NTSUMI Natural Gas Furnace Pilot Burner Ignitor Assembly Instruction Manual

1. Product Overview

This manual provides instructions for the NTSUMI Natural Gas Furnace Pilot Burner Ignitor Assembly, Model 1011483. This component is designed to replace original ignitor assemblies in various natural gas furnace systems, ensuring reliable ignition.

The assembly includes a spark ignition system electrode, a natural gas igniter expansion component, and 250°C white temperature-resistant wiring. It features a 1/4 inch compression fitting inlet, a "B" type mounting bracket, an "F" Tip, and a 0.18mm orifice natural gas nozzle, configured for right-hand pilot assembly.

Figure 1: NTSUMI Natural Gas Furnace Pilot Burner Ignitor Assembly.

Figure 2: Overview of the NTSUMI Ignitor Assembly.

2. Safety Information

WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death. Read the installation, operating, and maintenance instructions thoroughly before installing or servicing this equipment.

• Always disconnect power to the furnace or appliance before attempting any installation, maintenance, or service.
• Ensure the gas supply is turned off before working on any gas components.
• Installation should be performed by a qualified service technician.
• Verify all gas connections are leak-free after installation.
• Do not bypass any safety devices.

3. Installation

This section outlines the general steps for installing the NTSUMI Pilot Burner Ignitor Assembly. Specific furnace models may have variations. Always refer to your furnace's service manual for detailed instructions.

3.1 Compatibility

This ignitor assembly is compatible with various systems, including those from Dayton, Sterling, Beacon Morris, and Honeywell. It is designed to replace part numbers J38R04578-001, J38R04578-001RC, 4365864A, Q3451U1000, and 1011483.

Compatible intermittent pilot system models include: S8600F, S8600H, S8600M, S8610F, S8610H, S8610M, S8610U, S8660D, 8660E, S8670D, S8670E, 3E366, 3E367, 3E4404, 3E468, 4E455, 4E456, 9E796, QVEF030, QVEF045, QVEF060, QVEF075, QVF030, QVF045, QVF060, QVF075, 3E366, 3E367, 3E368, 3E406, 4E454, 4E455, 4E455, 4E456.

Figure 3: Compatible furnace systems and models.

3.2 Pre-Installation Steps

1. Turn off the main power supply to the furnace at the circuit breaker.
2. Turn off the gas supply to the furnace.
3. Allow the furnace to cool completely if it has been in operation.
4. Locate the existing pilot burner ignitor assembly within the furnace.

3.3 Removal of Old Ignitor

1. Carefully disconnect the electrical wiring from the old ignitor.
2. Disconnect the gas line from the old pilot burner.
3. Unscrew or unclip the mounting bracket to remove the old assembly.

3.4 New Ignitor Assembly

The NTSUMI ignitor assembly is designed for straightforward replacement. The video below demonstrates the assembly of the components.

Video 1: Assembly of the NTSUMI Pilot Burner Ignitor components.

1. Attach the 1/4 inch compression fitting to the pilot burner inlet.
2. Secure the "B" type mounting bracket to the pilot burner assembly.
3. Ensure the "F" Tip and 0.18mm orifice natural gas nozzle are correctly positioned.
4. Connect the electrical wiring to the ignitor electrode.

3.5 Installation Steps

1. Mount the new ignitor assembly in the original position using the provided bracket.
2. Connect the gas line to the 1/4 inch compression fitting on the new pilot burner. Ensure a secure, leak-free connection.
3. Connect the electrical wiring from the furnace control board to the ignitor assembly.
4. Double-check all connections for tightness and proper placement.

3.6 Post-Installation Check

1. Slowly turn on the gas supply to the furnace.
2. Check for any gas leaks using a soap solution on all gas connections. Bubbles indicate a leak. If a leak is detected, turn off the gas supply immediately and tighten connections or replace faulty parts.
3. Restore electrical power to the furnace.
4. Initiate a call for heat to test the ignitor's operation. Observe for proper pilot ignition and main burner light-off.

4. Operation

The NTSUMI Pilot Burner Ignitor Assembly operates as part of your furnace's ignition system. When the thermostat calls for heat, the furnace control board sends a signal to the ignitor. The ignitor then creates a spark to ignite the pilot flame, which in turn ignites the main burner. The ignitor also includes a flame sensor to confirm the presence of a flame.

5. Maintenance

Regular maintenance of your furnace, including the ignitor assembly, is crucial for safe and efficient operation. It is recommended to have your furnace inspected annually by a qualified HVAC technician.

• Cleaning: Periodically inspect the ignitor and pilot burner for any soot, carbon buildup, or debris. Gently clean with a soft brush if necessary. Ensure the ignitor electrode and flame sensor are free from obstructions.
• Inspection: Check the wiring for any signs of wear, fraying, or damage. Ensure all connections are secure.
• Pilot Flame: Observe the pilot flame during operation. It should be a steady, blue flame. An erratic or yellow flame may indicate a problem with the gas supply or pilot burner.

6. Troubleshooting

If your furnace is not igniting or experiencing issues, consider the following common troubleshooting steps. Always ensure power and gas are off before inspecting components.

• No Ignition/No Spark:
  - Check electrical connections to the ignitor for looseness or corrosion.
  - Verify the ignitor wiring is not damaged.
  - Ensure the ignitor electrode is clean and properly positioned relative to the pilot burner.
• Pilot Lights, but Main Burner Does Not:
  - The flame sensor may be dirty or faulty. Clean the flame sensor rod with fine sandpaper.
  - The pilot flame may be too small or weak to properly heat the flame sensor. Check gas pressure or pilot orifice for obstructions.
• Intermittent Operation:
  - Loose wiring connections can cause intermittent issues.
• Gas Leak Smell:
  - Immediately turn off the gas supply and power to the furnace.
  - Ventilate the area.
  - Do not operate any electrical switches or appliances.
  - Contact a qualified service technician or your gas provider immediately.

If these steps do not resolve the issue, contact a qualified HVAC technician for further diagnosis and repair.

7. Specifications

Figure 4: Product dimensions.

Figure 5: Wire length measurement.

8. Warranty and Support

For warranty information and technical support, please refer to the NTSUMI official website or contact their customer service department. Keep your purchase receipt for warranty claims.