69-0166 - S86E, F, G, Intermittent Pilot Control Module

The 586 provides interminent ignition for gas heating
appliances. it can be used with standard capacihi dual
valve combination gas ~ o n t r o and
l ~ automatic vent
damper motors. The 586 provides timed trial for ignition
or continuous trial for ignition and remote reset an
System ioCkoU1.
1. Check the wiring diagram furnished by the
appiiance manufacturer, if available, for
Circuits differing from the wiring hookups
shown. Carefully foliow any special instructions affecting the general procedures Outiined
2. All wiring must comply with applicable eiec-
:1 Readtheseinstructions~refully.Failure to follow
them could damage the module or cause a hazardous
~ _ _ _ _ _ _ _ ~
2. Check the relings given in the inStruCtionS and on
the moduie to make sure it i s Suitable for your
3. ln~tallermuSt be a trained3pGienced Service
4. Aiter~instaTatianis complete, check out module
operation as provided in these inStrUCtionS.
tricsl codes and ordinances.
3. Disconnect the power supply before making
wiring Connections to prevent electrical shock
or equipment damage.
4. AS shown in wirin(l hookuPS, a common
ground is required onthe folloiing:
a. Mounting bracket O f the 0345, Q346 or
0348 pilot burner (ground strap and pilot
burner head are mechanically assembled to
b. GND terminal on the 586.
1. ln~tallthe transformer, the low voltage thermostat
or controiler, and the Other ~ o n t r o krequired for System
2. Connect the control Circuit l o the 586 terminals as
shown in Figs. 1-9.
3. Adjust the IhermOStat heat anticipator lo its proper
sening, ~ e e T a b l e1
NOTE The S86E1044 has a Special internal Circuit for
use with a Honeywell D80D or Penn Bas0 plug-in
vent damper motor (Figs. 5, 7.and 9).
I.Disconnect power supply before connecting
wiring to prevent electrical Shock or equipmentdamage.
2. NEvEC Zpply%jumper~ C F ~ E G ~ Eh-t ~ E ? ~ ]
valve coil terminals, even temporarily.
~r~~~-, Pilot applications.
MOUNT 586 CONTROL MODULESelect a location that is close enough to the burner
$0 that it permits a s h o r t - d m a b i e
route[0.9 m] maximum) to the pilot bumer/igniter-sensoT.
Readv ~ C C B S Sto the terminals is desirable for wirinu
and servicing. Do not exceed the ambient temperaturi
rating (minus 40 F to plus 175 F [minus 40 C to
PIUS 79 C]).
0.2 pius pilot valve and main valve (4.0 A
the appliance
manufacturer usually provides wiring diagrams,
stamp and checkout instruotions. and service
procedures for the specific ~ o n l r oemployed.
i n ~ t r u ~ t i o nare
s not provided. the information
below may be used as a general guide for
0.2 oius pilot valve and main valve (4.0 A
aHoneywell 0600--0.2 A or Penn Bas0 G60 and G660.4 A.
A con inon qrO.na z eq. rc3
'Or 1 - J
9nO I 1 P
The 586 may b e mounted in any position. Fasten
securely With four No. 6-32 machine or NO. 8 sheetmetal screws 1 in. L25.4 mm] long.
Rev. 1-85.
Form Number 69-0166-1
'Honeywell 1°C. 1985
2. Fit a 114 in. [6.4 mml female quick-Connect t i oneend Of the leadwire and attach it to the male quickConnect GNDterminal on the S86.
3. Strip the Other end 6fithi%X8wire and fasten~ii
under the Piiot burner bracket mounting screw. If
necessary, use a Shield to protectthe lead i o m radiant
heat of the main burner.
1. Connect one end iif the cable tcththe r e c e s s e d ~ x d
terminal on the 586.
2. Connect the other end Of the cable to the ignitersensor Stud on the pilot burnerligniter-sensor.
The 0808 Automatic Vent Damper can be used with
all 586 modeis except 586E1044 (Figs. 5.7.and 9).
NOTE If there is not good metal-to-metal contact
between the pilot burner bracket and the main
burner, run B ground wire from the 586 to the pilot
b"mei/igniteT-SenS(Ir as described above and then
run a Second leadwire from the pilot burner to a
common ground with the main burner.
The 0800 Automatic Vent Damper can be used With
the 586Ei044. After the S86E1044 has powered a vent
be- u s e d ~ lLn g a c s y $ e m ~ Without a vent damper motor. This is became a nonreplaceable fuse i s blown, allowing only a single
purpose appiication after the vent damper motor is
plugged in.
To connectthe plug-in model1. Remove the plug from the top of the S86E case
and discard.
2. Use wiring harness suppiied and insert matching
pin plug into case receptacie. Connect Other end to
Honeywsll 0800 Or Pen" Beso G60 or G68 Vent
Use either 392125 Ignition Cable Assembly or conStrUCt an ignition cable that conforms to suitable
national Standards such as Underwriters Laboratories
Inc. If a cable is constructed, fit both ends with 114 in.
