Honeywell Boiler S9360A User Manual

S9360A, S9361A, S9370A, S9371A  
Integrated Boiler Controllers  
INSTALLATION INSTRUCTIONS  
SPECIFICATIONS  
IMPORTANT:  
The specifications given in this publication do  
not include normal manufacturing tolerances.  
Therefore, an individual unit may not match the  
listed specifications exactly. Also, this product is  
tested and calibrated under closely controlled  
conditions, and some minor differences in  
performance can be expected if those  
conditions are changed.  
Model Numbers  
APPLICATION  
S—Switching Control  
9 3—Integrated Hydronic Control Platform  
These integrated boiler control modules provide ignition  
sequence, flame monitoring and safety shutoff for either  
intermittent pilot spark ignition or direct hot surface  
ignition heating systems. They also provide limit rated  
water temperature control and display interface capability  
for either “on-board” or remote user interface  
applications.  
6—Spark Ignition  
7—Hot Surface Ignition  
0—Remote Display Required  
1—Integrated On-Board Display  
A—Boiler Control  
B—Water Heater Control  
C—Pool Heater Control  
1—No Circulator  
S9360A—Spark Ignition, Intermittent Pilot, Remote  
Display.  
S9361A—Spark Ignition, Intermittent Pilot, “On board”  
Display.  
2—On/Off Circulator  
S9370A—Hot Surface Ignition, Remote Display.  
S9371A—Hot Surface Ignition, “On board” Display.  
Enabled with EnviraCOM™ communication capability  
to support remote monitoring and diagnostics.  
Limit-rated Temperature Sensing Probe.  
One or Two Sensor Models.  
S
9
3
6
0
A
1
000  
Dimensions:  
See Fig. 1.  
69-2076-01  
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
Table 1. Recommended Ignition Cables.  
High Humidity or Dripping Water  
Temperature Rating  
°C °F  
Over time, dripping water or high ambient humidity can  
create unwanted electrical paths on the module circuit  
board, causing the module to fail. Never install an  
appliance where water can drip on the controls.  
Voltage  
Cable Type Rating (rms)  
UL Style  
3217  
10,000  
10,000  
150  
302  
In addition, high ambient humidity can cause the control  
to corrode and finally fail.  
UL Style  
3257  
250  
484  
Where the appliance may be installed in a humid  
atmosphere, make sure air circulation around the module  
and gas control is adequate to prevent condensation. It is  
also important to regularly check out the system. A NEMA  
4 enclosure may be needed.  
Transformer Requirement:  
Add current ratings of module, pilot valve, main valve,  
vent damper and any other components of the control  
system to determine transformer size requirement.  
Approvals:  
Varies with control model.  
ANSI Z21.20 Automatic Gas Ignition Systems and  
Components.  
ANSI Z21.23 Gas Appliance Thermostats.  
EN298: Automatic Gas Burner Control Systems  
ANSI Z21.87: Automatic Gas Shutoff Devices for Hot  
Water Supply Systems.  
Corrosive Chemicals  
Corrosive chemicals can also attack the module and gas  
control and eventually cause a failure. Where chemicals  
may be used routinely for cleaning, make sure the  
cleaning solution cannot reach the controls. Where  
chemicals are likely to be suspended in the air, as in some  
industrial and agricultural applications, protect the module  
from exposure with a NEMA 4 enclosure.  
UL353 Limit Controls.  
PLANNING THE INSTALLATION  
Dust or Grease Accumulation  
Heavy accumulation of dust or grease may cause the  
controls to malfunction. Where dust or grease may be a  
problem, provide covers for the module and gas control  
that limit environmental contamination. A NEMA 4  
enclosure is recommended for the module.  
Automatic Ignition Control domestic and commercial  
boiler systems are used on a wide variety of equipment.  
Some of these applications may make heavy demands on  
the controls, either because of frequent cycling, or  
because of moisture, corrosive chemicals, dust or  
excessive heat in the environment. In these situations,  
special steps may be required to prevent nuisance  
shutdowns and premature control failures. These  
applications require Honeywell Engineering review;  
contact your Honeywell Sales Representative for  
assistance.  
Heat  
The controls can be damaged by excessively high  
temperatures. Make sure the maximum ambient  
temperature at the control locations will not exceed the  
rating of the control. If the appliance normally operates at  
very high temperatures, insulation, shielding, and air  
circulation may be necessary to protect the controls.  
Proper insulation or shielding should b provided by the  
appliance manufacturer; make sure adequate air  
circulation is maintained when the appliance is installed.  
Frequent Cycling  
These controls are designed for use on domestic and  
commercial boiler systems that typically cycle less than  
10,000 cycles per year. In an application with significantly  
greater cycling rates, we recommend monthly checkout  
because the controls may wear out more quickly.  
