Johnson Controls G77 Series User manual

Installation Sheets Manual 121

Gas Combustion Combination Controls and Systems G

Technical Bulletin G77x

Issue Date 0600

Part No. 24-8143-588, Rev. A www.johnsoncontrols.com

Code No. LIT-121250

Figure 1: G77x Intermittent Pilot Ignition Controls

The G77x family of controls is designed for indirect ignition of natural

gas, Liquefied Petroleum (LP) gas, manufactured gas, mixed gas, or

LP gas-air mixtures.

Following are the application requirements of the G77x control.

•The G77x can be used on gas-fired equipment with a maximum firing

rate of 117 kW (400,000 Btu/hr). Any application over 117 kW

(400,000 Btu/hr) must have written approval in advance from the

Johnson Controls Heating Products Engineering Department.

•All G77x applications must use a redundant gas valve system where

the pilot and main valve seats are in series and opened in sequence for

intermittent pilot ignition.

G77x Intermittent Pilot Ignition Controls

Description

Application

Requirements

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2 GG77x Intermittent Pilot Ignition Controls Technical Bulletin

Table 1: Specifications

Ignition Type Indirect

Ignition Source High voltage spark, capacitive discharge

High Voltage Cable

Maximum Length

1,220 mm (48 in.)

Flame Sense Cable

Maximum Length

1,220 mm (48 in.)

Flame Detection Means Flame rectification

Flame Detection Types Integral and remote

Minimum Flame Current 0.15 microampere

Flame Failure Response

Time

0.8 second maximum

1.5 seconds maximum (G776_G models only)

Spark Gap 2.5 mm (0.1 in.) nominal

Ignition Trials 1 or 3

Ignition Trial Times 8, 25, 50, 85, or 120 seconds*

Prepurge Times 0, 4, 15, or 30 seconds*

Interpurge 0, 15, or 30 seconds*

Automatic Recycle Delay

Period

No recycle (G770, G777)

5 minutes* (G775, G779)

60 minutes* (G776, G778)

Power Requirements Control: 24 VAC, 60 Hz, nominal

Operation Current: 0.2A nominal + valves

Contact Rating Main Valve: 2A continuous, 5A inrush

Pilot Valve: 2A continuous, 5A inrush

Ambient Operating and

Storage Temperature

-40 to 70°C (-40 to 160°F) standard models

-40 to 80°C (-40 to 175°F) high temperature models

Humidity 95% RH non-condensing

Wiring Connections Spark: Spike, Rajah, or 6.35 mm (1/4 in.) male spade

Control: 6.35 mm (1/4 in.) male spade

4.76 mm (3/16 in.) male spade optional

Types of Gas Natural, Liquefied Petroleum (LP), manufactured, mixed, or

LP gas-air mixture

Packaging Bulk pack supplied to original equipment manufacturer

(individual pack optional).

Bulk Pack Quantity 50

Bulk Pack Weight 15 kg (33 lb)

Agency Listing CSA (AGA/CGA) Certificate Number 164933-1073441

Australian Gas Certificate Number 4524 (G770 models only)

Specification Standards ANSI Standard Z21.20, Z21.20a, Z21.20b

CAN/CSA-C22.2 No.199

*Timings listed are for 60 Hz operation. Timings increase 20% for 50 Hz operation.

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.

Refer to the G77x Series Product Bulletin (LIT-4350430) for necessary information on operating

and performance specifications of this product.

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GG77x Intermittent Pilot Ignition Controls Technical Bulletin 3

The following definitions describe operating conditions:

•Prepurge--Initial time delay between thermostat contact closure and

trial for ignition.

•Trial for Ignition--Period during which the pilot valve and spark are

activated, attempting to ignite gas at the pilot burner. The control

attempts to prove flame at the pilot burner within the trial-for-ignition

time.

•Run--Pilot and main gas valves remain energized and spark is turned

off after successful ignition.

