T C

OM

BIN

AT

ION

GA

S C

ON

TR

OLS

569

-122

5—4

Fig

. 1. T

op

vie

w o

f co

nve

rtib

le

pre

ssu

re r

egu

lato

r ca

p.

Inst

all

Ad

ap

ters

To C

on

trol

If ad

apte

rs a

re b

eing

inst

alle

d on

the

cont

rol,

mou

nt th

em

as fo

llow

s:

Fla

ng

es

1.C

hoos

e th

e ap

prop

riate

flan

ge fo

r yo

ur a

pplic

atio

n.2.

Rem

ove

the

seal

ove

r th

e ga

s co

ntro

l inl

et o

r ou

tlet.

3.M

ake

sure

that

the

O-r

ing

is fi

tted

in th

e gr

oove

of

the

flang

e. If

the

O-r

ing

is n

ot a

ttach

ed o

r is

m

issi

ng, d

o no

t use

the

flang

e.4.

With

the

O-r

ing

faci

ng th

e co

ntro

l, al

ign

the

scre

w

hole

s on

the

gas

cont

rol w

ith th

e ho

les

in th

e fla

nge.

Inse

rt a

nd ti

ghte

n th

e sc

rew

s pr

ovid

ed w

ith

the

flang

e. S

ee F

ig. 2

. Tig

hten

the

scre

ws

to 2

5 in

ch-p

ound

s of

torq

ue to

pro

vide

a g

as-t

ight

sea

l.

Bu

shin

gs

1.R

emov

e th

e se

al o

ver

the

cont

rol i

nlet

or

outle

t.2.

App

ly a

mod

erat

e am

ount

of g

ood

qual

ity p

ipe

com

poun

d to

the

bush

ing,

leav

ing

two

end

thre

ads

bare

. On

an L

P in

stal

latio

n, u

se c

ompo

und

that

is

resi

stan

t to

LP g

as. D

o no

t use

Tef

lon

tape

.3.

Inse

rt th

e bu

shin

g in

the

cont

rol a

nd c

aref

ully

th

read

the

pipe

into

the

bush

ing

until

tigh

t.

Com

plet

e th

e in

stru

ctio

ns b

elow

for

inst

allin

g th

e pi

ping

, in

stal

ling

the

cont

rol,

conn

ectin

g th

e pi

lot g

as tu

bing

and

th

e w

iring

. Mak

e su

re th

e le

ak te

st y

ou p

erfo

rm o

n th

e co

ntro

l afte

r co

mpl

etin

g th

e in

stal

latio

n in

clud

es le

ak

test

ing

the

adap

ters

and

scr

ews.

If y

ou u

se a

wre

nch

on

the

valv

e af

ter

the

flang

es a

re in

stal

led,

use

the

wre

nch

only

on

the

flang

e, n

ot o

n th

e co

ntro

l. S

ee F

ig. 5

.

Fig

. 2.

Fir

mly

fas

ten

fla

ng

e to

val

ve, b

ut

do

no

t o

vert

igh

ten

scr

ews.

Loca

tion

The

com

bina

tion

gas

cont

rol i

s m

ount

ed in

the

appl

ianc

e ve

stib

ule

on th

e ga

s m

anifo

ld. I

f thi

s is

a r

epla

cem

ent

appl

icat

ion,

mou

nt th

e ga

s co

ntro

l in

the

sam

e lo

catio

n as

the

old

cont

rol.

Loca

te th

e co

mbi

natio

n ga

s co

ntro

l whe

re it

can

not b

e af

fect

ed b

y st

eam

cle

anin

g, h

igh

hum

idity

, or

drip

ping

w

ater

, cor

rosi

ve c

hem

ical

s, d

ust o

r gr

ease

acc

umul

atio

n or

exc

essi

ve h

eat.

To a

ssur

e pr

oper

ope

ratio

n, fo

llow

th

ese

guid

elin

es:

•Lo

cate

gas

con

trol

in a

wel

l-ven

tilat

ed a

rea.

•M

ount

gas

con

trol

hig

h en

ough

abo

ve c

abin

et b

otto

m

to a

void

exp

osur

e to

floo

ding

or

spla

shin

g w

ater

.•

Ass

ure

the

ambi

ent t

empe

ratu

re d

oes

not e

xcee

d th

e am

bien

t tem

pera

ture

rat

ings

for

each

com

pone

nt.

•C

over

gas

con

trol

if a

pplia

nce

is c

lean

ed w

ith w

ater

, st

eam

, or

chem

ical

s or

to a

void

dus

t and

gre

ase

accu

mul

atio

n.•

Avo

id lo

catin

g ga

s co

ntro

l whe

re e

xpos

ure

to

corr

osiv

e ch

emic

al fu

mes

or

drip

ping

wat

er a

re li

kely

.

Insta

ll P

ipin

g to

Co

ntr

ol

All

pipi

ng m

ust c

ompl

y w

ith lo

cal c

odes

and

ord

inan

ces

or w

ith th

e N

atio

nal F

uel G

as C

ode

(AN

SI Z

223.

1,

NF

PA

No.

54)

, whi

chev

er a

pplie

s. T

ubin

g in

stal

latio

n m

ust c

ompl

y w

ith a

ppro

ved

stan

dard

s an

d pr

actic

es.

1.U

se n

ew, p

rope

rly r

eam

ed p

ipe

that

is fr

ee fr

om

chip

s. If

tubi

ng is

use

d, m

ake

sure

the

ends

are

sq

uare

, deb

urre

d an

d cl

ean.

All

tubi

ng b

ends

mus

t be

sm

ooth

and

with

out d

efor

mat

ion.

2.R

un p

ipe

or tu

bing

to th

e co

ntro

l. If

tubi

ng is

use

d,

obta

in a

tube

-to-

pipe

cou

plin

g to

con

nect

the

tubi

ng to

the

cont

rol.

3.In

stal

l a s

edim

ent t

rap

in th

e su

pply

line

to th

e co

ntro

l. S

ee F

ig. 3

.

PR

ES

SU

RE

R

EG

ULA

TO

R

CA

P

M11

678

NAT

NAT

LP

L P

NAT

NAT

OR

OT

HE

R S

IDE

OF

CA

P

M90

46

VA

LVE

OU

TLE

T

FLA

NG

E

9/64

INC

H H

EX

SC

RE

WS

(4)

DO

NO

T O

VE

RT

IGH

TE

N S

CR

EW

S.

TIG

HT

EN

TO

25

INC

H-P

OU

ND

S.

1

1

VR

8104

, VR

8204

AN

D V

R83

04 IN

TE

RM

ITT

EN

T P

ILO

T C

OM

BIN

ATIO

N G

AS

CO

NT

RO

LS

69-1

225—

48

Fig

. 8. T

ypic

al w

irin

g c

on

nec

tio

ns

for

24 v

olt

co

ntr

ol

in in

term

itte

nt

ign

itio

n s

yste

m w

ith

S86

00.

ST

AR

TU

P A

ND

CH

EC

KO

UT

WA

RN

ING

Fir

e o

r E

xplo

sio

n H

azar

d.