INSTALLATION AND CHECKOUT  
Water or Steam Cleaning  
When Installing This Product…  
Once a module or gas control has been wet, it may  
operate unreliably and must be replaced. If the appliance  
is likely to be cleaned with water or steam, the controls  
and associated wiring should be covered so that water or  
steam cannot reach them. The controls should be high  
enough above the bottom of the cabinet so they will not  
be subjected to flooding or splashing during normal  
cleaning procedures. If necessary, shield the controls to  
protect them from splashing water. A NEMA 4 enclosure  
is recommended.  
1. Read these instructions carefully. Failure to follow  
them could damage the product or cause a  
hazardous condition.  
2. Check the ratings given in the instructions and on  
the product to make sure they are suitable for your  
application.  
3. Installer must be a trained, experienced service  
technician.  
4. After installation is complete, check out product  
operation as provided in these instructions.  
3
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S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
WARNING  
WARNING  
Fire or Explosion Hazard.  
Fire or Explosion Hazard.  
Can cause severe injury, death or property  
damage.  
1. The module can malfunction if it gets wet,  
leading to accumulation of explosive gas.  
• Never install where water can flood, drip or  
condense on module.  
Can cause severe injury, death or property  
damage.  
Do not attempt to take the module apart or to  
clean it. Improper reassembly and cleaning may  
cause unreliable operation, leading to an  
accumulation of explosive gas.  
• Never try to use a module that has been  
wet—replace it.  
2. Liquefied petroleum (LP) gas is heavier than air  
and will not vent upward naturally.  
• Do not light pilot or operate electric switches,  
lights, or appliances until you are sure the  
appliance area is free of gas.  
Maintenance frequency must be determined individually  
for each application. Some considerations are:  
Cycling frequency. Appliances that may cycle more than  
10,000 times annually should be checked monthly.  
3. If a new gas control is to be installed, turn off  
gas supply before starting installation. Conduct  
Gas Leak Test according to gas control  
manufacturer instructions after the gas control  
is installed.  
4. If module must be mounted near moisture or  
water, provide suitable waterproof enclosure.  
Intermittent use. Appliances that are used seasonally  
should be checked before shutdown and again before the  
next use.  
Consequence of unexpected shutdown. Where the cost of  
an unexpected shutdown would be high, the system  
should be checked more often.  
Dusty, wet, or corrosive environment. Since these  
environments can cause the controls to deteriorate more  
rapidly, the system should be checked more often.  
WARNING  
Electrical Shock Hazard.  
Can cause severe injury, death or property  
damage.  
Disconnect power supply before beginning wiring  
to prevent electrical shock or equipment damage.  
Any control should be replaced if it does not perform  
properly on checkout or troubleshooting. In addition,  
replace any module if it is wet or looks like it ever has  
been wet. Protective enclosures as outlined under  
Planning the Installation are recommended regardless of  
checkout frequency.  
Perform Preinstallation Safety Inspection  
The preinstallation checks described in ANSI Standard  
Z21.71 must be done before a replacement module is  
installed. If a condition which could result in unsafe  
operation is detected, the appliance should be shut off  
and the owner advised of the unsafe condition. Any  
potentially unsafe condition must be corrected before  
proceeding with the installation.  
Mount Module  
Select a location close enough to the burner to allow a  
short (3 ft. [0.9 m] maximum), direct cable route to the  
igniter. Ambient temperature at the module must be within  
the range listed under Specifications. The module must  
be protected from water, moisture, corrosive chemicals  
and excessive dust and grease. Refer to Fig. 2 and 3 for  
recommended slot/hole pattern in appliance.  
Maintenance Requirements in Severe  
Environments  
Regular preventive maintenance is important in any  
application, but especially so in commercial, agricultural,  
and industrial applications, because:  
99.5  
1. In such applications, particularly commercial, the  
equipment can operate 100,000 to 200,000 cycles  
per year. Such heavy cycling can wear out the gas  
control in one to two years. A normal boiler applica-  
tion, for which the controls were intended, typically  
operate fewer than 10,000 cycles per year.  
4
16  
2. Exposure to water, dirt, chemicals, and heat can  
damage the module or the gas control and shut  
down the control system. A NEMA 4 enclosure can  
reduce exposure to environmental contaminants.  
The maintenance program should include regular  
checkout of the system as outlined under Checkout.  
100  
4
16  
55  
M24198  
Fig. 2. Recommended slot/hole pattern in appliance  
(in mm).  
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4
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
WATER  
HEATER  
CONTROL  
BOX  
M24229  
Fig. 3. Align module with slots in control box.  
IMPORTANT  
Wire the System  
1. All wiring must comply with applicable local  
electrical codes and ordinances.  
