Johnson Controls G861 Series Service manual

Installation Sheets Manual 121

Gas Combustion Combination Controls and Systems Section G

Technical Bulletin G861

Issue Date 0699

Part No. 24-8143-553, Rev. A www.johnsoncontrols.com

Code No. LIT-121920

Figure 1: G861 Integrated Function

Direct Spark Ignition Control

The G861 is a microprocessor-based, 100% shutoff, direct spark, and

remote flame sense, integrated function ignition control. The G861

responds to inputs from the thermostat, high limit switch, pressure switch,

and flame sensor. It provides outputs for timing and sequencing of the main

gas valve, induced draft motor, circulator/blower, and spark igniter.

The G861 utilizes quick-connect terminals for all off board connections,

except thermostat inputs and spark output. The thermostat inputs are

connected to a terminal strip with screw terminals and the spark output is

connected by a rajah, spike, or 1/4 in. male tab-type spark connector.

All G861 applications must use redundant gas valves and the pressure

switch must carry main valve current. Any application over

117 kW (400,000 Btu/hr) must be approved in advance by

Johnson Controls Application Engineering.

G861 Series Integrated Function

Direct Spark Ignition Control

Application

2 G—G861 Series Integrated Function Direct Spark Ignition Control Technical Bulletin

Table 1: Specifications

Ignition Type Direct

Ignition Source High voltage spark, capacitive discharge

High Voltage Cable Length 1,220 mm ( 48 in.) maximum

Flame Detection Means Flame rectification

Flame Detection Types Remote sensing

Minimum Flame Current

Flame Threshold Current (ITH)

Insufficient Flame

Marginal Flame

Good Flame

0.250 microampere ±25%

Flame current <ITH

ITH < flame current <4 x ITH

Flame current >4 x ITH

Flame Failure Response Time 0.8 second @ 0.500 microampere flame current

Spark Gap 3.17 mm (0.125 in.) nominal

Ignition Trials 3

Ignition Trial Time 7, 8, 10, or 11 seconds*

Prepurge Time 0, 10, or 30 seconds*

Postpurge 15, 30, or 45 seconds*

Interpurge 10 seconds*

Automatic Retry Delay Period 60 minutes*

Flameout Recycles 16 including the initial ignition trial

Circulator/Blower “On Delay” 30 seconds*

Circulator/Blower “Off Delay” 90, 120, 180, or 240 seconds*

Power Requirements Line Voltage 120 VAC, 50/60 Hz

Control: 24 VAC, 50/60 Hz, nominal

Operation Current: 0.3A @ 24 VAC

Contact Rating Main Valve: 2A continuous at 24 VAC, 5A inrush

Inducer: 2A continuous, 120 VAC

Blower: 1/3 hp (7.20 FLA), 125 VAC

Ambient Operating and Storage

Temperature -40 to 70°C (-40 to 160°F)

Humidity 95% RH non-condensing

Wiring Connections Spark: Spike, rajah, or 1/4 in. male tab

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 24

Bulk Pack Weight 8 kg (18 lb)

Agency Listing CSA (AGA/CGA) Certificate Number 11250-7

Specification Standards ANSI Standard Z21.20

CSA C22.2-No. 199

*Timings listed are for 60 Hz operations. Timings increase by 20% under 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 G861 Product Bulletin (LIT-4350440) for necessary information on operating and

performance specifications of this product.

G—G861 Series Integrated Function Direct Spark Ignition Control Technical Bulletin 3

The following conditions occur in normal control operation:

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

trial for ignition.

•Trial-for-Ignition Time--Maximum time period that the main gas valve

and igniter energizes in an attempt to light the main burner.

•Interpurge--Time period between trials for ignition when both the gas

valve and ignition source turn off and the inducer is on, allowing

unburned gas to escape before a succeeding trial can occur. (Retry takes

place only if proper ignition did not occur during the previous trial and

if total trials are less than three.)

•Run--Main gas valve remains energized after a successful ignition trial.

•Circulator/Blower “On Delay”--Fixed time delay after the flame is

sensed until the circulator/blower is energized.

•Circulator/Blower “Off Delay”--Field selectable time delay after the

thermostat contacts open when the circulator/blower remains energized.

•Postpurge--Time delay after the thermostat is satisfied when the

inducer remains energized.

Figure 2 illustrates the sequence of operation of the G861 control.

Upon receiving a call for heat from the system thermostat, the G861

follows this normal sequence of operation:

1. Pressure Switch Detection--The control checks the inducer pressure

switch to ensure that it is open.

