G73x Series Intermittent Pilot Ignition Controls ... - ShanControls

Heating Line Product Guide 435.0Ignition Controls SectionProduct Bulletin G73xIssue Date 0300G73x Series Intermittent Pilot Ignition ControlsThe CE compliant G73x family of controls aredesigned for indirect ignition of natural gas, LiquefiedPetroleum (LP) gas, manufactured gas, mixed gas, orLP gas-air mixtures.Figure 1: G73x Intermittent PilotIgnition ControlFeatures and Benefits❑ Microprocessor-basedDesign❑ Multiple Safety Times andWaiting Times (optional)❑ Optional DiagnosticLight-Emitting Diode (LED)❑ CE CompliantProvides precise timing and sequencingfunctionsOffers selectability of timing functions that willbest suit the applianceReduces troubleshooting time by visuallyinforming service technicians of current statusBroadens applications to include markets inEurope, Australia, etc.© 2000 Johnson Controls, Inc. 1Code No. LIT-4350425www.johnsoncontrols.com

Application RequirementsFollowing are the application requirements of the G73xcontrol.• The G73x can be used on gas-fired equipmentwith a maximum firing rate of 117 kW(400,000 Btu/hr). Any application greater than117 kW (400,000 Btu/hr) must have writtenapproval in advance from the Johnson ControlsHeating Products Engineering Department.• All G73x applications must use a redundant gasvalve system with the pilot and main valve seats inseries.• The control cannot be used on applications with apilot rating greater than 250 watts (850 Btu/hr).• The control does not directly monitor the pressureswitch. External circuitry is required on applicationsthat require proof of an open pressure switchbefore energizing the inducer.• All G73x controls have volatile lockout.• The G73x control does not contain an independentmanual reset function. The application of this typeof control is restricted to those appliances whereresetting by switching off the heat demand isallowed by European standards. Reset of anappliance in lockout must occur by means of aconscious manual action and not by means of(automatic) devices like thermostats or timers.• The ignition connections are not safe to touch.Additional protection against electric shock shouldbe provided by the appliance.Operating Mode DefinitionsThe following definitions describe operating conditions:●●●Start Signal--The signal from a thermostat thatbegins the ignition program.Waiting Time--The initial delay between the startsignal and the safety time to allow ventilation of thecombustion chamber and flue passages todisplace any unburned gas and/or products ofcombustion.Inter-waiting Time--The delay following a failedignition attempt or loss of flame signal to allowventilation of the combustion chamber and fluepassages to displace any unburned gas and/orproducts of combustion.• Safety Time--The time between energizing the pilotgas valve and de-energizing the pilot gas valve ifthe flame signal is not detected.●●●●●●Spark Restoration--The process of energizing thespark following the loss of flame signal within thefirst 5 seconds of the running position without totalinterruption of the gas supply.Running Position--The main valve and pilot valveremain energized and the spark is de-energized.The appliance is in normal operation under thesupervision of the ignition control and its flamedetector device.Retrial--Failing an ignition attempt, the controlenters the inter-waiting time and than startsanother safety time (models with optional retrials).Recycling--The process of automatically repeatinga full startup sequence after a safety shutdown(removing the power to the gas valve and igniter).Startup Sequence--The sequence of actionsexecuted by the system that brings the burner fromthe start to the running position.Volatile Lockout--The safety shutdown of thesystem where a startup sequence can only beginafter the thermostat contacts or main power iscycled.Normal Sequence of OperationFigure 2 illustrates the normal sequence of operationof the G73x control.The G73x control is energized upon receiving a startsignal from the system thermostat.1. Waiting Time--If the control has an optional waitingtime, the appliance fan or relay is energizedthrough the thermostat contacts. The controldelays for the waiting time before continuing to thesafety time.2. Safety Time--The control simultaneously energizesthe spark igniter and pilot valve in an attempt tolight the pilot burner. During the safety time, thespark igniter is energized until a flame signal issensed or the safety time has elapsed, whicheveroccurs first.3. Running Position--Once a flame signal is sensed,the control energizes the main valve. The controlcontinues to energize the pilot and main valvesuntil the start signal is removed.2 G73x Series Intermittent Pilot Ignition Controls Product Bulletin

