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Y8610U INTERMITTENT PILOT RETROFIT KIT
21 68-0291—03
Troubleshooting Guide
Refer to the Fig. 22 for troubleshooting the S8610U control
module.
Fig. 22. Troubleshooting Guide.
POWER TO
TH-W TERMINAL?
(NOMINAL
24 V )
PILOT
BURNER
LIGHTS?
SPARK
STOPS WHEN
PILOT IS
LIT?
MAIN
BURNER
LIGHTS?
SYSTEM
RUNS UNTIL “CALL
FOR HEAT”
ENDS?
“CALL FOR HEAT” ENDS
SYSTEM
SHUTS
OFF?
REPEAT PROCEDURE UNTIL
TROUBLE FREE OPERATION
IS OBTAINED
CHECK IGNITION CABLE, GROUND WIRING, CERAMIC INSULATOR, AND GAP AND CORRECT.
CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING.
TAKE PROTECTIVE ACTION TO SHIELD CABLE AND BOOT FROM EXCESSIVE TEMPERATURES.
CHECK THAT ALL MANUAL GAS VALVES ARE OPEN, SUPPLY TUBING AND GAS PRESSURES ARE TO SPECIFICATION, AND
PILOT BURNER ORIFICE IS NOT BLOCKED.
CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL.
CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF VOLTAGE IS OKAY, REPLACE GAS CONTROL. IF NOT,
REPLACE MODULE.
NOTE: IT MAY BE NECESSARY TO RECYCLE THE “CALL FOR HEAT” TO CLEAR THE PILOT SUPPLY TUBING OF AIR.
CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF NO VOLTAGE, REPLACE MODULE.
CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL. IF OKAY, REPLACE GAS CONTROL.
CHECK FOR PROPER THERMOSTAT (CONTROLLER) OPERATION.
REMOVE MV LEAD AT MODULE. IF VALVE CLOSES, RECHECK TEMPERATURE CONTROLLER AND WIRING. IF NOT, REPLACE
GAS CONTROL.
SPARK OK?
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
REPLACE MODULE.
YES
NOTE: 24 VAC “CALL FOR HEAT” IS ALWAYS CONNECTED TO THE TH-W TERMINAL ON THE MODULE.
START:
BEFORE TROUBLESHOOTING,
FAMILIARIZE YOURSELF WITH THE
STARTUP AND CHECKOUT
PROCEDURES.
TURN THERMOSTAT
(CONTROLLER) TO
“CALL FOR HEAT”
CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING.
ALSO, CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE END SWITCH (IF USED) IS MADE.
SPARK
ACROSS IGNITER/
SENSOR
GAP?
PULL IGNITION LEAD AND
CHECK SPARK AT MODULE.
TURN GAS SUPPLY ON AND
RECYCLE “CALL FOR HEAT”
NOTE: IF MODULE GOES INTO RETRY DELAY, RESET THE “CALL FOR HEAT.”
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
CLEAN FLAME ROD.
CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE.
CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR.
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE.
ADJUST PILOT FLAME IF NECESSARY.
IF PROBLEM PERSISTS, REPLACE MODULE.
NOTE: IF MODULE GOES INTO RETRY DELAY, RESET THE “CALL FOR HEAT.”
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
NOTE: IF GROUND IS POOR OR ERRATIC, SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL
AT THE TIME OF CHECKOUT.
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE.
ADJUST PILOT FLAME.
IF CHECKS ARE OKAY, REPLACE MODULE.
M24904
TURN GAS SUPPLY OFF
NO
RECYCLE “CALL FOR HEAT“ TO
ALLOW TIME TO CHECK SPARK.