68-0133 - Y8610U Intermittent Pilot Retrofit Kit - Air & Water

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Y8610U INTERMITTENT PILOT RETROFIT KIT 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 section for more information. • As the first Troubleshooting step. • Anytime work is done on the system. 68-0133—2 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. Perform the Gas Leak Test after initial Installation and anytime work is done to the gas piping. STEP 1: Perform a Visual Inspection. • With the power off, make sure all wiring connections are clean and tight. • Turn off all power to appliances and the ignition module. • Open manual shutoff valves in the gas line to the appliance. • Perform Gas Leak Test. WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE, SEVERE INJURY, OR DEATH. Check for gas leaks with soap and water solution anytime work is done on a gas control. Gas Leak Test Paint all pipe connections upstream of the gas control with a rich soap and water solution. Bubbles indicate a gas leak. If a gas leak is detected, tighten the pipe connection. Stand clear while lighting the main burner to prevent injury caused from hidden gas leaks, which could cause flashback in the appliance vestibule. Light the main burner. With the main burner in operation, paint all pipe joints (including adapters) and gas control inlet and outlet with a rich soap and water solution. If another gas leak is detected, tighten the adapter screws, joints, and pipe connections. Replace the part if the gas leak cannot be stopped. STEP 2: Review Normal Operating Sequence and Module Specifications. • See Specifications and Operation sections. STEP 3: Reset the Module. • Turn the thermostat to its lowest setting. • Wait one minute. As you perform Steps 4 through 9, watch for points where operation deviates from normal. See the Troubleshooting Guide, Fig. 19, to correct the problem. 12 STEP 4: Check Safety Shutoff Operation. • Turn the gas supply off at the manual shutoff valve. • Set the thermostat or controller above the room temperature to call for heat. • Watch for spark at pilot burner. • Time spark from start to shutoff. See Specifications section. • Open the gas control knob and ensure no gas is flowing to the pilot or main burner. • Set the thermostat below the room temperature and wait one minute before continuing. STEP 5: Check and Adjust Gas Input to Main Burner. CAUTION 1. Do not exceed the input rating stamped on the appliance nameplate, or manufacturer recommended burner orifice pressure for the size orifice(s) used. Make sure the main burner primary air supply is properly adjusted for complete combustion (see the appliance manufacturer instructions). 2. If checking gas input by clocking the gas meter: • Make sure that the only gas flow through the meter is that of the appliance being tested. • Make sure that other appliances are turned off and that the pilot burners are extinguished (or deduct the gas consumptions from the meter reading). • Convert the flow rate to Btuh as described in the Gas Controls Handbook, form 70-6202 and compare to the Btuh input rating on the appliance nameplate. 3. If checking gas input with a manometer (pressure gauge): • Make sure the gas control knob is in the PILOT position before removing the outlet pressure tap plug to connect the manometer. • Turn the gas control knob back to PILOT when removing the manometer and replacing the outlet pressure tap plug. • Shut off the gas supply at the appliance service valve or, for LP gas, at the gas tank before removing the outlet pressure tap plug and before disconnecting the manometer and replacing the outlet pressure tap plug. • Perform the Gas Leak Test at the inlet pressure tap plug. The gas control output pressure should match the manifold pressure listed on the appliance nameplate. With the main burner operating, check the gas control flow rate using the meter clocking method or check the gas pressure using a manometer connected to the gas control outlet pressure tap. See Fig. 3. If necessary, adjust the pressure regulator to match the appliance rating. Gas control outlet pressure is normally set at 3.5 in. wc (0.9 kPa) nominal for natural gas. It can be adjusted from 3 to 5 in. wc (0.74 to 1.2 kPa). Gas control outlet pressure is normally set at 10 in. wc (2.5 kPa) nominal for LP gas. It can be adjusted from 8 to 12 in. wc (2 to 3 kPa). a. Remove the pressure regulator adjustment cap and screw. b. Using a screwdriver, turn the inner adjustment screw clockwise to increase or counterclockwise to decrease the main burner gas pressure. c. Always replace the cap screw and tighten firmly.