Can

cau

se p

rop

erty

dam

age,

sev

ere

inju

ry

or

dea

th.

1.D

o no

t for

ce th

e ga

s co

ntro

l kno

b on

the

appl

ianc

e. U

se o

nly

your

han

d to

turn

the

gas

cont

rol k

nob.

Nev

er u

se a

ny to

ols.

2.If

the

knob

doe

s no

t ope

rate

by

hand

, the

co

ntro

l sho

uld

be r

epla

ced

by a

qua

lifie

d se

rvic

e te

chni

cian

.

Gas

Co

ntr

ol K

nob

Sett

ings

Gas

con

trol

kno

b se

tting

s ar

e as

follo

ws:

OF

F: P

reve

nts

pilo

t and

mai

n ga

s flo

w th

roug

h th

e co

ntro

l.O

N: P

erm

its g

as to

flow

into

the

cont

rol b

ody.

Und

er

cont

rol o

f the

ther

mos

tat a

nd in

term

itten

t pilo

t mod

ule,

ga

s ca

n flo

w to

the

pilo

t and

mai

n bu

rner

s.

NO

TE

:C

ontr

ols

are

ship

ped

with

the

gas

cont

rol k

nob

in th

e O

N p

ositi

on.

Turn

On

Syste

mR

otat

e th

e ga

s co

ntro

l kno

b co

unte

rclo

ckw

ise

to

ON

.

Tu

rn O

n M

ain

Bu

rner

Fol

low

app

lianc

e m

anuf

actu

rer

inst

ruct

ions

or

turn

up

ther

mos

tat t

o ca

ll fo

r he

at.

Pe

rform

Ga

s L

ea

k T

est

WA

RN

ING

Fir

e o

r E

xplo

sio

n H

azar

d.

Can

cau

se p

rop

erty

dam

age,

sev

ere

inju

ry

or

dea

th.

Per

form

Gas

Lea

k Te

st e

very

tim

e w

ork

is d

one

on a

gas

sys

tem

.

IMP

OR

TA

NT

Do

not s

pray

soa

p an

d w

ater

sol

utio

n on

the

gas

cont

rol.

Do

not u

se a

n ex

cess

ive

amou

nt o

f so

ap a

nd w

ater

sol

utio

n to

per

form

the

gas

leak

te

st. T

hese

can

dam

age

the

cont

rol.

Gas L

eak T

est

1.P

aint

pip

e co

nnec

tions

ups

trea

m o

f the

gas

con

trol

w

ith r

ich

soap

and

wat

er s

olut

ion.

Bub

bles

indi

cate

a

gas

leak

.2.

If a

leak

is d

etec

ted,

tigh

ten

the

pipe

con

nect

ions

.3.

Ligh

t the

mai

n bu

rner

. Sta

nd c

lear

of t

he m

ain

burn

er w

hile

ligh

ting

to p

reve

nt in

jury

cau

sed

from

hi

dden

leak

s th

at c

ould

cau

se fl

ashb

ack

in th

e ap

plia

nce

vest

ibul

e.

4.W

ith th

e m

ain

burn

er in

ope

ratio

n, p

aint

the

pipe

jo

ints

(in

clud

ing

adap

ters

) an

d th

e co

ntro

l inl

et a

nd

outle

t with

ric

h so

ap a

nd w

ater

sol

utio

n.5.

If an

othe

r le

ak is

det

ecte

d, ti

ghte

n th

e ad

apte

r sc

rew

s, jo

ints

, and

pip

e co

nnec

tions

.6.

Rep

lace

the

part

if a

leak

can

not b

e st

oppe

d.

Ch

eck

an

d A

dju

st

Pilo

t F

lam

eT

he p

ilot f

lam

e sh

ould

env

elop

3/8

to 1

/2 in

. (10

to 1

3 m

m)

of th

e tip

of t

he ig

nite

r-se

nsor

. See

Fig

. 9. I

f the

pilo

t fla

me

is s

mal

l or

lazy

, the

inle

t gas

pre

ssur

e m

ay b

e to

o lo

w, o

r th

e pi

lot o

rific

e m

ay b

e pa

rtia

lly c

logg

ed. C

heck

an

d re

pair

as n

eces

sary

. If t

he p

ilot f

lam

e is

har

d an

d no

isy,

the

inle

t gas

pre

ssur

e m

ay b

e to

o hi

gh. T

he g

as

cont

rol h

as a

pilo

t adj

ustm

ent m

echa

nism

to r

educ

e th

e pi

lot f

low

if n

eces

sary

. If p

ilot a

djus

tmen

t is

nece

ssar

y,

proc

eed

as fo

llow

s:1.

Rem

ove

pilo

t adj

ustm

ent c

over

scr

ew. S

ee F

ig. 6

.2.

The

pilo

t adj

ustm

ent i

s sh

ippe

d at

the

full

pilo

t gas

flo

w r

ate.

Tur

n th

e in

ner

adju

stm

ent s

crew

cl

ockw

ise

if t

he in

let p

ress

ure

is to

o hi

gh.

Turn

the

inne

r ad

just

men

t scr

ew c

lock

wis

e

to d

ecre

ase

or c

ount

ercl

ockw

ise

to

incr

ease

pi

lot f

lam

e.3.

Rep

lace

the

cove

r sc

rew

afte

r th

e ad

just

men

t to

prev

ent g

as le

akag

e.

Fig

. 9. P

rop

er f

lam

e ad

just

men

t.

MV

MV

/PV

PV

GN

D(B

UR

NE

R)

24V

GN

D24

VS

PA

RK

S86

00

PO

WE

R S

UP

PLY

. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S

AN

D O

VE

RLO

AD

PR

OT

EC

TIO

N A

S R

EQ

UIR

ED

.

ALT

ER

NA

TE

LIM

IT C

ON

TR

OLL

ER

LO

CA

TIO

N.

MA

XIM

UM

WIR

E L

EN

GT

H 3

ft [.

9 m

].

CO

NT

RO

LS IN

24V

CIR

CU

IT M

US

T N

OT

BE

IN

GR

OU

ND

LE

G T

O T

RA

NS

FO

RM

ER

.

FO

R M

OD

ULE

WIT

H T

H-W

TE

RM

INA

L A

ND

VE

NT

DA

MP

ER

P

LUG

, CO

NN

EC

T T

HE

RM

OS

TA

T T

O T

H-W

. LE

AV

E

24V

OP

EN

. D

O N

OT

RE

MO

VE

VE

NT

DA

MP

ER

PLU

G.

