Johnson Controls G670 Assembly instructions

Installation Sheets Manual 121

Gas Combustion Combination Controls and Systems Section G

Technical Bulletin G670

Issue Date 0300

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

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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

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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?

Yes

Run

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

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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

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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

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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

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G670 Intermittent Pilot Ignition Controls Technical Bulletin 7

0.21 in

RW Y

Thermostat

162 43

Jumper

Ground Terminals

Limits in

the Thermostat

Line Only

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

MV PV

Limits in

the Thermostat

Line Only

VAC

Power

Supply

Pilot

Burner

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

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G670 Intermittent Pilot Ignition Controls Technical Bulletin

RW Y

Thermostat

162 43

Jumper

Y79

High Voltage

Cable

Flame

Sensor

Pilot

Burner

Ground

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

Flame

Sensor

High Voltage

Cable

Pilot

Burner

Ground

VAC

High Limits

In This Line

Only

Power

Supply

White

Red

Black

Figure 9: Wiring Diagram for G670 with a Y79A _ _

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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

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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

AC Ammeter Low Scale Setting

Clamp-on Ammeter

(Divide reading by ten.)

Heating

System

Heating

System

Figure 10: Measuring the Thermostat Current

Thermostat

Heat

Anticipator

Settings

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