2. When installing a hot surface igniter, the  
leadwires should be kept as short as possible  
and should not be allowed to rest against  
WARNING  
Can cause severe injury, death or property  
damage.  
Disconnect the power supply before making wiring  
connections to prevent electrical shock or  
equipment damage.  
Electrical Shock Hazard.  
grounded metal surfaces.  
3. A common ground is required for the S93XX and  
the main burner. The 24V “secondary” plug inter-  
nally grounds one side of the transformer. Any  
auxiliary controls or limits must not be in the  
grounded leg. In addition, the appliance should  
be earth-grounded.  
4. Make sure the transformer has adequate VA.  
The ignition module requires at least 0.2A at 24  
Vac. Add the current draws of all other devices in  
the control circuit, including the gas control, and  
multiply by 24 to determine the total VA  
requirements of these components. Add this  
total to 5.0 VA (for the module). The result is the  
minimum transformer VA rating. Use a Class II  
transformer if replacement is required.  
Check the wiring diagram furnished by the appliance  
manufacturer for circuits differing from the wiring hookup  
shown in Fig. 4 and 5. Carefully follow any special  
instructions affecting the general procedures outlined  
below.  
5. Check that L1 (hot) and L2 (neutral) are wired to  
the proper terminals.  
Connect Ignition Cable (S936XAXXXX)  
Use Honeywell ignition cable or construct an ignition  
cable that conforms to suitable national standards, such  
as Underwriters Laboratories Inc. See Specifications  
section. To construct a cable, fit one end (the module end)  
with 1/4 in. connector receptacle and the other with a  
connector to match the pilot assembly. Protect both ends  
with insulated boots.  
5
69-2076—01  
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
NOTE: Cable length must be 36 in. (0.9 m) or less. The  
cable must not be in continuous contact with a  
metal surface or spark voltage will be greatly  
reduced. Use ceramic or plastic standoff  
insulators as required.  
the ground wire; asbestos insulation is not acceptable. If  
necessary, use a shield to protect the wire from radiant  
heat generated by the burner.  
The burner serves as the common grounding area. If  
there is not a good metal-to-metal contact between the  
burner and ground, run a lead from the burner to ground.  
1. Connect one end of the cable to the male  
quick-connect SPARK terminal on the module.  
2. Connect the other end of the cable to the igniter or  
igniter-sensor stud on the pilot burner/igniter-  
sensor.  
NOTE: “Earth” ground is not required.  
S937XA Hot Surface Ignition Versions  
These models provide operating control of a direct ignition  
system using a hot surface igniter. Additional components  
required to complete the system must be ordered  
separately. They include:  
Connect Vent Damper (Vent Damper Models)  
A vent damper can be used with modules provided with a  
®
vent damper plug connector. The Molex plug provided  
simplifies wiring connections.  
Dual Valve Combination Gas Control: Any direct  
ignition gas control with 2.0A maximum main valve  
rating. VR8205, VR845, VR854, VR8450, or VR8540  
recommended.  
Hot Surface Igniter: Norton Model 201 or 271 or  
equivalent.  
To connect the vent damper, follow the wiring diagrams  
supplied with the vent damper for typical connections.  
Connect Remaining Module Connectors  
Connect remaining system components to the ignition  
module terminals as shown in the appropriate wiring  
diagrams, Fig. 4 and 5.  
NOTE: If igniter other than Norton Model 201 or 271 is  
used, the igniter must meet the following  
minimum specifications, required over the life of  
the igniter:  
Connect Igniter (HSI Models)  
Prepare wiring harness:  
1. Use wire suitable for the temperatures near the HSI  
igniter.  
2. Use wire suitable for the voltage ratings of the  
specific igniter.  
3. Attach connector per Table 4, HSI Specific  
Connectors.  
1.  
2.  
Igniter must reach 1000°C (1832°F) within 34  
seconds with 102 Vac applied.  
Igniter must maintain at least 500 megohms  
insulation resistance between the igniter  
leadwires and the igniter mounting bracket.  
Igniter current draw at 132 Vac must not  
exceed 5 A.  
3.  
Sensor: Separate sensor required. Honeywell Q354  
recommended.  
Connect Gas Control  
Use No. 18 AWG solid or stranded wire. Connect to gas  
control terminals as shown in wiring diagrams, using  
terminals appropriate to the gas control.  
Igniter Wiring: Provide wiring harness to suit application.  
Leadwires: No. 18 AWG, stranded copper with 105°C  
rated, 1/16 in. AWM insulation.  
Terminals: Insulated. See Table 4 for HSI specific  
connectors.  
Ground Control System  
The igniter, flame sensor and module must share a  
common ground with the main burner. Use AWM  
insulated wire with a minimum rating of 105°C (221°F) for  
Transformer: Add current ratings of module, gas control,  
vent damper and any other components of the control  
system to determine transformer size requirements.  