1 2 3 4 5

M90

56

GR

OU

ND

PIL

OT

GA

SS

UP

PLY

24

3

Q34

5, Q

346,

Q34

8, Q

362,

Q38

1 P

ILO

T B

UR

NE

R/

IGN

ITE

R-S

EN

SO

RL1 (H

OT

) 1L2

LIM

IT

CO

NT

RO

LLE

R

TH

ER

MO

ST

AT

5

TH

-W(O

PT

)

VE

NT

DA

MP

ER

PLU

G

(OP

T)

5

GA

S C

ON

TR

OL

TE

RM

INA

LS

PV

PV

/MV

MV

SE

NS

E

PR

OP

ER

FLA

ME

A

DJU

ST

ME

NT

IGN

ITE

R-

SE

NS

OR

M30

80A

3/8

TO

1/2

INC

H(1

0 T

O 1

3 m

m)

VR

8104

, VR

8204

AN

D V

R83

04 IN

TE

RM

ITT

EN

T P

ILO

T C

OM

BIN

AT

ION

GA

S C

ON

TR

OLS

769

-122

5—4

Fig

. 5.

Pro

per

use

of

wre

nch

on

gas

co

ntr

ol w

ith

an

d w

ith

ou

t fl

ang

es.

Fig

. 6. T

op

vie

w o

f g

as c

on

tro

l.

Fig

. 7. A

lway

s u

se n

ew c

om

pre

ssio

n f

itti

ng

.

Wir

ing

Fol

low

the

wiri

ng in

stru

ctio

ns fu

rnis

hed

by th

e ap

plia

nce

man

ufac

ture

r, if

avai

labl

e, o

r us

e th

e ge

nera

l ins

truc

tions

pr

ovid

ed b

elow

. Whe

n th

ese

inst

ruct

ions

diff

er fr

om th

e ap

plia

nce

man

ufac

ture

r, fo

llow

the

appl

ianc

e m

anuf

actu

rer

inst

ruct

ions

.

All

wiri

ng m

ust c

ompl

y w

ith a

pplic

able

ele

ctric

al c

odes

an

d or

dina

nces

.

Dis

conn

ect p

ower

sup

ply

befo

re m

akin

g w

iring

co

nnec

tions

to p

reve

nt e

lect

rical

sho

ck o

r eq

uipm

ent

dam

age.

1.C

heck

the

pow

er s

uppl

y ra

ting

on th

e ga

s co

ntro

l an

d m

ake

sure

it m

atch

es th

e av

aila

ble

supp

ly.

Inst

all a

tran

sfor

mer

, the

rmos

tat a

nd o

ther

con

trol

s as

req

uire

d.2.

Con

nect

con

trol

circ

uit t

o th

e ga

s co

ntro

l ter

min

als.

S

ee F

ig. 8

.

AP

PLY

WR

EN

CH

F

RO

M T

OP

OR

B

OT

TO

M O

F G

AS

C

ON

TR

OL

TO

E

ITH

ER

SH

AD

ED

AR

EAW

HE

N F

LA

NG

E IS

NO

T U

SE

D

AP

PLY

WR

EN

CH

TO

FLA

NG

E O

NLY

WH

EN

FL

AN

GE

IS U

SE

D

M30

79

HI-

LO

AD

JUS

TM

EN

T S

CR

EW

S

(UN

DE

R C

AP

)

RE

GU

LAT

OR

VE

NT

CO

VE

R

INL

ET

INL

ET

OU

TL

ET

M10

968A

HI

LO

OU

TLE

TP

RE

SS

UR

E

TA

P

WIR

ING

TE

RM

INA

LS (

3)

INLE

TP

RE

SS

UR

E T

AP

PR

ES

SU

RE

RE

GU

LAT

OR

AD

JUS

TM

EN

T(U

ND

ER

CA

P S

CR

EW

)

PIL

OT

OU

TLE

T

PIL

OT

AD

JUS

TM

EN

T(U

ND

ER

CA

P S

CR

EW

)G

AS

CO

NT

RO

LK

NO

B

TW

O-S

TA

GE

P

RE

SS

UR

ER

EG

ULA

TO

R

MO

DE

L

GA

S C

ON

TRO

L

TIG

HTE

N N

UT

ON

E T

UR

NB

EY

ON

D F

ING

ER

TIG

HT.

FITT

ING

BR

EA

KS

OFF

AN

D C

LIN

CH

ES

TU

BIN

G A

S N

UT

IS T

IGH

TEN

ED

.

TO P

ILO

TB

UR

NE

R

M30

76A

VR

8104

, VR

8204

AN

D V

R83

04 IN

TE

RM

ITT

EN

T P

ILO

T C

OM

BIN

ATIO

N G

AS

CO

NT

RO

LS

69-1

225—

410

4.W

ith m

ain

burn

er o

pera

ting,

che

ck th

e ga

s co

ntro

l flo

w ra

te u

sing

the

met

er c

lock

ing

met

hod

or c

heck

pr

essu

re u

sing

a m

anom

eter

con

nect

ed to

the

outle

t pre

ssur

e ta

p on

the

gas

cont

rol.

See

Fig

. 6.

5.If

nece

ssar

y, a

djus

t the

hig

h pr

essu

re r

egul

ator

to

mat

ch th

e ap

plia

nce

ratin

g. S

ee T

able

s 8A

and

8B

fo

r fa

ctor

y-se

t nom

inal

out

let p

ress

ure

and

adju

stm

ent r

ange

.a.

Rem

ove

the

pres

sure

regu

lato

r adj

ustm

ent c

ap

(Fig

. 6).

b.U

sing

a s

crew

driv

er, t

urn

the

inne

r ad

just

men

t sc

rew

for

HI p

ress

ure

cloc

kwis

e to

in

crea

se o

r co

unte

rclo

ckw

ise

to

decr

ease

the

gas

pres

sure

to th

e bu

rner

.6.

Afte

r hi

gh p

ress

ure

has

been

che

cked

, che

ck lo

w

pres

sure

reg

ulat

ion.

Tw

o-st

age

appl

ianc

e op

erat

ing

sequ

ence

s va

ry. C

onsu

lt th

e ap

plia

nce

man

ufac

ture

rs in

stru

ctio

ns fo

r th

e sp

ecifi

c op

erat

ing

sequ

ence

and

reg

ulat

or a

djus

tmen

t pr

oced

ure

for

the

appl

ianc

e in

whi

ch th

e co

ntro

l is

inst

alle

d an

d fo

r in

stru

ctio

ns o

n ho

w to

pre

vent

the

cont

rol f

rom

mov

ing

to h

igh

stag

e w

hile

che

ckin

g th

e lo

w p

ress

ure

regu

lato

r se

tting

.7.

Che

ck th

e lo

w r

ate

man

ifold

pre

ssur

e lis

ted

on th

e ap

plia

nce

nam

epla

te. G

as c

ontr

ol lo

w r

ate

outle

t pr

essu

re s

houl

d m

atch

this

rat

ing.

8.W

ith m

ain

burn

er o

pera

ting,

che

ck th

e ga

s co

ntro

l flo

w r

ate

as b

efor

e (u

sing

the

met

er c

lock

ing

met

hod

or c

heck

pre

ssur

e us

ing

a m

anom

eter

co

nnec

ted

to th

e ou

tlet p

ress

ure

tap

on th

e co

ntro

l).9.

If ne

cess

ary,

adj

ust t

he lo

w p

ress

ure

regu

lato

r to

m

atch

the

appl

ianc

e ra

ting.