•Shutoff--Pilot gas did not ignite within the trial-for-ignition time. The

control de-energizes the spark circuit and pilot valve, and enters

automatic recycle period.

•Automatic Recycle--If shutoff occurs, the control delays for a specific

recycle delay period before beginning another trial for ignition (models

with recycle only).

•Interpurge--Period between trials for ignition when both the gas valve

and spark are deactivated to allow unburned gas to escape before the

next trial. Interpurge occurs between unsuccessful trials on a multi-trial

control or after a flameout (if the control has an interpurge).

•Ignition Lockout--Pilot gas did not ignite within the final

trial-for-ignition time. Open thermostat contacts for 30 seconds, then

close, to restart the sequence of operation. (Models with an optional

Light-Emitting Diode (LED) will flash the LED to indicate ignition

lockout.)

•Flameout--Loss of proven flame.

•Hard Lockout--The control detected a fault. Open thermostat contacts

for 30 seconds, then close to restart the sequence of operation. (Models

with an optional LED will turn off the LED to indicate a hard lockout.)

Operating

Mode

Definitions

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4 GG77x Intermittent Pilot Ignition Controls Technical Bulletin

Figure 2 illustrates the sequence of operation of the G77x control.

The control is energized on a call for heat from the system thermostat.

(Models with an optional LED will turn on the LED [steady on] until the

call for heat is satisfied.) The vent damper, if used, is energized and when

fully opened, also energizes the ignition control. If the control is equipped

with the optional prepurge, the appliance prepurge fan or relay is also

energized through the thermostat contacts. In the prepurge mode, the

control will delay for the time selected (e.g., 15 seconds) before

simultaneously opening the pilot valve and supplying a continual spark at

the pilot burner. If prepurge is not selected, the pilot valve is opened and

spark initiated within one second after the call for heat.

Under normal conditions, the pilot burner gas ignites within the

trial-for-ignition time (e.g., 8 seconds), the pilot flame sensor detects pilot

flame, and signals the control to energize the main valve. The main gas

valve will not be energized until the flame sensor detects the presence of

pilot flame. The spark will continue until flame is sensed at the pilot

burner or the trial-for-ignition period has elapsed, whichever occurs first.

If the pilot flame is not sensed before the end of the trial-for-ignition

period, the control may:

•proceed to interpurge, followed by another trial (three trial models

whose first two trials produced no flame)

•proceed to a lockout (no automatic recycle models whose final trial

produced no flame)

•proceed to a recycle delay period followed by another trial (automatic

recycle models whose final trial produced no flame)

If the pilot burner flame extinguishes during the run state (flameout), the

control de-energizes the pilot and main gas valve for the interpurge period.

After this period, another trial for ignition is initiated. If the flameout cycle

repeats for a total of 16 times (pilot burner flame established then lost), the

control will:

•Enter the lockout mode if the control is a G770/G777. The thermostat

contacts must be opened for 30 seconds and then closed to escape the

lockout condition.

•Enter the shutoff mode and recycle period (5 minute recycle for the

G775/G779 and 60 minute recycle for the G776/G778) before

beginning another trial for ignition, starting with prepurge.

Sequence of

Operation

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GG77x Intermittent Pilot Ignition Controls Technical Bulletin 5

No Yes

Yes

No Maximum

number of trials

attempted?

Yes

Yes No

Yes

De-energize

control and valves

Sixteenth

flameout?

Control with

ignition

recycle?

Ignition lockout

(optional LED

flashes)

Yes

Recycle delay

period Shutoff

Flame present when

not expected

Hard Lockout

(optional LED

turns off)

Start

Thermostat

call for heat

Prepurge

Flame

present for

30 seconds?

Detected fault

Trial for

ignition

Pilot

flame

sensed?

Energize

main valve Run

Thermostat

calling for heat?

Flameout?

Interpurge

End

Figure 2: G77x Sequence of Operation

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6 GG77x 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 gas before wiring control into circuit.

