S8 610 U UNIVERSAL INTERM ITTEN T P H O T MODULE
Table 2. Honeywell Preassembled Ignition
Cables (UL Style 3257).
Cable Part
Number Length
Module
End Igniter End
394800-30 30 in. 1/4 in.
quick
connect,
insulated
Rajah connector
receptacle, 90
degree rubber
boot
394801-30 30 in. 1/4 in.
quick
connect,
insulated
Rajah connector
receptacle,
straight rubber
boot
NOTE: The cable must not run in continuous contact
with a metal surface or spark voltage is greatly
reduced. Use ceramic or plastic standoff
insulators, as required.
Arc Table
Arc Length Action
No arc or arc
less than 1/8 in.
(3 mm)
Check external fuse, if provided.
Verify power at module input
terminal. Replace module if fuse
and power are okay.
Arc 1/8 in. (3 mm)
or longer.
Voltage output is okay.
Table 3. Conversion from Honeywell S86, S90, S8600 and S8610 to S8610U1003.
Replacement
Control Old Control
Terminal
Function S8610U1003 S86A,C S86B,D S86E,F,G,H
S8600A,B,C
S8610A,B,C
S90A,B
S8600F,H,M
S8610F,H,M Procedural Notes
Main valve
operator
MV MV MV MV MV MV
Main valve
and pilot
common
MV/PV MV/PV MV/PV MV/PV MV/PV MV/PV
Pilot valve
operator
PV PV PV PV PV PV
Burner
ground
connection
GND
(BURNER)
GND GND GND
(BURNER)
GND
(BURNER)
GND
(BURNER)
Transformer
secondary
(unswitched
leg)
24V GND 25V (1) 25V (GND)
25V (1)e
24V GND 24V GND
Transformer
secondary
(switched
leg)
24V* 25V (2) 25V
25V (2)e*
24V* 24V* *
Im p orta n t:
If the old module had a vent
damper plug but a vent damper was not
installed, or if it did not have a vent
damper plug: leave the vent damper plug
in position on the S8610 and connect the
25V (2) or 24V wire from the old module
to the Th-W terminal on the S8610U.
D o
n o t u s e th e 2 4 V te rm in a l o n the
S8610U.
25V (2) or 24V used only in systems where
plug-in cable connects damper to module.
If the old module had a vent damper with
a plug connection to a Molex connector,
wire the terminals as indicated in the
table.
TH-W
TH-Ra TH-Ra TH-Ra
TH-W (This
terminal
not included on
S90.)
TH-W
TH-Wb
TH-W
TH-Wb
Flame
sensor
SENSEf
d d d
SENSEf
d
Igniter/
sensor
SPARK
IGN COILc IGN COILc IGN COILc
SPARK SPARK
a If 25V (2) and TH-R have wires connected, disconnect and splice together with solderless connector.
b If TH-R and TH-W are jumpered together, connect 25V (2) lead from S86 to TH-W on S8610U1003.
c Use Rajah to quick connector adapter (supplied) or cut Rajah connector off ignition cable at module end; attach insulated quick
connect for connection to S8610.
d Leave black jumper connected.
e Terminals may be marked 25V on some models and 24V on later models. These are functionally equivalent.
f On dual igniter and sensor models, remove jumper quick connect from S8610U1003 Sense terminal, cut jumper wire at circuit board,
and discard.
5
69-0729—3
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