See

Tab

les

8A a

nd 8

B

for

fact

ory-

set n

omin

al o

utle

t pre

ssur

e an

d ad

just

men

t ran

ge.

a.R

emov

e th

e pr

essu

re re

gula

tor a

djus

tmen

t cap

(F

ig. 6

).U

sing

a s

crew

driv

er, t

urn

the

inne

r ad

just

men

t scr

ew fo

r LO

pre

ssur

e cl

ockw

ise

to in

crea

se o

r co

unte

rclo

ckw

ise

to d

ecre

ase

the

gas

pres

sure

to

the

burn

er.

10.

Onc

e hi

gh a

nd lo

w p

ress

ure

have

bee

n ch

ecke

d an

d ad

just

ed, r

epla

ce p

ress

ure

regu

lato

r ad

just

men

t cap

. If t

he d

esire

d ou

tlet p

ress

ure

or

flow

rat

e ca

nnot

be

achi

eved

by

adju

stin

g th

e ga

s co

ntro

l, ch

eck

the

cont

rol i

nlet

pre

ssur

e us

ing

a m

anom

eter

at t

he in

let p

ress

ure

tap

of th

e co

ntro

l. If

the

inle

t pre

ssur

e is

in th

e no

min

al r

ange

(s

ee T

able

s 8A

and

8B

), r

epla

ce th

e ga

s co

ntro

l. O

ther

wis

e, ta

ke th

e ne

cess

ary

step

s to

pro

vide

pr

oper

gas

pre

ssur

e to

the

cont

rol.

Ch

eck

Sa

fety

Sh

utd

ow

n P

erf

orm

an

ce

WA

RN

ING

Fir

e o

r E

xplo

sio

n H

azar

d.

Can

cau

se p

rop

erty

dam

age,

sev

ere

inju

ry

or

dea

th.

Per

form

the

safe

ty s

hutd

own

test

any

tim

e w

ork

is d

one

on a

gas

sys

tem

.

NO

TE

:R

ead

step

s 1

thro

ugh

7 be

fore

sta

rtin

g, a

nd

com

pare

to th

e sa

fety

shu

tdow

n or

saf

ety

lock

out t

ests

rec

omm

ende

d fo

r th

e in

term

itten

t pi

lot (

IP)

igni

tion

mod

ule.

Whe

re d

iffer

ent,

use

the

proc

edur

e re

com

men

ded

for

the

mod

ule.

1.Tu

rn o

ff ga

s su

pply

.2.

Set

ther

mos

tat o

r co

ntro

ller

abov

e ro

om

tem

pera

ture

to c

all f

or h

eat.

3.W

atch

for

igni

tion

spar

k or

for

glow

at h

ot s

urfa

ce

igni

ter

eith

er im

med

iate

ly o

r fo

llow

ing

prep

urge

. S

ee IP

mod

ule

spec

ifica

tions

.4.

Tim

e th

e le

ngth

of t

he s

park

ope

ratio

n. S

ee th

e IP

m

odul

e sp

ecifi

catio

ns.

5.A

fter

the

mod

ule

lock

s ou

t, op

en th

e m

anua

l gas

co

ck a

nd m

ake

sure

no

gas

is fl

owin

g to

the

pilo

t or

mai

n bu

rner

. With

mod

ules

that

con

tinue

to s

park

un

til th

e pi

lot l

ight

s or

the

syst

em s

huts

dow

n m

anua

lly, t

he p

ilot s

houl

d lig

ht w

hen

the

man

ual

gas

cont

rol k

nob

is o

pene

d.6.

Set

the

ther

mos

tat b

elow

roo

m te

mpe

ratu

re a

nd

wai

t one

min

ute.

7.O

pera

te s

yste

m th

roug

h on

e co

mpl

ete

cycl

e to

m

ake

sure

all

cont

rols

ope

rate

pro

perly

.

Tab

le 8

A. P

ress

ure

Reg

ula

tor

Sp

ecif

icat

ion

Pre

ssu

res

(in

. wc)

.

a Lo

w F

ire s

ettin

g ra

nge

for

VR

8304

Q 1

/2 in

. by

1/2

in. a

nd 1

/2 in

. by

3.4

in. i

s 1.

5 to

3.0

in. w

c.

Mo

del

Typ

eTy

pe

of

Gas

No

min

al In

let

Pre

ssu

re R

ang

e

Fac

tory

Set

No

min

al O

utl

et

Pre

ssu

reS

etti

ng

Ran

ge

Ste

pF

ull

Rat

eS

tep

F

ull

Rat

e

Sta

ndar

d,

Slo

wN

AT

5.0

to 7

.0—

3.5

—3.

0 to

5.0

LP12

.0 to

14.

0—

10.0

—8.

0 to

12.

0

Ste

pN

AT

5.0

to 7

.00.

93.

5N

one

0.7

to 1

.7

LP12

.0 to

14.

02.

210

.0N

one

1.4

to 5

.5

Two-

Sta

geN

AT

5.0

to 7

.0—

1.7

Low

3.5

Hig

h—

0.9

to 3

.0 L

owa

3.0

to 5

.0 H

igh

LP12

1.0

to 1

4.0

—4.

9 Lo

w10

.0 H

igh

—3.

5 to

5.5

Low

8.0

to 1

1.0

Hig

h

VR

8104

, VR

8204

AN

D V

R83

04 IN

TE

RM

ITT

EN

T P

ILO

T C

OM

BIN

AT

ION

GA

S C

ON

TR

OLS

969

-122

5—4

Che

ck a

nd A

dju

st G

as I

np

ut

and

Bu

rner

Ign

itio

n

IMP

OR

TAN

T1.

Do

not e

xcee

d in

put r

atin

g st

ampe

d on

ap

plia

nce

nam

epla

te, o

r m

anuf

actu

rer’s

re

com

men

ded

burn

er o

rific

e pr

essu

re fo

r si

ze

orifi

ce(s

) us

ed. M

ake

cert

ain

prim

ary

air

supp

ly

to m

ain

burn

er is

pro

perly

adj

uste

d fo

r com

plet

e co

mbu

stio

n. F

ollo

w a

pplia

nce

man

ufac

ture

r in

stru

ctio

ns.

2.IF

CH

EC

KIN

G G

AS

INP

UT

BY

CLO

CK

ING

G

AS

ME

TE

R: M

ake

cert

ain

ther

e is

no

gas

flow

th

roug

h th

e m

eter

oth

er th

an to

the

appl

ianc

e be

ing

chec

ked.

Oth

er a

pplia

nces

mus

t rem

ain

off w

ith th

e pi

lots

ext

ingu

ishe

d (o

r de

duct

thei

r co

nsum

ptio

n fr

om th

e m

eter

rea

ding

). C

onve

rt

flow

rat

e to

Btu

h as

des

crib

ed in

form

70-

2602

, G

as C

ontr

ols

Han

dboo

k, a

nd c

ompa

re to

Btu

h in

put r

atin

g on

app

lianc

e na

mep

late

.3.

