Honeywell Q345A User's Manual
Contents
1. APPEARANCE CAUSE SMALL BLUE FLAME CHECK FOR LACK OF GAS FROM A CLOGGED ORIFICE FILTER l CLOGGED PILOT FILTER at LOW GAS SUPPLY PRESSURE o PILOT ADJUSTMENT AT ANIMUM LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM h LARGE ORIFICE f DIRTY LINT SCREEN IF USED DIRTY PRIMARY AIR e bi OPENING IF THERE IS ONE PILOT ADJUSTMENT AT HINIMUM WAVING BLUE FLAME oinak y 2 EXCESSIVE DRAFT AT PILOT LOCATION AL OF COMBUSTION NOISY LIFTING SLOWING FLAME CHECK FOR lt HIGH GAS PRESSURE HARG SHARP FLAME THIS FLAME IS CHARACTERISTIC OF MANUFACTURED GAS CHECK FOR al HIGH GAS PRESSURE ear ORIFICE TOO SMALL sare Fig 7 Examples of unsatisfactory pilot flame CHECK GROUNDING 1 1 ground is poor or erratic safety shutdown will occur Therefore if nuisance shutdowns are reported check the ground precautions on page 2 2 f leadwire is damaged or deteriorated Use No 14 to 18 gauge moisiure resisiant thermoplastic insulated wire with 224 F 105 C minimum rating as replacement 3 Excessive temperature at the ceramic flame rod in sulator wiil permit electrical leakage to ground a If bracket is bent bend it back to correct position b If insulator is cracked replace pilot burner ig niter sensor SAFETY LOCKOUT Refer to appliance manufacturers instructions to test for proper safety lockout times 68 0526 Honeywell Inc International Sales Offices in aft princip2. heat The pilot should light but the main burner will remain off because the main valve actuator is disconnected Check the pilot flame Make sure it is blue steady and envelops 3 8 to 1 2 in 10 to 13 mm of the igniter sensor See Fig 6 for possible flame problems and their causes If necessary adjust pilot flame by turning the pilot adjustment screw on the gas control clock wise to decrease or counterclockwise x to increase pilot flame Following adjustment always replace pilot adjustment cover screw and tighten firmly to assure proper gas control operation Set thermostat below room temperature to end call for heat Recheck ignition sequence as follows Reconnect main valve wire Set thermostat to call for heat Watch ignition sequence at burner if spark still doesn t stop after pilot lights re place ignition module if main burner doesn t light or if main burner lights but system focks out check module ground wire and gas contro as described in control module instruction sheet o Tyeicat el eal Fig 6 Proper shielding of pilot flame CHECK IGNITION CABLE 1 Ensure that ignition cable is not in contact with metal surfaces 2 Ensure that ignition cable is not more than 3 feet t m long 3 Ensure connections to the control module stud or quick connect terminals and the igniter sensor are clean and tight 4 Check electrical continuity of ignition cable
3. T 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 teak 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 in cluding 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 can t be stopped 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 tem perature to call for heat 2 Disconnect lead to MV terminal on gas control pilot by setting thermostat to call for heat owa pilot adjustment cover screw from gas con trol 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 ensure proper operation PROPER 72 INCH LAME ADJUSTMENT ont IGNITER SENSOR Fig 4 igniter sensor tip must be in pilot flame SERVICE WARNING _ FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE IN JURY OR DEATH Perform Gas Leak T
4. TRADELINE Q345A PILOT BURNERAGNITER SENSOR APPLICATION The Q345A Pilot Burner Igniter Sensor provides pilot flame ignition and sensing in intermittent pilot systems A pilot burner igniter sensor consists 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 PILOT BURNERS IGNITER SENSOR MUST BE RIGIOLY POSITIONED RELATIVE FO MAIN BURNER Fig i Mount pilot burner igniter sensor on main burner Ci MgA ly AN wey Se Wy Mee tN K fizor surnery henirer senson enrren sensor puss aicHT Pizot evANEAs Jicirten senzox 700 HIGH WARNING SIs FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE IN JURY OR DEATH Foliow these warnings exactly 1 Disconnect power supply before wiring to prevent electrical shock or equipment dam age 2 To avoid dangerous accumulation of fuel gas turn off gas supply at appliance service valve before starting installation an