Table 2. Specific Ignition Timings.  
Ignition  
No. of  
Ignition  
Trials  
Igniter/ Automatic  
Activation Prepurge Postpurge  
Sensor  
Type  
Restart  
Time  
a
b
b
Model  
S9360A  
Ignition Type Draft Type  
Period  
N/A  
Timing  
15  
Timing  
Intermittent  
Pilot - Spark  
Induced  
3
3
3
Separate 1 hour  
Separate 1 hour  
Separate 1 hour  
5
5
S9360A  
S9370A  
Intermittent  
Pilot - Spark  
Atmospheric  
Induced  
N/A  
2.5  
1
5
Direct Hot  
Surface  
15  
a
b
Ignition Activation Period is the time that the hot surface igniter remains powered after the gas valve opens.  
Purge Timing specified in seconds.  
69-2076—01  
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S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
FLAME  
SENSE  
SPARK  
IGNITER  
CIRCULATOR  
L1  
L2  
GND  
GND  
1
INDUCER  
24 VAC  
TRANSFORMER  
1
DAMPER  
ENVIRACOM  
DIAGNOSTIC  
ENVIRACOM  
DISPLAY  
MV  
GAS  
CONTROL  
PRESSURE SWITCH  
LIMIT SWITCH  
PV  
PV/  
MV  
SENSOR 1  
SENSOR 2  
1
OPTIONAL DEPENDING ON CONFIGURATION  
M24216  
Fig. 4. Spark Ignition Wiring (S936X).  
7
69-2076—01  
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
CIRCULATOR  
INDUCER  
GND  
HOT SURFACE  
IGNITER  
FLAME  
SENSE  
24 VAC  
TRANSFORMER  
L2  
GND  
L1  
ENVIRACOM  
DIAGNOSTIC  
ENVIRACOM  
DISPLAY  
MV  
GAS  
CONTROL  
PRESSURE SWITCH  
LIMIT SWITCH  
MV  
SENSOR 1  
SENSOR 2  
M24218  
Fig. 5. Hot Surface Ignition Wiring (S937X).  
Common Connectors  
Table 3. Connectors Common to Both Spark-to-Pilot and Hot Surface Ignition Options.  
Connection/Color  
Pin  
Mating Plug  
Description  
Flame Sense  
1 of 1  
3/16 in. female quick- Connection to Flame  
connect  
Rod  
®
Sensor 1/White  
1 of 3  
2 of 3  
3 of 3  
1 of 2  
2 of 2  
NTC 1-1  
Molex 43061-0003  
Sensor Common  
NTC 1-2  
a
®
NTC Temperature  
Sensor  
Sensor 2 /White  
Molex 43061-0002  
69-2076—01  
8
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
Table 3. Connectors Common to Both Spark-to-Pilot and Hot Surface Ignition Options. (Continued)  
Connection/Color  
Pin  
Mating Plug  
Description  
ECOM Data “1”  
ECOM R “2”  
EnviraCOM/Black  
1 of 3  
2 of 3  
3 of 3  
1 of 3  
2 of 3  
3 of 3  
Stripped Bare Wire  
ECOM C “3”  
EnviraCOM Diag/  
White  
“Pen” Diagnostic Tool ECOM Data “1”  
with 0.1 in. spacing  
ECOM R “2”  
ECOM C “3”  
®
Transformer Primary/ 1 of 3  
L1  
Molex 50-81-1030  
White  
2 of 3  
Earth Ground  
Neutral  
3 of 3  
®
Transformer  
Secondary/White  
1 of 2  
2 of 2  
1 of 9  
24 Vac Input  
Earth Ground  
Molex 50-81-1020  
®
a
a
“Control”/White  
Molex 50-81-1090  
Pressure Switch  
a
2 of 9  
3 of 9  
Pilot Valve  
Pressure Switch  
AC N.C. Switch  
Main Valve  
4 of 9  
5 of 9  
6 of 9  
7 of 9  
8 of 9  
AC N.C. Switch  
N.C.  
MV/PV (Valve  
Common)  
9 of 9  
N.C.  
a
Indicates optional connection based on configuration.  
HSI Model Specific Connectors  
In addition to the common connectors listed above, Table 4 identifies connectors available on the HSI model board  
assemblies.  
Table 4. HSI Model Specific Connectors.  