IF C

HE

CK

ING

GA

S IN

PU

T W

ITH

M

AN

OM

ET

ER

: Mak

e su

re th

e ga

s co

ntro

l kno

b is

in th

e O

FF

pos

ition

bef

ore

rem

ovin

g ou

tlet

pres

sure

tap

plug

to c

onne

ct m

anom

eter

(p

ress

ure

gaug

e). A

lso

mov

e th

e ga

s co

ntro

l kn

ob to

the

OF

F p

ositi

on w

hen

rem

ovin

g th

e ga

uge

and

repl

acin

g th

e pl

ug. B

efor

e re

mov

ing

inle

t pre

ssur

e ta

p pl

ug, s

hut o

ff ga

s su

pply

at

the

man

ual v

alve

in th

e ga

s pi

ping

to th

e ap

plia

nce

or, f

or L

P, a

t the

tank

. Als

o sh

ut o

ff ga

s su

pply

bef

ore

disc

onne

ctin

g m

anom

eter

an

d re

plac

ing

plug

. Rep

eat G

as L

eak

Test

at

plug

with

mai

n bu

rner

ope

ratin

g.

NO

TE

:C

heck

the

inle

t pre

ssur

e be

fore

adj

ustin

g th

e pr

essu

re r

egul

ator

.

Sta

nd

ard

an

d S

low

-Op

en

ing

(H

, K

an

d M

) M

od

els

1.

Car

eful

ly c

heck

the

mai

n bu

rner

ligh

toff.

Mak

e su

re

that

the

mai

n bu

rner

ligh

ts s

moo

thly

and

that

all

port

s re

mai

n lit

.2.

Che

ck th

e fu

ll ra

te m

anifo

ld p

ress

ure

liste

d on

the

appl

ianc

e na

mep

late

. Gas

con

trol

full

rate

out

let

pres

sure

sho

uld

mat

ch th

is r

atin

g.3.

With

mai

n bu

rner

ope

ratin

g, c

heck

the

cont

rol f

low

ra

te u

sing

the

met

er c

lock

ing

met

hod

or c

heck

pr

essu

re u

sing

a m

anom

eter

con

nect

ed to

the

outle

t pre

ssur

e ta

p on

the

cont

rol.

See

Fig

. 6.

4.If

nece

ssar

y, a

djus

t the

pre

ssur

e re

gula

tor

to

mat

ch th

e ap

plia

nce

ratin

g. S

ee T

able

s 8A

and

8B

fo

r fa

ctor

y-se

t nom

inal

out

let p

ress

ure

and

adju

stm

ent r

ange

.a.

Rem

ove

the

pres

sure

regu

lato

r adj

ustm

ent c

ap

scre

w.

b.U

sing

a s

crew

driv

er, t

urn

the

inne

r ad

just

men

t sc

rew

(F

ig. 6

) cl

ockw

ise

to in

crea

se o

r co

unte

rclo

ckw

ise

to d

ecre

ase

the

gas

pres

sure

to th

e bu

rner

.c.

Alw

ays

repl

ace

the

cap

scre

w a

nd ti

ghte

n fir

mly

to p

reve

nt g

as le

akag

e.5.

If th

e de

sire

d ou

tlet p

ress

ure

or fl

ow r

ate

cann

ot

be a

chie

ved

by a

djus

ting

the

gas

cont

rol,

chec

k th

e ga

s co

ntro

l inl

et p

ress

ure

usin

g a

man

omet

er a

t th

e in

let p

ress

ure

tap

of th

e ga

s co

ntro

l. If

the

inle

t pr

essu

re is

in th

e no

min

al r

ange

(se

e Ta

bles

8A

an

d 8B

), r

epla

ce th

e ga

s co

ntro

l. O

ther

wis

e, ta

ke

the

nece

ssar

y st

eps

to p

rovi

de p

rope

r ga

s pr

essu

re to

the

cont

rol.

NO

TE

:If

the

burn

er fi

ring

rate

is a

bove

150

,000

Btu

h on

VR

8304

mod

els

(see

Tab

le 1

for

VR

8304

ca

paci

ties)

, it m

ay n

ot b

e po

ssib

le to

del

iver

the

desi

red

outle

t pre

ssur

e. T

his

is a

n ap

plic

atio

n is

sue,

not

a c

ontr

ol fa

ilure

. Tak

e w

hate

ver

step

s ar

e re

quire

d to

cor

rect

the

situ

atio

n.

Ste

p-O

pen

ing (

P)

Mo

dels

S

tep-

open

ing

mod

els

requ

ire th

at y

ou c

heck

and

adj

ust

the

full-

rate

pre

ssur

e fir

st a

nd th

en c

heck

the

step

pr

essu

re. T

he s

tep

pres

sure

is n

ot fi

eld

adju

stab

le.

1.C

aref

ully

che

ck th

e m

ain

burn

er li

ghto

ff. M

ake

sure

th

at th

e m

ain

burn

er li

ghts

sm

ooth

ly a

nd th

at a

ll po

rts

rem

ain

lit.

2.C

heck

the

full

rate

man

ifold

pre

ssur

e lis

ted

on th

e ap

plia

nce

nam

epla

te. G

as c

ontr

ol fu

ll ra

te o

utle

t pr

essu

re s

houl

d m

atch

this

rat

ing.

3.W

ith m

ain

burn

er o

pera

ting,

che

ck th

e ga

s co

ntro

l flo

w r

ate

usin

g th

e m

eter

clo

ckin

g m

etho

d or

che

ck

pres

sure

usi

ng a

man

omet

er c

onne

cted

to th

e ou

tlet p

ress

ure

tap

on th

e ga

s co

ntro

l. S

ee F

ig. 6

.4.

If ne

cess

ary,

adj

ust t

he p

ress

ure

regu

lato

r to

m

atch

the

appl

ianc

e ra

ting.

See

Tab

les

8A a

nd 8

B

for

fact

ory-

set n

omin

al o

utle

t pre

ssur

e an

d ad

just

men

t ran

ge.

a.R

emov

e th

e pr

essu

re re

gula

tor a

djus

tmen

t cap

sc

rew

.U

sing

a s

crew

driv

er, t

urn

the

inne

r ad

just

men

t scr

ew

(Fig

. 6)

cloc

kwis

e to

incr

ease

or

coun

terc

lock

wis

e to

dec

reas

e th

e ga

s pr

essu

re

to th

e bu

rner

.b.

Alw

ays

repl

ace

the

cap

scre

w a

nd ti

ghte

n fir

mly

to p

reve

nt g

as le

akag

e.5.

If th

e de

sire

d ou

tlet p

ress

ure

or fl

ow r

ate

cann

ot b

e ac

hiev

ed b

y ad

just

ing

the

gas

cont

rol,

chec

k th

e ga

s co

ntro

l inl

et p

ress

ure

usin

g a

man

omet

er a

t th

e in

let p

ress

ure

tap

of th

e co

ntro

l. If

the

inle

t pr

essu

re is

in th

e no

min

al r

ange

(se

e Ta

bles

8A

an

d 8B

), r

epla

ce th

e co

ntro

l. O

ther

wis

e, ta

ke th

e ne

cess

ary

step

s to

pro

vide

pro

per

gas

pres

sure

to

the

cont

rol.

