Honeywell Q348A User's Manual
Contents
1. SHIELD LJ Set the thermostat to call for heat QI Watch the pilot burner during the ignition sequence See if e Ignition spark continues after the pilot is lit e The pilot lights and the spark stops but main burner does not light e 8600B H S86H only The pilot lights the spark stops and main burner lights but the system locks out LJ If so assure adequate flame current as follows Turn off furnace at circuit breaker or fuse box e Clean the flame rod with emery cloth e Make sure electrical connections are clean and tight Replace damaged wire with moisture resistant no 18 wire rated for continuous duty up to 221 F 105 C e Check for cracked ceramic insulator which can cause short to ground and replace pilot burner igniter sensor if necessary e At the gas control disconnect main valve wire from the TH or MV terminal Turn on power and set thermostat to call for heat The pilot should light but the main burner will remain off because the main valve actuator is dis connected e Check the pilot flame Make sure it is blue steady and envelops 3 8 to 1 2 in 10 to 13 mm of the flame rod See Fig 7 for possible flame problems and their causes I fnecessary adjust pilot flame by turning the pilot adjustment screw on the gas control clockwise to decrease or counterclockwise to increase pilot flame After adjustment always replace pilot adjustment cover screw and tighten firmly to assure proper2. one turn beyond finger tight Do not overtighten 6 Connect other end of tubing to gas control according to gas control manufacturer instructions WIRE IGNITER SENSOR The igniter sensor must be mounted on the burner Connect the control module ground wire to one of the igniter sensor mounting screws to complete the system grounding Connect ground wire as follows 1 Use 221 F 105 C minimum thermoplastic insulated wire for the ground leadwire asbestos insulation is not acceptable 2 A male 1 4 in 6 mm quick connect terminal is provided on Honeywell ignition modules Fasten female quick connect to wire end at ignition module 3 Strip other end and fasten under igniter sensor mounting screw 4 If necessary use shield to protect lead from radi ant heat of burner 5 The pilot burner serves as the grounding area for the flame signal Run lead from pilot burner to the common ground selected Connect the ignition cable as follows 1 The high tension ignition cable must conform to applicable local or national standards 2 Connect one end of the ignition cable to stud terminal on igniter sensor using 1 4 in 6 mm diam eter snap spring or cage clips on cable ends 3 Connect the other end of the ignition cable to the igniter terminal on ignition module 4 Use ceramic or plastic standoff insulators as nec essary to prevent cable from contacting metal surfaces INSTALL BLEED GAS TUBE optional 1 Route bleed
3. tube from bleed tap on gas control to the pilot burner igniter sensor 2 Push clip into place See Fig 4 3 Insert bleed gas tube until 3 8 in 10 mm to tubing is above pilot burner igniter sensor bracket Tip of bleed gas tube must not extend into pilot flame Fig 4 Install bleed gas tube THIS DIMENSION SHOULD BE MAXIMUM OF 3 8 INCH 9 5 mm WHEN BLEED TUBE IS IN FINAL POSITION BLEED TUBE CLIP 1 8 IN STEEL TUBING M1261 Startup and Checkout PERFORM GAS LEAK TEST A WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Check for gas leaks with soap and water solu tion any time work is done on a gas system Gas Leak Test 1 Ensure that gas supply is turned on at the appliance service valve 2 Paint pipe connections upstream of pilot burner with rich soap and water solution Bubbles indicate gas leak 3 If leak is detected tighten pipe connections 4 Set thermostat to call for heat to light main burner 5 With main burner in operation paint pipe joints including adapters and gas control inlet and outlet with rich soap and water solution 6 If another leak is detected tighten adapter screws joints and pipe connections 7 Replace part if leak cannot be stopped Fig 5 Igniter sensor tip must be in pilot flame 3 8 TO 1 2 INCH 10 TO 13 mm PROPER FLAME ADJUSTMENT IGNITER SENSOR Q373A PROPER FLAME ADJUSTMENT 3 8