Connection  
Pin  
1 of 4  
Mating Plug  
Description  
L1 Relay Out  
a
®
On/Off Circulator /White  
Molex 50-84-1061  
2 of 4  
3 of 4  
4 of 4  
1 of 3  
2 of 3  
3 of 3  
1 of 4  
2 of 4  
3 of 4  
4 of 4  
1 of 2  
2 of 2  
Earth Ground  
Neutral  
Neutral  
®
Line Voltage Input/Red  
L1  
Molex 50-84-1031  
Earth Ground  
Neutral  
®
Induced Draft Blower (Combustion Air)/Red  
L1 Relay Out  
Earth Ground  
Neutral  
Molex 50-84-1041  
Neutral  
®
HSI/Red  
L1 Relay Out  
Flame Sense/(N) Relay Out  
Molex 50-84-1021  
a
Indicates optional connection based on configuration.  
9
69-2076—01  
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
Table 5. Spark Model Specific Connectors.  
Connection  
Line Voltage Input/White  
Pin  
1 of 4  
Mating Plug  
Description  
®
L1  
Molex 50-81-1040  
2 of 4  
3 of 4  
4 of 4  
1 of 6  
2 of 6  
3 of 6  
4 of 6  
5 of 6  
6 of 6  
1 of 6  
2 of 6  
Earth Ground  
Earth Ground  
Neutral  
a
®
Earth Ground  
N/C  
Induced Draft Blower (Combustion Air )/White  
Molex 39-01-2060  
Neutral  
N/C  
L1 Relay Out  
N/C  
a
24 Vac  
Vent Damper /White  
Damper E.S.  
Feedback  
3 of 6  
24V Common if  
damper connected  
4 of 6  
5 of 6  
6 of 6  
1 of 1  
24V Common  
Damper Activation  
N/C  
Spark Rod  
1/4 in. female quick-  
connect  
Connection to Spark  
Rod  
a
®
1 of 2  
2 of 2  
L1 Relay Out  
Neutral  
On/Off Circulator /Red  
Molex 50-84-1021  
a
Indicates optional connections based on configuration.  
Table 6. Pin Configuration.  
Wire Harness Housing Pin Configuration  
®
Pin/Socket  
Molex Number  
Line In  
pin  
socket  
02-08-2004  
Transformer Primary  
02-08-1002  
02-08-1002  
02-08-2004  
03-06-2103  
39-00-0039  
02-08-1002  
08-50-0106  
08-50-0106  
08-50-0114  
Transformer Secondary socket  
Circulator  
Damper  
pin  
pin  
Inducer  
socket  
socket  
socket  
socket  
socket  
Control  
Sensor 1  
Sensor 2  
E-COM Diagnostic  
The overall range of the setpoint is model-dependent but  
is within 130°F to 240°F (54°C to 116°C). Select devices  
may have different ranges.  
Temperature Control  
Temperature control setpoint on the module can be  
adjusted as described in the following sections. Some  
modules with temperature control also include a three-  
digit display on the printed circuit board to facilitate  
adjustments and troubleshooting.  
Adjusting Settings or Models with “On-  
Board” Display  
For modules that do not include temperature control on  
the module refer to the Honeywell Installation Instructions  
for the specific interface module or the appliance  
manufacturer’s instructions. A separate automatic gas  
shutoff device is not required in a system that uses this  
control to meet requirements for CSA International ANSI  
Z21.87 and UL 353.  
To discourage unauthorized changing of settings, a  
procedure to enter the adjustment mode is required. To  
enter the adjustment mode, press the UP, DOWN, and I  
buttons (see Fig. 1) simultaneously for three seconds.  
Press and release the I button until the parameter  
requiring adjustment is displayed:  
69-2076—01  
10  
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
“SP_”  
“Df_”  
“°F_”  
Setpoint.  
LOCATION AND MOUNTING  
Setpoint Differential (select models).  
Degrees Fahrenheit  
Then press the UP or DOWN button until the parameter  
has reached the desired value. After 60 seconds without  
any button inputs, the control will automatically return to  
the READ mode.  
Sensing Bulb(s)  
The water heater manufacturer usually provides a tapping  
for the sensing bulb at a point where average water  
temperature can be measured. Some water heaters use  
two (2) sensors, one limit rated near the center or bottom  
of the tank, the other non-limit rated near the top. See Fig.  
7. Follow the heater manufacturer instructions.  
Display  
In the RUN mode, status items and parameters are  
viewable. For example, to display setpoint, the control will  
flash “sp” (setpoint) followed by the temperature (i.e.,  
135), followed by °F or °C.  
The sensing bulb can be installed in an immersion well.  
Wells and fittings must be ordered separately. See 68-  
0040.  
To read settings, press and release the I key to find the  
parameter of interest. For example, press and release I  
until setpoint (sp) is displayed, followed by a three-digit  
number, i.e., 220, followed by °F or °C. Pressing the I  
button again will display the (S1T) Sensor 1 Temperature  
followed by a three-digit number and the corresponding  
degree designator. See Display Readout, Fig. 6.  
