Supco Robert Shaw 41-405 Replacement Hot Surface Igniter User Manual

1. Product Overview

The Supco Robert Shaw 41-405 is a replacement hot surface igniter designed for various heating applications, including furnaces, boilers, rooftops, unit heaters, water heaters, and swimming pool heaters. This igniter features a flat silicon carbide (SiC) composition, offering dependable ignition and an efficient, stronger, and more reliable design compared to older silicon carbide models.

Key features include:

• SUPCO IG405 Flat Silicon Carbide Hot Surface Igniter
• Faster time to temperature response
• Stronger, more durable design
• Equipped with 18 gauge nickel copper high-temperature fiberglass insulated lead wires
• Designed for a longer usable life

Image of the Supco Robert Shaw 41-405 Replacement Hot Surface Igniter, showing its flat silicon carbide design and lead wires.

2. Safety Information

WARNING: Installation and servicing of heating equipment should only be performed by qualified service technicians. Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal injury, or loss of life.

• Always disconnect power to the appliance before attempting any installation, maintenance, or troubleshooting.
• Hot surface igniters operate at extremely high temperatures. Avoid contact with the igniter element during and immediately after operation.
• Handle the igniter carefully. The silicon carbide material is brittle and can break if dropped or subjected to impact.
• Ensure all wiring connections are secure and comply with local electrical codes.
• Wear appropriate personal protective equipment (PPE), such as gloves and safety glasses, during installation.

3. Package Contents

The package typically contains:

• 1 x Supco Robert Shaw 41-405 Hot Surface Igniter with lead wires

Note: Connectors may not be included and might need to be sourced separately or reused from the existing igniter.

4. Setup and Installation

This section provides general guidelines for replacing a hot surface igniter. Always refer to the specific appliance manufacturer's instructions for detailed steps.

1. Disconnect Power: Turn off all electrical power to the heating appliance at the main service panel. Verify power is off using a voltage tester.
2. Access Igniter: Locate and open the access panel to the burner compartment of your heating appliance. The igniter is typically positioned near the main burner.
3. Disconnect Wiring: Carefully disconnect the electrical wires leading to the old igniter. Note the routing and connection points for reinstallation.
4. Remove Old Igniter: Unscrew or unclip the old igniter from its mounting bracket. Handle it gently as it may be fragile.
5. Inspect Mounting: Examine the mounting bracket for any damage or corrosion. Clean if necessary.
6. Install New Igniter: Mount the new Supco 41-405 igniter onto the bracket, ensuring it is securely fastened and positioned correctly according to the appliance manufacturer's specifications. Avoid overtightening.
7. Connect Wiring: Connect the new igniter's lead wires to the appliance's wiring harness. Ensure connections are tight and secure. If the new igniter's wires are a thinner gauge than the existing wiring, use appropriate wire nuts or connectors to ensure a robust and safe connection.
8. Verify Placement: Double-check that the igniter element is properly aligned with the burner and not touching any metal surfaces.
9. Close Access Panel: Securely close the access panel.
10. Restore Power: Restore electrical power to the appliance.
11. Test Operation: Initiate a heating cycle to confirm proper operation of the new igniter and the appliance. Observe the igniter glowing and the main burner igniting.

5. Operating Principles

The hot surface igniter functions as a safety ignition device in many modern heating systems. When a call for heat is initiated, the control board sends voltage to the igniter. The silicon carbide element rapidly heats up to a very high temperature (typically around 1800-2500°F or 980-1370°C), becoming incandescent. Once the igniter reaches its optimal temperature, the gas valve opens, allowing gas to flow to the main burner. The hot surface igniter then ignites the gas. After successful ignition, the igniter typically remains energized for a short period to ensure stable flame establishment, then de-energizes until the next call for heat.

6. Maintenance

Hot surface igniters are generally considered maintenance-free components. However, regular inspection during routine appliance servicing is recommended:

• Visual Inspection: Annually, or as part of your appliance's maintenance schedule, visually inspect the igniter for cracks, discoloration, or signs of physical damage. A healthy igniter should appear intact.
• Cleanliness: Ensure the igniter is free from dust, debris, or carbon buildup, which can hinder its heating efficiency. Use a soft brush or compressed air for cleaning, being careful not to touch the brittle element.
• Wiring: Check the lead wires for any signs of fraying, burning, or loose connections.

If any damage is observed, the igniter should be replaced by a qualified technician.

7. Troubleshooting

If your heating appliance is not igniting, the hot surface igniter may be a potential cause. Here are common symptoms and troubleshooting steps:

• Igniter Does Not Glow:
  • Possible Cause: No power to the igniter, faulty igniter, or issue with the control board.
  • Action: Verify power supply to the appliance. With power disconnected, check for continuity across the igniter element using a multimeter. If there is no continuity, the igniter is likely faulty and needs replacement. If continuity is present, the issue may lie with the control board or wiring.
• Igniter Glows but No Ignition:
  • Possible Cause: Insufficient igniter temperature, gas supply issue, faulty gas valve, or flame sensor problem.
  • Action: Ensure the igniter is glowing brightly. Check that the gas supply to the appliance is open. A qualified technician should inspect the gas valve and flame sensor.
• Igniter Cracks or Breaks:
  • Possible Cause: Physical damage during handling or installation, or thermal stress over time.
  • Action: The igniter is damaged and must be replaced.

For complex issues, it is always recommended to consult a qualified HVAC technician.

8. Specifications

9. Warranty and Support

For specific warranty information regarding your Supco Robert Shaw 41-405 Replacement Hot Surface Igniter, please refer to the documentation provided with your purchase or contact Supco customer support directly. Keep your proof of purchase for warranty claims.

For technical assistance or further inquiries, please visit the official Supco website or contact their customer service department.