6.C

aref

ully

che

ck th

e bu

rner

ligh

toff

at s

tep

pres

sure

. M

ake

sure

the

burn

er li

ghts

sm

ooth

ly a

nd w

ithou

t fla

shba

ck to

the

orifi

ce. M

ake

sure

all

port

s re

mai

n lit

. Cyc

le th

e bu

rner

sev

eral

tim

es, a

llow

ing

at le

ast

60 s

econ

ds b

etw

een

cycl

es fo

r th

e re

gula

tor

to

resu

me

the

step

func

tion.

Rep

eat a

fter a

llow

ing

the

burn

er to

coo

l. R

eadj

ust t

he fu

ll ra

te o

utle

t pr

essu

re, i

f nec

essa

ry, t

o im

prov

e lig

htof

f ch

arac

teris

tics.

Tw

o-S

tag

e (

Q)

Mo

dels

Tw

o-st

age

mod

els

requ

ire th

at y

ou c

heck

and

adj

ust b

oth

high

and

low

pre

ssur

e re

gula

tor

setti

ngs.

Tw

o-st

age

appl

ianc

e op

erat

ing

sequ

ence

s va

ry. C

onsu

lt th

e ap

plia

nce

man

ufac

ture

r in

stru

ctio

ns fo

r th

e sp

ecifi

c op

erat

ing

sequ

ence

and

reg

ulat

or a

djus

tmen

t pro

cedu

re

for

the

appl

ianc

e in

whi

ch th

e co

ntro

l is

inst

alle

d.

1.S

et a

pplia

nce

to o

pera

te o

n hi

gh.

2.C

aref

ully

che

ck th

e m

ain

burn

er li

ghto

ff. M

ake

sure

th

at th

e m

ain

burn

er li

ghts

sm

ooth

ly a

nd th

at a

ll po

rts

rem

ain

lit.

3.C

heck

the

full

rate

(hi

gh)

man

ifold

pre

ssur

e lis

ted

on th

e ap

plia

nce

nam

epla

te fo

r hi

gh p

ress

ure.

The

ga

s co

ntro

l ful

l rat

e ou

tlet p

ress

ure

shou

ld m

atch

th

is r

atin

g.

69-1

225—

4

G.R

. R

ev. 9

-00

ww

w.h

oney

wel

l.com

Hom

e an

d B

uild

ing

Con

trol

Hom

e an

d B

uild

ing

Con

trol

Hon

eyw

ell I

nc.

Hon

eyw

ell L

imite

d-H

oney

wel

l Lim

itée

1985

Dou

glas

Dri

ve N

orth

35 D

ynam

ic D

rive

Gol

den

Val

ley,

Min

neso

ta 5

5422

Scar

boro

ugh,

Ont

ario

M1V

4Z

9

VR

8104

, VR

8204

AN

D V

R 8

304

INT

ER

MIT

TE

NT

PIL

OT

CO

MB

INAT

ION

GA

S C

ON

TR

OLS

Prin

ted

in U

.S.A

. on

recy

cled

pa

per

cont

aini

ng a

t lea

st 1

0%

post

-con

sum

er p

aper

fibe

rs.

INS

TR

UC

TIO

NS

TO

TH

E

HO

ME

OW

NE

R

WA

RN

ING

Fir

e o

r E

xplo

sio

n H

azar

d.

Can

cau

se p

rop

erty

dam

age,

sev

ere

inju

ry,

or

dea

th.

Fol

low

thes

e w

arni

ngs

exac

tly:

1.P

ilot f

lam

e is

lit a

utom

atic

ally

. Do

not l

ight

the

pilo

t fla

me

man

ually

.2.

Bef

ore

light

ing

the

pilo

t bur

ner

flam

e, s

mel

l ar

ound

the

appl

ianc

e fo

r ga

s. B

e su

re to

sm

ell

next

to th

e flo

or b

ecau

se L

P g

as is

hea

vier

th

an a

ir. If

you

sm

ell g

as:

•Tu

rn o

ff th

e ga

s su

pply

at t

he a

pplia

nce

serv

ice

valv

e. O

n LP

gas

sys

tem

s, tu

rn o

ff th

e ga

s su

pply

at t

he g

as ta

nk.

•D

o no

t lig

ht a

ny a

pplia

nces

in th

e ho

use.

•D

o no

t tou

ch e

lect

rical

sw

itche

s or

use

the

phon

e.•

Leav

e th

e bu

ildin

g an

d us

e a

neig

hbor

’s

phon

e to

cal

l you

r ga

s su

pplie

r.•

If yo

u ca

nnot

rea

ch y

our

gas

supp

lier,

call

the

fire

depa

rtm

ent.

3.R

epla

ce th

e ga

s co

ntro

l in

the

even

t of a

ny

phys

ical

dam

age,

tam

perin

g, b

ent t

erm

inal

s,

mis

sing

or

brok

en p

arts

, str

ippe

d th

read

s, o

r ev

iden

ce o

f exp

osur

e to

hea

t.

IMP

OR

TAN

TF

ollo

w th

e op

erat

ing

inst

ruct

ions

pro

vide

d by

th

e he

atin

g ap

plia

nce

man

ufac

ture

r. T

he

info

rmat

ion

belo

w d

escr

ibes

a ty

pica

l con

trol

ap

plic

atio

n, b

ut th

e sp

ecifi

c co

ntro

ls u

sed

and

the

proc

edur

es o

utlin

ed in

you

r ap

plia

nce

man

ufac

ture

r in

stru

ctio

ns c

an d

iffer

, req

uirin

g sp

ecia

l ins

truc

tions

.

ST

OP

: R

ea

d t

he

Wa

rnin

gs

Ab

ove

Be

fore

Pro

cee

din

g.

The

pilo

t fla

me

is li

t aut

omat

ical

ly. I

f the

app

lianc

e do

es

not t

urn

on w

hen

the

ther

mos

tat i

s se

t sev

eral

deg

rees

ab

ove

room

tem

pera

ture

, fol

low

thes

e in

stru

ctio

ns:

1.S

et th

e th

erm

osta

t to

its lo

wes

t set

ting

to r

eset

the

safe

ty c

ontr

ol.

2.D

isco

nnec

t all

elec

tric

pow

er to

the

appl

ianc

e.3.

Rem

ove

the

burn

er a

cces

s pa

nel i

f pro

vide

d on

yo

ur a

pplia

nce.

4.Tu

rn th

e ga

s co

ntro

l kno

b cl

ockw

ise

to t

he

OF

F p

ositi

on.

5.W

ait f

ive

min

utes

to c

lear

out

any

unb

urne

d ga

s.

The

n if

you

smel

l gas

, ST

OP

! Fol

low

Ste

p 2

in th

e W

arni

ng a

bove

. If y

ou d

o no

t sm

ell g

as, c

ontin

ue

with

the

next

ste

p.6.

Turn

the

gas

cont

rol k

nob

coun

terc

lock

wis

e

to th

e O

N p

ositi

on.