When an immersion well is used, the sensor should fit  
snugly and should touch the bottom of the well for best  
temperature response. Use heat-conductive compound  
(Honeywell part no. 107408) to fill the space between the  
bulb and the well to improve heat transfer characteristics  
(optional). Make sure the sensor is held firmly in the well.  
Remote Display  
Display  
For units that use a remote display, refer to I&I sheet for  
SD7000A.  
Text  
Description  
Current State  
Shows  
sta  
s1t  
s2t  
sp  
Sensor 1 Temperature  
Sensor 2 Temperature*  
Setpoint  
WIRING  
IMPORTANT:  
For maximum trouble free operation, run the  
sensor leadwires separately from any other cur-  
rent-carrying wires.  
dff  
hr  
Setpoint Differential  
Heat Request Status  
All wiring must comply with local codes and ordinances.  
Disconnect power supply before beginning wiring.  
Connect according to water heater manufacturer  
instructions.  
err  
fla  
F
Error Code  
Flame Current  
Degrees Fahrenheit  
Degrees Celsius  
C
INDUCER  
MOTOR  
INLET  
uA  
Micro Amps  
(OPTIONAL)  
LIMIT  
M24052  
SENSOR  
SUPPLY  
PUMP  
Fig. 6. Display readout definitions.  
Boiler Temperature Controller  
When the water temperature reaches setpoint, the  
controller ends the heating cycle. When the water  
temperature drops below the setpoint minus the  
differential, the control restarts a heat cycle to re-heat the  
tank of water.  
INTEGRATED  
BOILER  
CONTROL  
MAIN  
BURNER  
If the water temperature exceeds the max allowed  
temperature, the control enters a manual reset lockout  
state. For models that have reset capability, press any on-  
board button (when present), cycle power, or use the  
remote display to reset.  
PILOT  
CHECKOUT  
M27076  
Put the system into operation and observe operation  
through at least one complete cycle to make sure that the  
controller operates properly. See Troubleshooting section  
to assist in determining system operation.  
Fig. 7. Typical location of limit function sensor and  
control module.  
11  
69-2076—01  
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
Mounting Sensor and Thermowell  
OPERATION AND CHECKOUT  
The remote upper temperature sensor is installed in an  
immersion well (Fig. 8) that extends into the supply water  
side of the boiler.  
Operation  
The S9360A, S9361A, S9370A and S9371A continuously  
monitor the temperature of the boiler water and enable or  
disable the burner based on this temperature data. In  
general, when a “Call for Heat” occurs, the ignition portion  
of the control module proceeds through the steps  
necessary to start the burner and heats the water in the  
boiler until the setpoint temperature is achieved. At this  
point the burner is de-activated, the ignition module  
completes the heating cycle, returns to idle and waits for  
the temperature to drop again. The circulator is turned on  
throughout the “Call for Heat.”  
Immersion Well Fitting  
The immersion well must snugly fit the sensing bulb for  
good thermal response. Install as follows:  
1. Use tapping provided by tank manufacturer, if pos-  
sible, or select an area where typical water temper-  
ature is best measured.  
2. If tank is filled, drain to below point where bulb will  
be installed.  
3. Screw well into tank.  
4. Insert bulb into well, pushing wires until bulb bot-  
toms in well.  
5. Attach mounting clamp end of well spud.  
6. With mounting clamp attached to well spud (make  
sure jaws of clamp hook over ridge at end of spud,  
as shown at points A in Fig. 8), adjust sensing lead-  
wire to fit through mounting clamp groove, as  
shown at point B in Fig. 8.  
7. Tighten draw nut until mounting clamp is firmly  
attached to well spud and wires are held securely in  
place.  
See Fig. 9 for a graphical representation of a simple  
control cycle. Note that the setpoint differential may vary  
based on OS number.  
High Limit Controller  
All models include a 3-wire temperature sensor interface,  
“Sensor 1,” which is utilized for High Limit functionality in  
addition to the thermostatic control of the water heater  
burner. If the temperature sensor ever indicates a  
temperature above the maximum limit then the control  
enters over temperature mode. In over temperature mode  
no heating will occur.  
CAUTION  
Do not secure draw nut so tightly that  
mounting clamp collapses tubing.  
200°F (93.3°C)  
BOILER  
SENSOR WIRES  
IMMERSION  
WELL  
SENSOR  
GAS VALVE OFF  
GAS VALVE ON  
SETPOINT  
15°F (8°C)  
DIFFERENTIAL  
HEAT-CONDUCTIVE COMPOUND  
(OPTIONAL)  
M23086A  
Fig. 8. Immersion well fitting for sensor.  