[6.4 mml diameter snap-spring or caae c l i m and
insulated boots.
NOTE Cable must be 3 f t [0.9m] or I ~ S Sin 1 e n g t h . m
cable must not run in Continuous contact with a
metal surface or $Perk Yoitage will be greatiy
reduced. Use Ceramic or pI8stic standoff insulators
as required.
TO Connect the fiveterminal modelFollow the wiring hookup inStlUCtionS supplied
Use No. 18 gauge solid or stranded wire and 114 in.
16.4 mm] lemale qUiCk-COnneCtS on wire ends. Connections may also be made to the gas Control by wrapping
Stripped wire ends around the terminal screws.
Connect the gas control to the 586 as shown in
Figs. 1-9.
Fig. 2-Wiring
Fig. 3-Wiring
hookup 101 S86F and
n in an lnteiminenl Pilot gas heating oynteK
hookup lor S88G in a two-stage lnterrnittent Pilot gas heating syst.m~
hookup lor 586 i ~ l n l e r m ' ~ Pilot
~ n 1gas heallng 6yslem with 0808 Vent Osrnp<C.
Fig. 6-Winng
hookup ii&6r
a n m a n IntTminent PilDfg..byste6ha heahng-cooling appiicalion.
1. 7-Wlnng
hookup foVS86E1044 l ~ a n l n t e r m i n e n tPilot ge
in a % a E l i n g
application with
0800 Vent Damper.
Fig. 8-wiring hookup lor S86E and F for anlnterminent Pilot system in a h e a l i n g - e o 3 K a a E 3 E n I
Fig. 9-Wiring hoOkYplorS86EiQ44With L8148EH66 Aquaslat RkaT8nd D80D YentDiimpG.
(S86G and H only)
The foliowing stanup and Checkout procedures apply
to all 586 systems that use VR844, VR852. VR8440. or
VR8520 intermittent Pilot Valve Combiqation Gas
control^. Refer to the valve manufacturer's inStrUCtionS
for systems that employ Other gas contr01~.Always
refer to the specific inStructionS provided by the
appliance manufacturer. if available, Since the applicelion and controls used may differ.
When safely lockout occurs, the system will remain
locked out until it is reset To reset the S86G and H,
tu!n_the thermostat control ppnt down-below call for
heat-for one minute. R8is.e the thermostat c o n t r ~ l
point above room temperature and check that normal
ignition occurs as described in START SYSTEM
Return the thermostat lo its normal sening.
NOTE If any component in the System faiis, the System
will either not operate or will go into safely lockout
(S86Gand H only). If the System does not perform as
outlined in START SYSTEM, below, refer to SERViCE
Section to determine the cause.
The 586 ~onfrolmodule performs the foliowing basic
Opens and closes the f i r s (pilot) main valve of the
gas Control.
Provides B spark far igniting the pilot burner.
Senses the pilot burner flame.
Shutsoffthe Sparkafferpilotflameis lit.
These fUnCtionS occur in two Stages-trial for pilot
ignition and main burner Operation-as described
1. Turn on ~ o w e r t othe 586 and turn oas suoolv on.
2. Checks86 Operation as foliows:
a. Set the thermostat or controller above room
temperatureto call for heat.
b. Watch for confinuou~
Spark at the piiot burner.
c. On S86G.time the spark operation. Time must
be within the lockout timing period (15 or 90
seconds). On S66H. check time until a "clicW
is heard which indicates that the first (pilot)
main valve in the gas valve has closed-safely
lockout. Time must be within the lockout
timing period (15 or 90 seconds). Spark does
not Shut off on the S86H when the SvStem
goes into safety IOCkOUt.
d. Turn thermostat down to end call for heat and
wait 60 Seconds on IoCkoUt modeis before
beginning step 3.
3. Turn on gas supply.
4. Set thermostat or controller above room temperature lo call for heat.
5. System Should Stan as foliows:
a. Spark will turn on and pilot gas wive will open
at once. Pilot burner should ionite affer oas
reaches the piiot burner.
b. Spark ignition Should cut off when pilot flame
is estabiished.
c. Main gas valve Should open and main burner
Should ignite after gas reaches the burner
On every call for heat (system stan). the 586 performs
a safe-start check that teStS the S86 internal components for a flame Simulating condition. if flame
Simuiating condition is present, the heating sysiem will
not start The 586 will not detect a leaking gas valve.
During a normal stan, the S86 opens the first (pilot)
main vaive in the gas control, which allows gas to flow
to the pilot burner. At the Same time, the eleCtrOniC
spark generator in the 586 produces a 15,000 volt
spark pulse output (open circuit). This voltage produces
a Spark at the igniter-sensor rod which ignites the pilot
burner flame.
If the pilot flame does not light or the presence Of the
pilot flame is not detected back through the flame rod,
the 588 will not allow the heating System to functioj.