4. Honeywell Q345A Q348A Q348B Q362A Q373A and Q381A Pilot Burner Igniter Sensors Application These pilot burner igniter sensors provide pilot flame ignition and sensing in intermittent pilot systems They consist of a target type pilot burner with a combination spark igniter and flame sensor mounted in place of the thermocouple Installation WHEN INSTALLING THIS PRODUCT 1 Read these instructions carefully Failure to follow instructions can damage product or cause a hazardous condition 2 Check ratings given in instructions and on product to make sure product is suitable for your application 3 Make sure installer is a trained experienced service technician 4 After completing installation use these instructions to check out product operation A WARNING Fig 1 Mount pilot burner igniter sensor on main burner PILOT BURNER IGNITER SENSOR MUST BE RIGIDLY POSITIONED RELATIVE TO MAIN BURNER M3271 Fig 2 Location of pilot burner igniter sensor i SAIA EA nyt SA lie L M FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Follow these warnings exactly 1 Disconnect power supply before wiring to prevent electrical shock or equipment damage 2 To avoid dangerous accumulation of fuel gas turn off gas supply at appliance service valve before starting inst
5. TO 1 2 INCH 10 TO 13 mm IGNITER SENSOR Q345A Q348A B Q362A AND Q 381A M3777 ADJUST PILOT FLAME The pilot flame should envelop 3 8 to 1 2 in 10 to 13 mm of the igniter sensor tip See Fig 5 To adjust pilot flame 1 Turn off system by setting thermostat below temperature to call for heat 2 Disconnect lead to MV terminal on gas control 3 Light pilot by setting thermostat to call for heat 4 Remove pilot adjustment cover screw from gas control 5 Turn inner pilot adjustment screw clockwise to decrease or counterclockwise to increase pilot flame 6 Always replace pilot adjustment cover screw and tighten firmly after completing adjustment to assure pro per operation Service A WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Perform Gas Leak Test anytime work is done to the system PILOT OUTAGE 1 If pilot flame goes out during ignition but is pro perly adjusted recheck mounting and location instructions in Location section 2 Refer to ignition module instructions to check wiring between igniter sensor and ignition module or between gas control and ignition module 3 If all mounting and location instructions are fol lowed but pilot continues to go out construct shielding to protect pilot flame from main burner ignition and extinction and drafts See Fig 6 4 Check pilot and main burner lightoff Fig 6 Proper shielding of pilot flame TYPICAL
6. allation and perform Gas Leak Test after completion of installation 3 Do not bend pilot tubing at the control or pilot after compression nut has been tightened Gas leakage at the connection may result Follow appliance manufacturer instructions if avail able otherwise use instructions provided below LOCATION 1 Position pilot burner igniter sensor for easy access and observation In replacement applications replace pilot burner igniter sensor with an identical unit and position new pilot burner igniter sensor in the same location and orientation as the original one ae ae XN N IONN Hy 2 PILOT BURNER PILOT BURNER PILOT BURNER IGNITER IGNITER IGNITER SENSOR SENSOR T SENSOR JUST RIGHT TOO LOW TOO HIGH a a IGNITION FLAME IGNITION MAIN BURNER JUST MISSES FLAME WILL MAIN BURNER 1 IMPINGE ON MAIN BURNER M3273 2 Mount pilot burner igniter sensor on main burner Mounting surfaces other than the main burner may shift bend or warp as furnace expands and contracts while operating See Fig 1 3 Mount pilot burner igniter sensor so the pilot flame remains properly positioned with respect to the main burner flame See Fig 2 4 Supply pilot flame with ample air free of combustion products 5 Do not impinge pilot flame on adjacent parts Do not impinge main burner flame on pilot burner igniter sensor 6 Do not expose pilot flame to falling scale which could impair main burner igniti