70°F (21°C)  
M27000  
Wiring  
Disconnect power supply before installation to prevent  
electrical shock or equipment damage. All wiring must  
comply with local codes and ordinances regarding wire  
size, type of insulation, enclosure, etc.  
Fig. 9. Basic control algorithm example.  
69-2076—01  
12  
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
IGNITION  
SEQUENCE  
CIRCULATOR  
CONTROL  
IDLE  
IDLE  
ALL OUTPUTS OFF  
ALL OUTPUTS OFF  
WATER TEMPERATURE LOW AND THERMOSTAT ACTIVE  
THERMOSTAT CALL FOR HEAT ACTIVE  
CHECK LEAKAGE/  
WATER TEMP.  
CIRCULATOR ON  
SET FLAME BIAS  
BIAS DONE  
HIGH OR CALL  
FOR HEAT LOST  
THERMOSTAT CALL FOR HEAT LOST  
TIME OUT OR  
MANUAL RESET  
WAIT LIMIT  
SWITCH CLOSE  
CIRCULATOR OFF  
LIMIT SWITCH  
OPEN  
LIMIT SWITCH CLOSE  
CHECK DAMPER/  
PRESSURE SWITCH  
OPEN  
SWITCH OPEN  
DRIVE DAMPER/  
INDUCER WAIT FOR  
SWITCH CLOSE  
SWITCH CLOSE  
SWITCH OPEN  
FLAME DEB ON  
FLAME DEB OFF  
TIME OUT  
CHECK FLAME  
PRE-TRIAL  
SOFT LOCKOUT  
PREPURGE  
TIME OUT  
TIME OUT  
A
SPARK  
TURN PILOT VALVE ON  
TIME OUT  
A
TIME OUT  
RETRY DELAY  
FLAME SENSED  
PROVE FLAME  
STOP SPARKING  
B
FLAME PROVED  
DAMPER/  
PRESSURE  
SWITCH OPEN  
TIME OUT  
FLAME STABILIZATION  
TURN MAIN VALVE ON  
A
RECYCLE DELAY  
TIME OUT  
RUN  
TIME OUT  
FLAME LOST  
WATER TEMPERATURE HIGH OR THERMOSTAT CALL FOR HEAT LOST  
FLAME DEB ON  
FLAME DEB OFF  
B
CHECK FLAME  
POST-TRIAL  
POSTPURGE  
M27073  
Fig. 10. Operating Sequence.  
13  
69-2076—01  
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
Disconnect the ignition cable at the SPARK terminal on  
the module.  
TROUBLESHOOTING  
IMPORTANT  
1. The following service procedures are provided  
as a general guide. Follow appliance manufac-  
turer’s service instructions if available.  
2. On lockout and retry models, meter readings  
between gas control and ignition module must  
be taken within the trial for ignition period. Once  
the ignition module shuts off, lockout models  
must be reset through the key buttons and dis-  
play. On retry models, wait for retry or reset at  
the thermostat.  
3. If any component does not function properly,  
make sure it is correctly installed and wired  
before replacing it.  
4. The ignition module cannot be repaired. If it mal-  
functions, it must be replaced.  
WARNING  
The ignition circuit generates over 10,000 volts  
and electrical shock can result.  
Energize the module and listen for the audible sparking  
noise. When operating normally, there should be a  
buzzing noise that turns on and off twice per second for a  
duration of 1–7 seconds, depending on the model.  
STEP 4: Check pilot and main burner lightoff.  
Set the system to call for heat by turning the  
thermostat above room temperature.  
Watch the pilot burner during the ignition sequence.  
See if:  
5. Only trained, experienced service technicians  
should service ignition systems.  
Ignition spark continues after the pilot is lit.  
The pilot lights and the spark stops, but main  
burner does not light.  
Perform the checkout as the first step in troubleshooting.  
Then check the appropriate troubleshooting guide and the  
schematic diagram to pinpoint the cause of the problem. If  
troubleshooting indicates an ignition problem, see Ignition  
System Checks below to isolate and correct the problem.  
If so, ensure adequate flame current as follows.  
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-resis-  
tant No. 18 wire rated for continuous duty up to  
105° C [221° F].  
Following troubleshooting, perform the checkout  
procedure again to be sure system is operating normally.  
Check for cracked ceramic insulator, which can  
cause short to ground, and replace igniter-sensor  
if necessary.  
Intermittent Pilot  
At the gas valve, disconnect main valve wire from  
the 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.  
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. 11 for possible flame problems  
and their causes.  
If necessary, adjust pilot flame by turning the pilot  
adjustment screw on the gas control clockwise to  
decrease or counterclockwise to increase pilot  
flame. Following adjustment, always replace pilot  
adjustment cover screw and tighten firmly to  
assure proper gas control operation.  