7.R

epla

ce th

e bu

rner

acc

ess

pane

l.8.

Rec

onne

ct a

ll el

ectr

ic p

ower

to th

e ap

plia

nce.

9.S

et th

e th

erm

osta

t to

the

desi

red

setti

ng.

10.

If th

e ap

plia

nce

does

not

turn

on,

turn

the

gas

cont

rol k

nob

to th

e O

FF

pos

ition

and

con

tact

a

qual

ified

ser

vice

tech

nici

an fo

r as

sist

ance

.

Tu

rnin

g O

ff th

e A

pplia

nce

Vaca

tion S

hu

tdow

nS

et th

e th

erm

osta

t to

the

desi

red

room

tem

pera

ture

whi

le

you

are

away

.

Com

ple

te S

hutd

ow

nTu

rn o

ff po

wer

to th

e ap

plia

nce.

Tur

n of

f the

gas

sup

ply

to th

e ap

plia

nce.

Tur

n th

e ga

s co

ntro

l kno

b to

OF

F. T

he

appl

ianc

e w

ill c

ompl

etel

y sh

ut o

ff. F

ollo

w th

e pr

oced

ure

in th

e In

stru

ctio

ns to

the

Hom

eow

ner

sect

ion

abov

e to

re

sum

e no

rmal

ope

ratio

n.

VR

8104

, VR

8204

AN

D V

R83

04 IN

TE

RM

ITT

EN

T P

ILO

T C

OM

BIN

AT

ION

GA

S C

ON

TR

OLS

1169

-122

5—4

Tab

le 8

B. P

ress

ure

Reg

ula

tor

Sp

ecif

icat

ion

Pre

ssu

res

(kP

a).

a Lo

w F

ire s

ettin

g ra

nge

for

VR

8304

Q 1

/2 in

. by

1/2

in. a

nd 1

/2 in

. by

3.4

in. i

s 0.

37 t

o 0.

75 k

Pa.

Non

-Re

gula

tin

g O

n-O

ff (

U)

Mo

de

lsN

on-r

egul

atin

g V

R82

04U

Val

ves

are

desi

gned

for

appl

icat

ion

in v

ario

us p

arts

of E

urop

e w

here

a s

epar

ate,

di

stin

ct, p

ress

ure

regu

lato

r is

req

uire

d. T

he V

R82

04U

is

sim

ilar t

o th

e V

R82

04A

in a

ll ot

her a

spec

ts a

nd s

houl

d be

in

stal

led

acco

rdin

gly.

MA

INT

EN

AN

CE

WA

RN

ING

Fir

e o

r E

xplo

sio

n H

azar

d.

Can

cau

se p

rop

erty

dam

age,

sev

ere

inju

ry,

or

dea

th.

Do

not d

isas

sem

ble

the

gas

cont

rol;

it co

ntai

ns

no r

epla

ceab

le c

ompo

nent

s. A

ttem

pted

di

sass

embl

y, r

epai

r, or

cle

anin

g ca

n da

mag

e th

e co

ntro

l, re

sulti

ng in

gas

leak

age.

Reg

ular

pre

vent

ive

mai

nten

ance

is im

port

ant f

or

appl

icat

ions

in th

e co

mm

erci

al c

ooki

ng a

nd a

gric

ultu

ral

and

indu

stria

l ind

ustr

ies

that

pla

ce a

hea

vy lo

ad o

n sy

stem

con

trol

s be

caus

e:

•In

man

y su

ch a

pplic

atio

ns, p

artic

ular

ly c

omm

erci

al

cook

ing,

the

equi

pmen

t ope

rate

s 10

0,00

0 to

200

,000

cy

cles

per

yea

r. S

uch

heav

y cy

clin

g ca

n w

ear

out t

he

gas

cont

rol i

n on

e to

two

year

s.•

Exp

osur

e to

wat

er, d

irt, c

hem

ical

s an

d he

at c

an

dam

age

the

gas

cont

rol a

nd s

hut d

own

the

cont

rol

syst

em.

The

mai

nten

ance

pro

gram

sho

uld

incl

ude

regu

lar

chec

kout

of t

he c

ontr

ol a

s ou

tline

d in

the

Sta

rtup

and

C

heck

out s

ectio

n, a

nd th

e co

ntro

l sys

tem

as

desc

ribed

in

the

appl

ianc

e m

anuf

actu

rer

liter

atur

e.

Mai

nten

ance

freq

uenc

y m

ust b

e de

term

ined

indi

vidu

ally

fo

r ea

ch a

pplic

atio

n. S

ome

cons

ider

atio

ns a

re:

•C

yclin

g fr

eque

ncy.

App

lianc

es th

at m

ay c

ycle

20,

000

times

ann

ually

sho

uld

be c

heck

ed m

onth

ly.

•In

term

itten

t use

. App

lianc

es th

at a

re u

sed

seas

onal

ly

shou

ld b

e ch

ecke

d be

fore

shu

tdow

n an

d ag

ain

befo

re

the

next

use

.•

Con

sequ

ence

of u

nexp

ecte

d sh

utdo

wn.

Whe

re th

e co

st o

f an

unex

pect

ed s

hutd

own

wou

ld b

e hi

gh, t

he

syst

em s

houl

d be

che

cked

mor

e of

ten.

•D

usty

, wet

, or

corr

osiv

e en

viro

nmen

ts. S

ince

thes

e en

viro

nmen

ts c

an c

ause

the

gas

cont

rol t

o de

terio

rate

m

ore

rapi

dly,

the

syst

em s

houl

d be

che

cked

mor

e of

ten.

The

sys

tem

sho

uld

be r

epla

ced

if:•

It do

es n

ot p

erfo

rm p

rope

rly o

n ch

ecko

ut o

r tr

oubl

esho

otin

g.•

The

gas

con

trol

is li

kely

to h

ave

oper

ated

for

mor

e th

an 2

00,0

00 c

ycle

s.•

The

con

trol

is w

et o

r lo

oks

as if

it h

as b

een

wet

.

SE

RV

ICE

WA

RN

ING

Fir

e o

r E

xplo

sio

n H

azar

d.

Can

cau

se p

rop

erty

dam

age,

sev

ere

inju

ry

or

dea

th.

Do

not d

isas

sem

ble

the

cont

rol;

it co

ntai

ns n

o re

plac

eabl

e co

mpo

nent

s. A

ttem

pted

di

sass

embl

y, r

epai

r, or

cle

anin

g ca

n da

mag

e th

e ga

s co

ntro

l, re

sulti

ng in

gas

leak

age.

CA

UT

ION

Eq

uip

men

t D

amag

e.C

an b

urn

ou

t va

lve

coil

term

inal

s.N

ever

app

ly a

jum

per

acro

ss (

or s

hort

) th

e va

lve

coil

term

inal

s, e

ven

tem

pora

rily.

Afte

r se

rvic

ing,

ver

ify p

rope

r sy

stem

ope

ratio

n.