2. Prepurge--The control energizes the inducer motor and verifies that the

pressure switch closes.

3. Pressure Switch Detection--The control checks the pressure switch to

ensure that it remains closed during the prepurge period.

4. Trial for Ignition--The control simultaneously energizes the spark

igniter and gas valve in an attempt to light the main burner. During the

trial time, the igniter is energized until flame is detected or until the

trial for ignition is complete, whichever occurs first.

5. Run--If main burner flame is sensed up to the last 0.5 second of the

trial, the gas valve and inducer remain energized for the duration of the

heat call. The circulator/blower is energized after a 30-second blower

“on delay” time and remains energized for the duration of the heat call.

6. Postpurge--Once the thermostat is satisfied, the gas valve is

de-energized and the inducer remains energized until the postpurge

period ends. The circulator/blower remains energized until the selected

blower “off delay” time has elapsed.

Operating

Mode

Definitions

Normal

Sequence of

Operation

Call for Heat

4 G—G861 Series Integrated Function Direct Spark Ignition Control Technical Bulletin

Start

Inducer on

Inducer off

Prepurge

Run

Interpurge

Yes

Flameout? Yes

Postpurge

End

Thermostat calls

for manual fan (G)

Run - manual

fan speed

Thermostat

call for heat

Pressure

switch open?

Yes

Retry mode

60 minute delay

Yes

Pressure

switch closed?

Third

trial?

Trial for

ignition Sixteenth

flameout?

Flame

sensed?

Circulator/Blower

“on delay”

Thermostat

satisfied?

Circulator/Blower

“off delay”

(field selectable)

Figure 2: G861 Sequence of Operation

G—G861 Series Integrated Function Direct Spark Ignition Control Technical Bulletin 5

Upon receiving a call for continuous manual fan, the G861 energizes the

circulator/blower motor at medium fan speed. The continuous fan on

request is immediately overridden by a call for heat.

The G861 offers the following responses based on abnormal system

operation.

A pressure switch within the appliance provides proof of combustion air

flow. During a heating cycle, the G861 control responds to the state of this

switch in the following ways:

•At the beginning of the heating cycle, if the pressure switch is not open

before the inducer is energized, the control will wait for the switch to

open for as long as the call for heat is present. The G861 control LED

(Light-Emitting Diode) will blink with a flash code of 3 while waiting

for the pressure switch to open.

•If the pressure switch does not close after the inducer has been

energized for 8 seconds, the control will keep the inducer energized and

the LED will blink with a flash code of 3 until the pressure switch

closes or the call for heat is removed.

•If the pressure switch opens any time after the G861 control has begun

the trial for ignition, the control will immediately de-energize the gas

valve. If the pressure switch fault occurs after the flame is sensed, the

circulator/blower will run for 90 seconds, the inducer motor will remain

energized, and the control will go into the Pressure Switch Open Fault

state. During this time, the LED will blink with a flash code of 3. As

long as the call for heat is still present, the control will continue to wait

for the pressure switch to close before resuming the heating cycle. If the

pressure switch fails three times with no more than 30 seconds between

successive faults, the control will go to PSWFLT1 and PSWFLT 2 state

with an LED flash code of 3.

If a flame is present at power up, the G861 allows the flame to extinguish

within 10 seconds. If this occurs, the normal sequence of operation

continues. If the flame is still present after 10 seconds, the G861 goes into

flame lockout. If flame is present any other time it should not be, the G861

goes into flame lockout after a 10-second delay.

During the flame lockout, the inducer motor and the circulator/blower

remain energized, and the main valve is de-energized. The G861 control

LED flashes with a duty cycle of 1/2 second On, 1/2 second Off for

five flashes with a longer Off time before repeating the series. The control

remains in this state until the main power is cycled.

Call for Manual

Fan

Abnormal

System

Operation

Pressure Switch

Detection

Undesired Flame

6 G—G861 Series Integrated Function Direct Spark Ignition Control Technical Bulletin

If a flame is not sensed by the end of the trial-for-ignition period, the gas

valve is de-energized, the inducer remains energized through the 10-second

interpurge period, and another trial for ignition begins. If a flame is not

sensed before the end of the third trial, the control proceeds to a 60-minute

retry delay period, where all outputs are de-energized, before resetting

itself. During the 60-minute retry delay period, the LED will blink with a

flash code of 2.

A “manual fan” call from the thermostat during the 60-minute retry will run

the circulator/blower at medium speed.

