Johnson Controls G670 Assembly instructions

Installation Sheets Manual 121
Gas Combustion Combination Controls and Systems Section G
Technical Bulletin G670
Issue Date 0300
© 2000 Johnson Controls, Inc. 1
Part No. 24-8143-162, Rev. B www.johnsoncontrols.com
Code No. LIT-121240
Figure 1: G670 Intermittent Pilot Ignition Control
The G670 is a Non-100% Lockout Intermittent Pilot Ignition (IPI) control
that replaces the G67AG and G67BG ignition controls. The G670 is used to
automatically light a pilot burner and energize the main burner gas valve in
response to a call for heat from the system thermostat. When the call for heat
is satisfied, the thermostat opens and the G670 de-energizes the pilot and
main burner gas valves.
Following are the application requirements of the G670 control.
•The G670 can be used with equipment with a maximum firing rate of
117 kW (400,000 Btu/hr). Any application greater than 117 kW
(400,000 Btu/hr) must have written approval in advance from the
Heating Products Engineering Department.
•All G670 applications must use a redundant gas valve system with the
main valve seats in series.
G670 Intermittent Pilot Ignition Controls
Description
Application
Requirements

2 G

G670 Intermittent Pilot Ignition Controls Technical Bulletin
Table 1: Specifications
Ignition Type Indirect
Ignition Source High voltage spark, capacitive discharge
High Voltage Cable
Length
915 mm (36 in.) maximum
Flame Detection Means Flame rectification
Flame Detection Types Remote sensing
Minimum Flame Current 0.2 microampere
Flame Failure Response
Time
0.8 second, maximum
Spark Gap 2.5 mm (0.1 in.) nominal
Ignition Trial Time Infinite
Power Requirements Control: 24 VAC, 50/60 Hz, nominal
Operation Current: 0.15A nominal + valves
Contact Rating Main Valve: 2A continuous, 5A inrush
Pilot Valve: 2A continuous, 5A inrush
Ambient Operating and
Storage Temperature
-40 to 66°C (-40 to 150°F)
Humidity 95% RH non-condensing
Types of Gas Natural
(Liquefied Petroleum [LP], manufactured, mixed, or
LP gas-air mixture may be used in a well vented or
outdoor application.)
Agency Listing CSA (AGA/CGA) Certificate Number 112520-0-19
Specification Standards ANSI Standard Z21.20
CSA C22.2-No. 199
The performance specifications are nominal and conform to acceptable industry
standards. For application at conditions beyond these specifications, consult the
local Johnson Controls office. Johnson Controls, Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
The following definitions describe operating conditions.
•Trial for Ignition--Period during which the pilot valve and spark are
activated attempting to ignite gas at the main burner. The
trial-for-ignition period is infinite for the G670s and ends once the
pilot flame is detected or the call for heat ends.
•Run--The main valve remains energized and the spark is turned off
after successful ignition.
•Flameout--Loss of proven flame. Should a flameout occur, the main
valve closes and the spark recurs within 0.8 second.
Operating
Mode
Definitions

G

G670 Intermittent Pilot Ignition Controls Technical Bulletin 3
Figure 2 illustrates the sequence of operation for the G670 ignition control.
On a call for heat from the system thermostat, the G670 simultaneously
opens the pilot valve and supplies a continuous spark to the pilot burner’s
electrode. When the pilot burner gas ignites, the pilot flame sensor detects
the pilot flame and signals the G670 to energize the main gas valve and
discontinue the spark. The main gas valve will not be energized until the
flame sensor detects the presence of the pilot flame.
If the pilot flame goes out (with the thermostat still calling for heat), the
G670 will de-energize the main gas valve and provide a continuous spark
at the pilot burner’s electrode. When the pilot flame is re-ignited and
detected by the pilot flame sensor, the main gas valve is energized and the
spark is shut off. The G670 de-energizes the pilot gas valve and main
burner gas valve when the thermostat stops calling for heat.
Start
Flameout?
No
No
Yes
No
Yes
Run
No
Yes
End
Yes
De-energize Control
Pilot and Main Valves
Thermostat
Calling for
Heat?
De-energize
Main Valve
Energize
Main Valve
Pilot
Flame
Sensed?
Trial for
Ignition
Flame
Present?
Thermostat
Call for Heat
Figure 2: Sequence of Operation
Sequence of
Operation