If the desired outlet gas pressure or gas flow rate cannot be achieved by adjusting the gas control, check the gas control inlet pressure using a manometer at the inlet pressure tap. If the inlet pressure is in the normal range, replace the gas control; otherwise, take the necessary steps to provide proper gas pressure to the gas control. STEP 6: Adjust Pilot Flame. The pilot flame should envelop 3/8 to 1/2 in. (10 to 13 mm) of the ground rod and tip of the igniter-sensor. See Fig. 17 to adjust the pilot flame. PROPER FLAME ADJUSTMENT IGNITER-SENOR TIP IN PILOT FLAME PILOT GAS TUBING GROUND ROD ELECTRODE SCREW IGNITER-SENSOR ASSEMBLY IGNITION CABLE STUD TERMINAL Fig. 17. Proper flame adjustment. M4677 Remove the pilot adjustment cover screw. See Fig. 3. Turn the inner adjustment screw clockwise to decrease or counterclockwise to increase the pilot flame. Always replace the cover screw after adjustment and tighten firmly. STEP 7: Check Other System Components • On Furnaces: Make sure the limit controller and fan controller are operating in accordance with the appliance manufacturer instructions. • On Boilers: Make sure the circulating water pumps, low water cutoffs, automatic feed controllers, pressure and temperature limit controllers, and relief valves are operating in accordance with the appliance manufacturer recommendations. STEP 8: Check Normal Operation • Set the thermostat or controller above the room temperature to call for heat. • Make sure the pilot lights smoothly when the gas reaches the pilot burner. 13 Y8610U INTERMITTENT PILOT RETROFIT KIT • Make sure the main burner lights smoothly without flashback. • Make sure the main burner operates smoothly without floating, lifting, or flame rollout to the furnace vestibule or heat buildup in the vestibule. • If the gas line has been disturbed, complete the Gas Leak Test following Step 1. • Turn the thermostat or controller below the room temperature. Make sure the main burner and pilot flames go out. OPERATION System operation is divided into two stages: 1. Trial for ignition. 2. Main burner operation. See Fig. 18 for the normal operating sequence. Trial for Ignition Pilot Ignition Following the call for heat, the module energizes the first main valve operator. The first main valve opens, which allows gas to flow to the pilot burner. At the same time, the electronic spark generator in the module produces a high voltage spark pulse output. The voltage generates a spark at the ignitersensor that lights the pilot. If the pilot does not light, or the pilot flame current is not at least 1.0 uA and steady, the module can not energize the second (main) valve and the main burner can not light. After 90 seconds maximum, the system shuts off and the pilot valve closes; trial for ignition restarts after a minimum of five minutes (six minutes nominal). Ignition, shutoff, and wait sequence repeats until pilot lights or call for heat ends. Main Burner Operation When the pilot flame is established, a flame rectification circuit is completed between the sensor and burner ground. The flame sensing circuit in the module detects the flame current, shuts off the spark generator and energizes the second main valve operator. The second main valve opens and gas flows to the main burner, where it is ignited by the pilot burner. When the call for heat ends, both valve operators are deenergized, and both valves in the gas control close. 68-0133—2
Page 1 and 2: GENERAL The Y8610U is a complete ki
Page 3 and 4: 392431 IGNITER-SENSOR ASSEMBLY GROU
Page 5 and 6: PLANNING THE INSTALLATION Intermitt
Page 7 and 8: Install Igniter-Sensor Assembly In
Page 9 and 10: TWO IMPERFECT THREADS GAS CONTROL P
Page 11: PV PV/MV MV VR8304M COMBINATION GAS
Page 15 and 16: STEP 3: Check spark ignition circui
Page 17 and 18: APPEARANCE CAUSE SMALL BLUE FLAME C
Page 19 and 20: ANSI STANDARDS 19 Y8610U INTERMITTE

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