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6. d perform Gas Leak Tesi after completion of installation 3 Do not bend pilot tubing at the control er pilot after compression nut has been tightened Gas leakage at the connection may result Follow appliance manufacturer s instructions if avail able otherwise use instructions provided befow 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 orienta tion as the original one 2 Mount pilot burnerfigniter sensor on main burner Mounting surfaces other than the main burner may shift bend or warp as furnace expands and contracts while operating Refer to Fig 1 3 Mount pilot burnerfgniter sensor so the pilot flame remains properly positioned with respect to the main burner flame Refer to Fig 2 4 Supply pilot flame with ample air free of combustion products 5 Do not impinge pilot flame on adjacent paris 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 ignition 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 puli pilot flame away from the igniter sensor IGterTiOn IGNITION Main BURNER FLAME JUST FLAME WILL FLAME WILE J ins
7. es main IMPINGE ON IMPINGE ON E sunner MAIN BURNER IGNITER SENSOR L Fig 2 Location of pilot burner igniter sensor 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 ignition after compression nut has been tightened as this may result in gas leakage at connection 2 Square oif 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 igniter sensar Never use old com pression fitting as it may not provide a gas tight seal Refer to Fig 3 4 While holding tubing all the way in engage threads and turn until finger tight 5 Using a wrench turn compression nut one turn be yond finger tight DO NOT OVERTIGHTEN 6 Connect other end of tubing to gas control according to gas contro manufacturer instructions z PILOT eunnER BODY on BRACKET OF PILOT BURNER ISNITER SENSOR compression FITTING BREAKS OFF AND CLINCHES TUBING TIGHTEN NUT ONE TURS ASAUTISTISHTENED BEYOND FINGER P TOGASCONTROL pawe Fig 3 Always use new compression fitting Form Number 69 0526 Honeywell Inc 1989 WIRE IGNITER SENSOR The igniter sensor must be mounted on t
8. est anytime work is done te the system PILOT OUTAGE 1 F pilot flame goes out during ignition but is properly adjusted recheck Mounting and Location instructions on page 1 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 followed but pilot continues to go out construct shielding to protect pilot flame from main burner ignition and extinction and drafts Refer te Fig 6 4 Check pilot and main burner lightoff Set the thermostat to call for heat O Watch the pilot burner during the ignition se quence See if Ignition spark continues after the pilot is lit The pilot lights and the spark stops but main burner does not light S8600B H S8660H only The pilot lights the spark stops and main burner lights but the sys tem locks out so ensure adequate flame current as follows gt Turn off furnace at circuit breaker or fuse box Clean the flame rod with emery cloth 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 Check for cracked ceramic insulator which can cause short to ground and replace igniter sensor if necessary Atthe gas control disconnect main valve wire from the TH or MY terminal Turn on power and set thermostat to cali for
9. he burner Con nect the control module ground wire to one of the igniter sensor mounting screws to complete the system ground ing Connect ground wire as foliows 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 4 mm quick connect terminal is provided on the Honeywell igniton module Fasten female quick connect to wire end at ignition module 3 Strip other end and fasten underigniter sensor mount ing screw 4 lf necessary use shield to protect lead from radiant 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 appii cable local or national standards 2 Connect one end of the ignition cable to stud terminal on igniter sensor using 1 4 in 6 4 mm diameter snap spiing or cage clips on cable ends 3 Connect other end of ignition cabie to igniter terminals on ignition module 4 Use ceramic or plastic standoff insulators as neces sary to prevent cable from contacting metal surfaces STARTUP AND CHECKOUT PERFORM GAS LEAK TEST 72 WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE IN JURY OR DEATH Check for gas leaks with soap and water solution any time work is done on a gas system GAS LEAK TES
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