! WARNING: Personal Injury Hazard. Avoid personal injury.The G73x ignition control has volatile lockout.The control restarts operation if the thermostator main power is cycled.StartFlame Present whenNot ExpectedDetected FaultStart SignalNoFlame signalpresent for30 seconds?YesVolatile Lockout(optional LEDturns off)Waiting TimeSafety TimePilotflamesensed?YesEnergizemain valveRunningPositionNoYesInter-waitingTimeNoMaximumnumber of retrialsattempted?Loss offlame signal?YesNoStart SignalNoYesVolatile Lockout(optional LEDflashes)YesFifth lossof flamesignal?De-energizeControl and ValvesNoEndNoDoes the controluse separate spark/senseand is it less than5 seconds of enteringrunning position?Spark RestorationYesFigure 2: G73x Sequence of OperationG73x Series Intermittent Pilot Ignition Controls Product Bulletin 3

Mounting and WiringChoose a location that provides the shortest, directcable route to the spark electrode, pilot burner/ignitersensorassembly. Easy access to the terminals isdesired for wiring and servicing.The control may be mounted in any position. Refer toFigure 3 for mounting dimensions, and Figures 4 and 5for wiring diagrams.80.311562.2260.25 Spade Terminals582.281Add 13 mm (0.50 in.) forRajah type connector.783.0660.22341.33200.771164.571204.704.10.162 Two Holesfor Mounting Screws60.22672.63512.00Figure 3: Mounting Dimensions, mm (in.)4 G73x Series Intermittent Pilot Ignition Controls Product Bulletin

Pilot BurnerAssemblyIntegralIgniter/SensorMain BurnerGroundPilotGas SupplyGROUND5LEDTHS 2RemoteLEDLimits in ThermostatLine OnlyALARMPV 1MV 3Ignition ControlPilotValveMainValveHighLimitThermostat2 Ampere FuseTransformerPowerSupplyIMPORTANT:The G73x ignition control does not respondto a high limit fault with non-volatile lockout.Therefore, a manually resettable high limitswitch must be used with the control to meetEuropean agency operating requirements.Figure 4: Wiring Diagram for Integral Spark/SensePilot BurnerAssemblyFlame SensorMain BurnerGroundPilotGas SupplyGROUND5LEDTHS 2Limits in ThermostatLine OnlyPV 1MV 3SENSE 4Ignition ControlPilotValveMainValveHighLimitThermostat2 Ampere FuseTransformerPowerSupplyIMPORTANT: The G73x ignition control does not respondto a high limit fault with non-volatile lockout.Therefore, a manually resettable high limitswitch must be used with the control to meetEuropean agency operating requirements.Figure 5: Wiring Diagram for Separate Spark/SenseG73x Series Intermittent Pilot Ignition Controls Product Bulletin 5

Ordering InformationSafetyG 7 3 _ _ _ _ - _ _Customer-specific RequirementsWaiting TimeA = 0 SecondB = 30 SecondsD = 15 SecondsDamper PlugG = NoH = YesTimeA = Three 8-second Safety TimesB = Three 25-second Safety TimesC = Three 50-second Safety TimesD = Three 85-second Safety TimesE = Three 120-second Safety TimesK = One 8-second Safety TimeL = One 25-second Safety TimeM = One 50-second Safety TimeN = One 85-second Safety TimeP = One 120-second Safety TimeT = Five 8-second Safety TimesU = Five 25-second Safety TimesV = Five 50-second Safety TimesW = Five 85-second Safety TimesY = Five 120-second Safety TimesSpark/Sense0 = Separate7 = IntegralThe presence of a particular construction in this information does not guaranteeits availability. Consult Johnson Controls for available constructions.Figure 6: Ordering Matrix6 G73x Series Intermittent Pilot Ignition Controls Product Bulletin

Specifications (Cont.)PackagingBulk Pack Quantity 50Bulk Pack WeightAgency ListingBulk pack supplied to original equipment manufacturer (individual pack optional)15 kg (33 lb)EC Certification Number 0063AU1371Specification Standards EN 298Standards Complying with the EMC DirectiveClassification Code ATOVXN**Enclosure Degree ofProtectionIP00*Timings listed are for 50 Hz operation.**The G730 control uses a combination of spark restoration and recycling. A failed ignition attempt always uses recycling.A loss of flame signal within the first 5 seconds of ignition causes spark restoration. After 5 seconds, a loss of flame signalcauses recycling.The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyondthese specifications, consult the local Johnson Controls office. Johnson Controls, Inc. shall not be liable for damages resultingfrom misapplication or misuse of its products.Refer to the G73x Series Technical Bulletin (LIT-121248) for necessary information on the installation, use, and servicing of this product.Controls Groupwww.johnsoncontrols.com507 E. Michigan Street FAN 435.0P.O. Box 423Heating Line Product GuideMilwaukee, WI 53201Printed in U.S.A.8 G73x Series Intermittent Pilot Ignition Controls Product Bulletin