CAUTION: Equipment Damage Hazard. Do not mount the

control where it will be exposed to direct infrared

radiation from the main burner or to temperatures in

excess of the maximum product temperature rating.

Choose a location that provides the shortest, direct cable route to the spark

electrode, pilot burner/igniter-sensor assembly. Easy access to the

terminals is desired for wiring and servicing. The control may be mounted

in any position. Mount the control on a grounded metal surface with metal

screws or bolts through the mounting holes provided in the enclosure.

Installation and

Wiring

Location and

Mounting

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GG77x Intermittent Pilot Ignition Controls Technical Bulletin 7

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. Be certain 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 3 through 7 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 a minimum of 6.35 mm (1/4 in.) and not wrapped around any

pipe, other wiring, or accessories.

Electrical

Connections

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8 GG77x Intermittent Pilot Ignition Controls Technical Bulletin

Vent Damper System

Thermostat

PLUG

GROUND

24 V

LED

THS 2

PV 1

MV 3

Transformer

Power

Supply

Vent Damper

Wiring Harness

Ignition Control Limits in Thermostat

Line Only

Pilot Burner

Assembly Integral

Igniter/Sensor

Main Burner

Ground

Pilot

Gas Supply

Pilot

Valve

Main

Valve

Figure 3: Wiring Diagram for Integral Spark/Sense

with Vent Damper

Thermostat

PLUG

GROUND

24 V

LED

THS 2

PV 1

MV 3

Transformer

Pilot Burner

Assembly Integral

Igniter/Sensor

Main Burner

Ground

Pilot

Gas Supply

Ignition Control Limits in Thermostat

Line Only

Pilot

Valve

Main

Valve

Figure 4: Wiring Diagram for Integral Spark/Sense

without Vent Damper

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GG77x Intermittent Pilot Ignition Controls Technical Bulletin 9

Flame Sensor

Thermostat

Vent Damper System

Transformer

PLUG

24 V

LED

THS 2

PV 1

MV 3

SENSE 4

GROUND

Ignition Control Limits in Thermostat

Line Only

Power

Supply

Vent Damper

Wiring Harness

Pilot Burner

Assembly

Main Burner

Ground

Pilot

Gas Supply

Pilot

Valve

Main

Valve

Figure 5: Wiring Diagram for Separate Spark/Sense

with Vent Damper

Flame Sensor

Thermostat Transformer

PLUG

24 V

LED

THS 2

PV 1

MV 3

SENSE 4

GROUND

Ignition Control

Pilot

Valve

Main

Valve

Limits in Thermostat

Line Only

Power

Supply

Main Burner

Ground

Pilot

Gas Supply

Pilot Burner

Assembly

Figure 6: Wiring Diagram for Separate Spark/Sense

without Vent Damper

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10 GG77x Intermittent Pilot Ignition Controls Technical Bulletin

Main Burner

Ground

Pilot

Gas Supply

Pilot Burner

Assembly Flame Sensor

Limits in Thermostat

Line Only

Thermostat Transformer

Power

Supply

Main

Valve

Pilot

Valve

Rollout

Switch

Ignition Control

SENSE 4

MV 3

PV 1

R1R.O. SWH

THS 2

GROUND

Figure 7: Wiring Diagram for G77x with Rollout Switch Terminal

The rollout switch is wired into the G77x ignition control at terminal R1

(see Figure 7). The rollout switch (a normally closed set of contacts) is

positioned to detect flames rolling out of the combustion chamber. If

rollout occurs, the switch contacts open and the G77x immediately goes

into a lockout condition, closing the main and pilot valves so that the

system is not allowed to function.

The thermostat contacts must be opened for 30 seconds, then closed to

escape the lockout condition. When the rollout switch contacts have

returned to the closed position, the G77x will start its operating sequence

when the thermostat contacts close.

Rollout Switch

Function

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