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Y8610U INTERMITTENT PILOT RETROFIT KIT
15 68-0291—03
Jumper
This jumper (labeled P4) is used to lock the operating
sequence selected by the DIP switch settings. See Fig. 18.
IMPORTANT
Once the Jumper has been pulled or the module
starts the 10
th
“Call for Heat”, the control operating
sequence is permanently locked and cannot be reset
by replacing the jumper or by resetting the Dip
Switches.
CHECKOUT
Check out the gas control system:
• At initial appliance installation.
• As part of regular maintenance procedures. Maintenance
intervals are determined by the application. See “Planning
the Installation” on page 6.
• As the first step in troubleshooting.
• Anytime work is done on the system.
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY, OR
DEATH.
1. If you smell gas or suspect a gas leak, turn off the
gas at the manual service valve and evacuate the
building. Do not try to light any appliance and do not
touch any electrical switch or telephone in the
building until no spilled gas remains.
2. A gas leak test must be done as described in the
steps below on initial installation and any time work
is done involving the gas piping.
Step 1: Perform Visual Inspection.
1. With power off, make sure all wiring connections are
clean and tight.
2. Turn on power to appliance and ignition control module.
3. Open manual shutoff valves in the gas line to the appli-
ance.
4. Perform a gas leak test ahead of the gas control.
GAS LEAK TEST:
Paint the gas control gasket edges and all pipe
connections upstream of the gas control with a rich soap
and water solution. Bubbles indicate gas leaks. Tighten
the joints and screws or replace component to stop gas
leak. Recheck with soap and water solution.
Step 2: Verify Ignition Control System
Ground.
The igniter, flame sensor, and ignition control module must
share a common ground with the pilot burner. Use
thermoplastic insulated wire with a minimum rating of 221°F
(105°C) for the ground wire; asbestos insulation is not
acceptable. If the temperature at the wire could exceed 221°F
(105°C), use a shield to protect the wire from radiant heat
generated by the burner. Connect the ground wire as follows:
1. Fit one end of the ground wire with a female 1/4 in.
quick-connect terminal and connect it to the male
quick-connect GND (BURNER) terminal on the ignition
control module.
2. Strip the other end of the wire and fasten it under the
igniter bracket mounting screw. If necessary, use a
shield to protect the ground wire from radiant heat.
3. The burner serves as the common grounding area. If
there is not good metal-to-metal contact between the
burner and ground, run a lead from the burner to ground.
NOTE: Earth ground is not required.
Step 3: Review Normal Operating Sequence
and Ignition Control Module Specifications.
See the Operation section on this page and “Specifications” on
page 2.
Step 4: Reset the Ignition Control Module.
1. Turn the thermostat to its lowest setting.
2. Wait one minute.
As you perform the remaining steps, watch for points where
operation deviates from normal. To correct problems, refer to
the “Troubleshooting Guide” on page 21.
Step 5: Check Safety Shutoff Operation.
1. Turn gas supply off at the appliance manual shutoff
valve.
2. Set thermostat or controller above room temperature to
“Call for Heat.”
3. Watch for spark at pilot burner. Time spark from start to
shutoff. Spark should shut off after 90 seconds. See
device label and “Settings” on page 14.
4. Wait 5 minutes. Ignition sequence should start again fol-
lowed by shutoff.
5. Set thermostat below room temperature and wait one
minute before continuing.
Step 6: Check Normal Operation.
1. Turn on the gas supply at the appliance manual shutoff
valve.
2. Turn gas control knob to ON and make sure that no gas
is flowing to the pilot or main burner.
3. Set thermostat or controller above room temperature to
“Call for Heat.”
4. Make sure pilot lights smoothly when gas reaches the
pilot burner.
5. Make sure main burner lights smoothly without flash-
back.
6. Make sure burner operates smoothly without floating, lift-
ing, or flame rollout to the furnace vestibule or heat
buildup in the vestibule.
Table 7. Jumper Usage.
Jumper
Action to lock the control’s operating sequence
P4 To ensure proper system operation (after
installation and checkout), pull jumper to lock the
DIP switch settings.
NOTE: If jumper is not removed during installa-
tion, the ignition control locks the DIP
switch settings after the 10
th
“Call for
Heat” cycle.