7. gas control operation Set thermostat below room temperature to end call for heat CI Recheck ignition sequence as follows e Reconnect main valve wire e Set thermostat to call for heat e Watch ignition sequence at burner Ifspark still does not stop after pilot lights replace ignition module If main burner does not light or if main burner lights but system locks out check module ground wire and gas control as described in control module instructions 60 0653 8 Fig 7 Example of unsatisfactory pilot flames APPEARANCE APPEARANCE CAUSE SMALL BLUE FLAME PY gt SMALL BLUE FLAME CHECK FOR LACK OF GAS FROM CLOGGED ORIFICE FILTER CLOGGED PILOT FILTER LOW GAS SUPPLY PRESSURE PILOT ADJUSTMENT AT MINIMUM LAZY YELLOW FLAME D LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM DIRTY ORIFICE DIRTY LINT SCREEN IF USED DIRTY PRIMARY AIR OPENING IF THERE IS ONE PILOT ADJUSTMENT AT MINIMUM WAVING BLUE FLAME A WAVING BLUE FLAME a 7 A CHECK FOR EXCESSIVE DRAFT AT PILOT LOCATION RECIRCULATING PRODUCTS OF COMBUSTION NOISY LIFTING BLOWING FLAME PY 2 NOISY LIFTING BLOWING FLAME CHECK FOR HIGH GAS PRESSURE HARD SHARP FLAME HARD SHARP FLAME THIS FLAME IS CHARACTERISTIC PY gt CHECK IGNITION CABLE 1 Assure that ignition cable is not in contact with metal surfaces 2 Assure that ignition cable
8. is not more than 3 feet 1 m long 3 Assure connections to the ignition module stud terminal and the igniter sensor are clean and tight 4 Check electrical continuity of ignition cable CHECK GROUNDING 1 If ground is poor or erratic safety shutdown will occur Therefore if nuisance shutdowns are reported check the ground precautions in Wire Igniter Sensor section OF MANUFACTURED GAS CHECK FOR HIGH GAS PRESSURE ORIFICE TOO SMALL M3778 2 If leadwire is damaged or deteriorated use no 14 to 18 gauge moisture resistant thermoplastic insulated wire with 221 F 105 C minimum rating as replacement 3 Excessive temperature at the ceramic flame rod insulator will permit electrical leakage to ground a If bracket is bent bend it back to correct position b If insulator is cracked replace pilot burner igniter sensor TEST SAFETY LOCKOUT Refer to appliance manufacturer instructions to test for proper safety lockout times Honeywell Home and Building Control Honeywell Inc 1985 Douglas Drive North Golden Valley Minnesota 55422 Printed in U S A Home and Building Control Honeywell Limited Honeywell Limit e 740 Ellesmere Road Scarborough Ontario MIP 2V9 Helping You Control Your World QUALITY IS KEY
9. on 7 Do not expose pilot burner igniter sensor to main burner rollout while igniting or extinguishing 8 Do not expose pilot flame to drafts that push or pull pilot flame away from the igniter sensor NOTE The Q381A Pilot Burner Igniter Sensor is for horizontal mounting only Mounting bracket must remain vertical Se G S Rev 7 93 Honeywell Inc 1993 Form Number 60 0653 8 CONNECT PILOT GAS TUBING 1 Cut tubing to desired length and bend as necessary for routing to pilot burner igniter sensor Do not make sharp bends or deform tubing Do not bend tubing at control after compression nut has been tightened because this can result in gas leakage at connection 2 Square off and remove burrs from end of tubing 3 Push tubing into compression nut clearance hole until tubing bottoms NOTE When replacing a control cut off old compression fitting and replace with new compression fitting provided with new pilot burner Never use old compression fitting because it may not provide a gas tight seal See Fig 3 Fig 3 Always use new compression fitting PILOT BURNER BODY ON BRACKET OF PILOT BURNER IGNITER SENSOR COMPRESSION FITTING BREAKS OFF AND CLINCHES TUBING AS NUT IS TIGHTENED TIGHTEN NUT ONE TURN BEYOND FINGER TIGHT TO GAS CONTROL M3296 4 While holding tubing all the way in engage threads and turn until finger tight 5 Using a wrench turn compression nut
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