4 G

G670 Intermittent Pilot Ignition Controls Technical Bulletin
IMPORTANT: These instructions are intended as a guide for qualified
personnel installing or servicing Johnson Controls
ignition controls. Carefully follow all instructions in
this bulletin and all instructions on the appliance. Limit
repairs, adjustments, and servicing to the operations
listed in this bulletin or on the appliance.
!
WARNING: Fire or Explosion Hazard. Avoid serious injury by
carefully following precautions in this bulletin and all
instructions on the appliance. Limit repairs,
adjustments, and servicing to the operations listed in
this bulletin or on the appliance.
!
WARNING: Fire or Explosion Hazard. If the control is installed
in an area that is exposed to water (dripping, spraying,
rain, etc.), it must be protected. If the control has been
exposed to water in any way, do not use it.
!
WARNING: Shock Hazard. Avoid electrical shock and equipment
damage. Disconnect electrical power and turn off the
gas before wiring the control.
!
CAUTION: Equipment Damage Hazard. Label all wires prior to
disconnection when servicing controls. Wiring errors
can cause improper and dangerous operation. Verify
proper operation after servicing.
Perform the following procedure to install the G670 ignition control.
1. Shut off power to the appliance.
2. Turn off gas at the manual shutoff valve adjacent to the appliance.
3. Label each wire with the correct terminal designation prior to
disconnection.
4. Disconnect the power supply (transformer) and the thermostat lead
wire at the ignition control.
5. Disconnect the sensing probe lead from Terminal 4 on the ignition
control.
6. Disconnect the high voltage cable from the spark transformer.
7. Disconnect the Pilot Valve 1 and Main Valve 3 leads from the ignition
control.
8. Disconnect any wires connected to the ground terminals on the ignition
control.
Installation
Mounting

G

G670 Intermittent Pilot Ignition Controls Technical Bulletin 5
9. Remove the screws holding the ignition control assembly in place.
10. Remove the ignition control and discard.
11. Using the same holes as the old ignition, mount the new G670 control
on a grounded metal surface with metal screws or bolts through the
mounting holes provided on the enclosure.
All spark ignition controls have a spark transformer connected to a high
voltage cable. There are three types of connection for the high voltage
cable: Spike, Rajah, and 6.35 mm (1/4 in.) male spade (see Figure 3). The
G670 has a Spike transformer. When replacing a control that has a Rajah
or male spade connection, the crimp-on connector must be cut off.
1. Slide the rubber boot up the cable.
2. Cut the lead just above the connector (see Figure 4). Make a straight
cut perpendicular to the cable.
3. Center the exposed wire on the end of the lead over the spike in the
spark transformer and push the wire lead down firmly over the spike
(see Figure 5).
4. Ensure the lead is inserted all the way into the spark transformer. Slide
the boot back down the cable and over the spark transformer.
Spike Connection Rajah Connection 6.35 mm (1/4 in.)
Male Spade
Figure 3: High Voltage Cable Connectors
High Voltage Cable
Insulating Boot Crimp-on
Connector
Cut off connector here.
Figure 4: High Voltage Cable with Crimp-On Connector
High Voltage Cable
Spike must be in contact
with the center wires.
Figure 5: Spark Transformer Connection
Modifying
Existing Ignition
Cable

6 G

G670 Intermittent Pilot Ignition Controls Technical Bulletin
!
CAUTION: Equipment Damage Hazard. Connect the high
voltage cable to the spark transformer terminal and
spark electrode (pilot burner assembly) before
applying power to the control. Ensure the ground wire
is attached to the pilot burner and control ground
terminal strip.
!
CAUTION: Equipment Damage Hazard. Locate all limit and
operating controls in series with the thermostat
terminal (THS 2) on the ignition control.
Check the voltage rating marked on the control and make sure it is suited to
the application. Use a National Electrical Code (NEC) Class 2 transformer
to provide 24 VAC under maximum load, including valves. A transformer
having excessive primary impedance due to poor coupling will affect the
ignition potential.
Refer to Figures 6 through 9 for wiring diagrams. All wiring should be in
accordance with the NEC and all other local codes and regulations. The
high voltage spark transformer cable must not be in continuous contact
with a metal surface. Use standoff insulators. Ensure that the flame sensor
wire and the high voltage spark transformer cable are separated from
one another by a minimum distance of 6.35 mm (1/4 in.) and are not
wrapped around any pipe, other wiring, or accessories.
Wiring