If M

ain

Bu

rner

Do

es N

ot

Co

me

O

n W

ith

Ca

ll F

or

He

at

1.C

onfir

m th

e ga

s co

ntro

l kno

b is

in th

e O

N p

ositi

on.

2.A

djus

t the

rmos

tat s

ever

al d

egre

es a

bove

roo

m

tem

pera

ture

.3.

Usi

ng a

c vo

ltmet

er, c

heck

for

24V

at g

as c

ontr

ol:

•If

pilo

t lig

hts,

mea

sure

acr

oss

MV

/PV

and

MV.

•If

pilo

t doe

s no

t lig

ht, m

easu

re a

cros

s M

V/P

V

and

PV

bef

ore

safe

ty lo

ckou

t occ

urs.

4.If

volta

ge is

inco

rrec

t or

not p

rese

nt, c

heck

con

trol

ci

rcui

t for

pro

per

oper

atio

n.5.

If 24

V is

pre

sent

, rep

lace

gas

con

trol

.

Mo

del

Typ

eTy

pe

of

Gas

No

min

al In

let

Pre

ssu

re R

ang

e

Fac

tory

Set

No

min

al O

utl

et

Pre

ssu

reS

etti

ng

Ran

ge

Ste

pF

ull

Rat

eS

tep

Fu

ll R

ate

Sta

ndar

d,

Slo

wN

AT

1.2

to 1

.7—

0.9

—0.

7 to

1.2

LP2.

9 to

3.9

—2.

5—

2.0

to 3

.0

Ste

pN

AT

1.2

to 1

.70.

20.

9N

one

0.17

to 0

.48

LP2.

9 to

3.9

0.5

2.5

Non

e1.

4 to

1.3

7

Two-

stag

eN

AT

1.2

to 1

.7—

0.48

Low

0.9

Hig

h—

0.22

to 0

.75

Low

a

0.75

to 1

.2 H

igh

LP2.

9 to

3.9

—1.

2 Lo

w2.

5 H

igh

—0.

9 to

1.4

Low

2.0

to 2

.5 H

igh

DELIMING PROCEDURE — Connect ACE deliming kitas shown in picture.

1. Close gas cock at heater.

2. Turn off water to and from heater and drain heater.

3. Type “C” ACE Heater, remove upper aquastat andwell and install faucet; Type “D”, “E” and "G" ACE

Heater, remove pipe plug on left side of upper heatermanifold and install faucet.

4. Attach hose from pump to top faucet and return hosefrom acid container to lower faucet as shown in pic-ture.

5. Pour water into plastic container and add equalamount of acid. Approximately 4 gallons of dilutedsolution is required for 400,000 BTU and smallerheaters, 5 gallons to 7 gallons for heaters up to760,000 BTU and 9 gallons for heaters between1,000,000 and 1,500,000 BTU.

6. Turn on pump and circulate solution until foamingaction of the solution stops indicating that dissolvingof the lime has been completed. Add approximatelyan additional quart of solution to insure that end offoaming is not due to spent acid. Do not continue topump acid solution for a prolonged time after foam-ing stops because the acid will dissolve the copperand brass.

7. Flush heater out with baking soda and water solutionand return it to service.

In case of a completely plugged coil it is recommendedthat a heater serviceman be called in to do the deliming.

CAUTION! AVOID SPILLING OR DRIPPING ACID ON HANDS,FACE, CLOTHING OR ELECTRICAL CONTROLS OR WIRING.COVER CONTROLS WITH PLASTIC SHEETING SUCH AS SARAN,OR POLYETHYLENE BAG, TO AVOID DAMAGE TO THESE PARTS.USE A BAKING SODA AND WATER SOLUTION TO NEUTRALIZE

ANY ACID ON HANDS, FACE, CONTROLS, ETC.

NON-ACID DELIMING SOLUTION — For those pre-ferring to use a non-acid base solution, it will be notedthat the effectiveness of such a solution is shorter-livedthan regular acid and usually requires more stock solu-tion. Such a solution, called “LIMINAL”, may beobtained from Polyteck Co., 5112 W. Jefferson Blvd.,Los Angeles, Calif. 90016. Also in the eastern areascontact Tri-Bros. Chemical Corp., P.O. Box 2, MortonGrove, Illinois 60053 for solution called “Lime Eater”.

Water heaters that use fresh water will develop a coat-

ing of lime if the fresh water is not softened or if it is not

naturally free from undissolved solids. When a water

softener does not function properly, due to lack of ser-

vicing or due to undersizing, the heater will develop

lime.

Inspection of Heater — Check heater every 6 months

by closing water plug cocks, and removing high limit

aquastat well, located in top manifold, and visually

inspect the inside of the coil for lime. ACE recommends

deliming if 1/32" or greater thickness of lime is found. If

recovery rate of heater falls off, this is usually a sign of

lime in the coil. The ACE coil will “bang” or “knock” if lim-

ing condition is severely restricting circulation.

Customers have reported operating ACE heaters and

softeners under heavy duty laundry service for 10 to 15

years without the need to delime or change the ACE

conical coil. Under moderate water hardness condi-

tions, ACE users have found that when operating with-

out a softener that deliming once a year could be

accomplished in approximately one hour.

For deliming, use solution of muriatic acid (which can be

purchased from any drug or pool supply store) and

dilute with equal amount of water to obtain a 50% solu-

tion for normal deliming. Caution: Always add acid to

water when diluting. Adding water to acid can result in

splashing and acid burns. If coil has a heavy coating of

lime, use only 10% solution of acid of acid to start with

to prevent chunks of lime from breaking loose and plug-

ging the coil before dissolving.

Deliming Kit

EFFECTIVE — AC E single coi l , noparal le l tubes, insures that a l l

l ime is removed

FAST — Simple hook up and sin-gle coi l a l lows del iming to be

accomplished in one hour or lessunder normal

condit ions

ECONOMICAL — Acid costsshould not exceed $15.00 on

largest heater. Muriatic acid canbe purchased at most drug stores or

pool supply dealers.

Ajax BO I L E R IN C .

2701 S. HA R B O R BLV D.

SA N TA AN A, CA 92704

PH O N E: (714) 437-9050

FA X: (714) 437-9060

website: www.ajaxboi ler.com

emai l : Info@ajaxboi ler.com

GAS FIRED COPPER FIN CONE COIL WATER HEATERS • HEAVY DUTY INDUSTRIAL WATER HEATERS • “MINI-PACK” SEMI-INSTANTANEOUS WATER HEATERS • PACKAGED STORAGE WATER HEATERS • CLEAN STEAM BOILERS • ASME HOT WATER STORAGE TANKS

Ace Boiler Inc., formerly Ace Buehler Inc.,is a division of Ajax Boiler Inc.

Ace Boiler Inc. maintains a policy of continuous improvements and therefore

reserves the right to change specificationswithout notice.

“Quality, Value and Service Since 1919”SECTION 265

EFFECTIVEDECEMBER 2002

Packages are availablefor domestic hot water

systems, laundryheaters, car wash sys-

tems, and swimmingpool heating.

ACE BOILER INC.SECTION 250

CONTINUED

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