Set temperature below room setpoint to end call  
for heat.  
Ignition System Checks  
STEP 1: Check ignition cable.  
Make sure:  
Ignition cable does not run in contact with any metal  
surfaces.  
Ignition cable is no more than 36 in. [0.9 m] long.  
Connections to the ignition module and to the igniter or  
igniter-sensor are clean and tight.  
Ignition cable provides good electrical continuity.  
STEP 2: Check ignition system grounding. Nuisance  
shutdowns are often caused by a poor or erratic ground.  
A common ground, usually supplied by the pilot burner  
bracket, is required for the module and the pilot burner/  
igniter sensor.  
Check for good metal-to-metal contact between  
the pilot burner bracket and the main burner.  
Check the ground lead from the GND(BURNER)  
terminal on the module to the pilot burner. Make  
sure connections are clean and tight. If the wire is  
damaged or deteriorated, replace it with No. 14-18  
gauge, moisture-resistant, thermoplastic insu-  
lated wire with 105° C [221° F] minimum rating.  
—Check the ceramic flame rod insulator for  
cracks or evidence of exposure to extreme  
heat, which can permit leakage to ground.  
Replace pilot burner/igniter-sensor and pro-  
vide shield if necessary.  
Recheck ignition sequence as follows.  
Reconnect main valve wire.  
Adjust thermostat above room temperature.  
Watch ignition sequence at burner.  
If spark still doesn’t stop after pilot lights, replace  
module.  
If main burner doesn’t light or if main burner lights  
but system locks out, check module, ground wire  
and gas control as described in appropriate trou-  
bleshooting chart.  
Troubleshooting Error Codes  
The integrated boiler control uses advanced diagnostic  
capability to assist in troubleshooting error conditions.  
The following table shows the codes that could arise on  
the remote or integrated display during a fault.  
Suggestions are provided in Table 7 for servicing these  
potential errors.  
—If flame rod or bracket are bent out of position,  
restore to correct position.  
STEP 3: Check spark ignition circuit.  
69-2076—01  
14  
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
Table 7. Error Codes.  
Segment  
Display  
Definition  
Pressure Switch failed to open (contacts stuck closed).  
Flame sensed out of normal sequence (before opening gas valve or after  
closing gas valve).  
Flame sensed during prepurge (before gas valve signaled opened).  
Flame sensed during postpurge (before gas valve signaled closed).  
Pressure Switch failed to close (contacts stuck open).  
Sensor 2 Error. Temperature sensor or interface failure (open or short  
connection) or failure of A/D conversion (invalid offset).  
Sensor 1 Error. Temperature sensor or interface failure (open or short  
connection, increased connection resistance, dual sensor mismatch) or  
failure of A/D conversion (invalid offset or gain, too many failures during  
A/D conversion).  
Atmospheric Damper End Switch failed to close (end switch contacts stuck  
open).  
Atmospheric Damper End Switch failed to open (end switch contacts stuck  
closed).  
Flame Rod shorted to burner ground.  
AC line frequency error—signal is too noisy or frequency is incorrect.  
Line voltage error—voltage out of spec high or low.  
Line voltage unstable—possibly too many heavy loads switching on and  
off cause erratic supply voltage.  
Soft Lockout—maximum number of retries exceeded.  
Soft Lockout—maximum number of recycles exceeded.  
Soft Lockout—electronics failure. Caused by general electronics failure  
such as relay open or shorted contacts, flame sensing circuit error, or A to  
D error.  
Over temperature error. Sensors measured temperature in excess of ECO  
limit.  
15  
69-2076—01  
 
S9360A, S9361A, S9370A, S9371A INTEGRATED BOILER CONTROLLERS  
CAUSE  
APPEARANCE  
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  
WAVING BLUE 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  
CHECK FOR:  
• EXCESSIVE DRAFT AT PILOT  
LOCATION  
• RECIRCULATING PRODUCTS  
OF COMBUSTION  
CHECK FOR:  
NOISY LIFTING  
BLOWING FLAME  
• HIGH GAS PRESSURE  
HARD SHARP FLAME  
THIS FLAME IS CHARACTERISTIC  
OF MANUFACTURED GAS  
CHECK FOR:  
• HIGH GAS PRESSURE  
• ORIFICE TOO SMALL  
M3272A  
Fig. 11. Examples of unsatisfactory pilot flames.  
Automation and Control Solutions  
Honeywell International Inc.  
1985 Douglas Drive North  
Golden Valley, MN 55422  
customer.honeywell.com  
Honeywell Limited-Honeywell Limitée  
35 Dynamic Drive  
Toronto, Ontario M1V 4Z9  
® U.S. Registered Trademark  
© 2007 Honeywell International Inc.  
69-2076—01 M.S. 10-07  
 

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