G

G670 Intermittent Pilot Ignition Controls Technical Bulletin 7
0.21 in
RW Y
Thermostat
162 43
Jumper
Ground Terminals
5
PV
MV
Limits in
the Thermostat
Line Only
24
VAC Power
Supply
Flame
Sensor
High Voltage
Cable
Pilot
Burner
Ground
Figure 6: Replacement Wiring Diagram
if the Original Control is a G67AG
RW Y
Thermostat
1243
Jumper
5
6
MV PV
Limits in
the Thermostat
Line Only
24
VAC
Power
Supply
Pilot
Burner
Ground
Ground
Terminals
Flame
Sensor
High Voltage
Cable
Install the jumper supplied
with the replacement control
between Terminals 2 and 6.
Figure 7: Replacement Wiring Diagram
if the Original Control is a G67BG

8 G

G670 Intermittent Pilot Ignition Controls Technical Bulletin
RW Y
Thermostat
162 43
Jumper
5
MV
PV
Y79
PV
MV
High Voltage
Cable
Flame
Sensor
Pilot
Burner
Ground
24
VAC
Power
Supply
High Limits
In This Line Only
Black
Brown
White
Install the jumper supplied
with the replacement control
between Terminals 2 and 6.
Figure 8: Wiring Diagram for G670 with Y79B _ _
RW Y
Thermostat
162 43
Jumper
Y79
THS
MV PV
5
Flame
Sensor
High Voltage
Cable
Pilot
Burner
Ground
24
VAC
High Limits
In This Line
Only
Power
Supply
White
Red
Black
Figure 9: Wiring Diagram for G670 with a Y79A _ _

G

G670 Intermittent Pilot Ignition Controls Technical Bulletin 9
!
WARNING: Fire or Explosion Hazard. Avoid personal injury or
property damage by making sure the control functions
properly and there are no gas leaks. Follow this
checkout and startup procedure before leaving the
installation.
!
WARNING: Fire or Explosion Hazard. Do not attempt to check
out this system by manually lighting the pilot. This
could energize the main valve.
Make sure all components are functioning properly by performing the
following shutoff test.
1. With the gas and thermostat off, turn on power to the appliance.
2. Turn on the thermostat to the highest setting and verify that the control
goes through the operating sequence to a shutoff condition.
Note: The burner will not light because the gas is off.
3. Turn off the thermostat.
4. Turn on the gas and purge gas lines of all air.
5. Test for gas leaks on all pipe joints and connections upstream of the
gas valve with a soap solution.
6. Turn on the thermostat to the highest setting and verify successful
ignition and a normal run condition for at least three minutes. If the
appliance fails to run, see the Service Checkout Procedures section.
7. Test for leaks on all pipe joints and connections downstream of the gas
valve with a soap solution.
8. Turn the thermostat down for at least 30 seconds and then back up
again. Verify successful ignition at least three times.
9. Return the thermostat to a normal temperature setting before leaving
the installation.
Checkout and
Startup
Procedure

10 G

G670 Intermittent Pilot Ignition Controls Technical Bulletin
The thermostat anticipator setting is normally equal to the ignition system
current draw, plus that of the pilot and main valve.
Due to variations in appliance wiring and valves, it is advisable to measure
the actual current draw of the heating system at the thermostat location.
Measuring this current can be accomplished by opening the thermostat
contacts (lowering the set point) and installing an AC ammeter across the
terminals, or by using a clamp-on ammeter with a 10-turn multiplier
attached to the terminals (see Figure 10).
IMPORTANT: Measuring the current with an ammeter will energize
the system. Wait until the gas valve and inducer
energize before taking a current draw measurement.
Ten Tur ns
WR
WR
AC Ammeter Low Scale Setting
Clamp-on Ammeter
(Divide reading by ten.)
To
Heating
System
To
Heating
System
Figure 10: Measuring the Thermostat Current
Thermostat
Heat
Anticipator
Settings