However, the S86E and F wiil continue to s b a X Z 3 o n g
as the thermmtat calls for heat or until a Dilot burner
main valve in the gas Confroi and requires the system
COnlrOi circuit to be reset from the thermostat. The
NOTE: Lightoff may not be satisfactow until the gas
input and COmbuStion air have been sdjusted. Refer
to the inStrUCtionS Supplied by the appliance manufacturer If the gas valve or piiot flame require
(S86G and H only)
period ends, the trial fo;pilot
ignition ends, and the
control module goes into safely lockout. On the S86G.
the spark stops when it goes into lockout. On the S86H.
the spark continues aner IoCkoUt has occurred.
Beforeanother attempt to Stan the heating System
can be made, the S86G and H must be reset Reset IS
performed bvturninq the thermostat control polntdown,
below a califor heat (or turning the power OM for one
1. If any condition exists which will cause the
S86G and H to go into safety lockout. meter
readings must be taken quickly afler restanwithin the trial lor ignition period. Always deenergize the system for at least one minute
before recycllng for further tests.
2. On S86F and H systems, Supplementary intalla at ion and service information may be
required for the gas control. Refer 10 the
healing appliance manufacturer for specific
3. The following Service procedures are only for
basic Intermittent Pilot systems. On eil installalions, refer to the appliance manufacturer's
service instructions tor the SoeCifiC fnStallatlo".
4 The electronic S86 Control Module cannot be
repaired iexcept for fuse replacement on G
Do not touch either Stripped end of jumper or
Stud terminal. This is a very high voitage Circuit
the t e s
and electrical Shock can r e s ~ l t Perform
immediately anei energizing the System.
NOTE: For S86G.complete check before it goes
into Safety lockout and interrupts the Spark
4. An arc length of 118 in. [3.2mml or more lndlcates
if no arc can be established
SPtiSfaCtOry voltage OUIPUI.
orthe maximum arc length is ieSS than 118 in. [3.2mm],
the 586 fuse is okay (G model only), and power to the
S86 inpUtterminai was proved, replace the 586.
model). I f the tmUbleShooting procedure indicates a malfUnction in the S86.the 586 must
be replaced.
5. Intermittent Pilot gas heating control systems
should be serviced only by trained. experienced service technicians.
The electronic module and step-up transformer in the
586 provides Spark ignition at 15.000 volts (open
Circuit). This Circuit can be checked at the 586 as
1. Turn off the manual gas valve to prevent the flow
01 gas.
2. Disconnect the ignition cable at the S86 stud
terminal to isolate the circuit from the pilot burner1
igniter-sensor. Prepare a short jumper lead using
heavily insulated wire Such as ignition cable.
3. Energize the 586 and touch one end Of the jumper
firmly to the 5 8 6 ground (GND) terminal. Do not
disconnectthe existing ground lead. Move the free end
of the jumper s1owly toward the stud terminal to
establish a spark and then pull the jumper slowly away
from the stud. Note the length of the gap at Which
arcing diSCOntinUeS.
The following Visual Checks should be made before
troubleshooting and aner maintenance.
1. Check power Switch and fuse to the S86.
2. Manual ShUtOff valves in the gas line to the heating
appliance must be open.
3. Make sure all wiring connectionS are clean and
4. The 5866 and H must not be in a safety lockout.
Turn the thermostat control point below room temperature and wait at least one minute. Then, move control
point above room temperature. This resets the control
System and allows a return to start condition
sensor must be clean and tight. Loose connections may
not conduct a flame current even though the ignition
spark is satisfactory. Check the electrical continuity of
the cable.
For sdditional information, refer to INSTALLATION
section-Connect Pilot BumerIlgniter-Sensor.
A common ground is required for the pilot burner/
igniter-sensor mounting bracket and the GND terminal
01 the 586.If ground is poor or erratic. safety Shutdown
may occur occasionally even though operation is
normal at the time of the checkout. Therefore. if
nuisance Shutdowns have been reported, be sure to
check item 4 under General Precautions. page 1.
(SBSG and H only)
NOTE: If the ground circuit path is incomplete, the
S86G and H will allow one trial for ignition before
going into safety lockout.
If a heating system goes into safety iockout, the S86
must be reset before attemptinD further operation or
checkout. The System will remain in safety lockout until
i t is reset. TO reset. Shut SYStem off. iAdiUSt the
thermostat control point b e l o i room temberiture or
disconnect electrical power.) Wait at least one minute,
then turn System on.
Electrical ground Connections at the pilot burner/
igniter-sensor and S86 must be clean and tight. If
leadwire is damaged or deteriorated, use only No. 14 to
18 gauge. moisture-resistant. thermoplastic insulated
wire with 105 C [221 F] minimum rating as replacement.
Excessive temperature at the ceramic flame rod
NOTE When S86H goes into safety IOCkOUt, the spark
continues, when S86G goes into safety lockout, the
spark stops.
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