If the main burner flame is established and then lost, the gas valve is

de-energized and the inducer and circulator/blower run through a

10-second interpurge. Once the interpurge period expires, the control

initiates another trial for ignition.

After the sixteenth flameout in any given heating cycle, the control

proceeds to a 60-minute retry delay peroid, where all outputs are

de-energized. A “manual fan” call from the thermostat will run the

circulator/blower at medium speed. During the 60-minute retry delay

period, the LED will blink with a flash code of 2.

A “manual fan” call from the thermostat during the 60-minute retry will run

the circulator/blower at medium speed.

The G861 offers the following responses to the two possible interrupted

thermostat situations:

•If the call for heat is removed before the gas valve is energized, the

G861 will de-energize all outputs and return to the Off state.

•If the call for heat is removed any time after the gas valve is energized,

the gas valve and spark igniter (if energized) are de-energized, the

inducer motor will run through the postpurge period, and the

circulator/blower will run for the selected blower “off delay” time.

The high limit switch is monitored whenever a call for heat is present. Any

time the switch opens, the gas valve and igniter are de-energized, and the

inducer and circulator/blower run continuously. When the switch is reset,

the inducer and circulator/blower run for 180 seconds before the control

returns to normal operation. Whenever the high limit switch is open while

the call for heat is present, the control LED will blink with a flash code of 4.

Failure to Sense

Flame Within

Trial Period

Flameout

Interrupted

Thermostat

High Limit

Switch

G—G861 Series Integrated Function Direct Spark Ignition Control Technical Bulletin 7

IMPORTANT: This technical bulletin is intended as a guide for

qualified personnel installing or servicing

Johnson Controls products. Carefully follow all

instructions in this sheet and all instruction on the

appliance. Limit repairs, adjustments, and servicing

to the operations listed in this sheet or on the

appliance.

WARNING: Fire or Explosion Hazard. Avoid serious injury by

carefully following precautions in this sheet and all

instructions on the appliance. Limit repairs,

adjustments, and servicing to the operations listed in

this sheet 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 the electrical

power and turn off the gas before wiring the

control into the circuit.

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

igniter and flame sensor. Easy access to the terminals is desired for wiring

and servicing. The G861 may be mounted in any position. Mount the

control on a grounded metal surface with No. 8 machine or No. 6 sheet

metal screws.

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.

Installation and

Wiring

Mounting

8 G—G861 Series Integrated Function Direct Spark Ignition Control Technical Bulletin

CAUTION: Equipment Damage Hazard. Connect the high

voltage cable to the spark transformer terminal and

spark igniter before applying power to the control.

Check the voltage rating marked on the control and ensure it is suited to the

application. Use an NEC Class 2 transformer to provide 24 VAC under

maximum load, including the valve. A transformer having excessive

primary impedance due to poor coupling will affect the ignition potential.

Refer to Figure 3 for the G861 wiring diagram. All wiring should be in

accordance with the National Electrical Code (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 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.

Electrical

Connections

G—G861 Series Integrated Function Direct Spark Ignition Control Technical Bulletin 9

Valve

ACBHeat

CMBBlower

Line

VACHot

Circulator/Blower

Motor

Inducer

Motor

Redundant

MainValve

Coils

3/16inch

Terminal

Line

Neutral

120VAC

Line

Transformer24VLine

24VCommon

Spark

Transformer

24VACHot

Ground

FlameSense

PSW

PressureSwitch

HighLimitIn

HighLimitOut

RolloutIn

Blower

“OffDelay”

Setting

HighLimitSwitch

RolloutSwitch

Thermostat

3/16inch

Terminal

Sensor

Note:Allterminalsare1/4inchunlessotherwisespecified.

Pressureswitchmustcarrymainvalvecurrentforredundancy.

Figure 3: G861 Terminal Interface Wiring Diagram

10 G—G861 Series Integrated Function Direct Spark Ignition Control Technical Bulletin

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.

Make sure all components function properly by performing the following

shutoff test:

1. With the gas and thermostat off, turn on power to the appliance.

2. Turn the thermostat to a high 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 the thermostat off.

4. Turn gas on and purge gas lines of all air.

5. Check for gas leaks on all pipe joints upstream of the gas valve with a

soap solution.

6. Turn the thermostat to a high setting and verify successful ignition and

a normal run condition for at least three minutes.

7. Check for gas leaks on all pipe joints 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 before leaving the

installation.

Checkout and

Startup

Procedures

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