780-001 / 780-002 / 780-003 universal ignition module ... ??installation data 780-001 / 780-002 /...

Download 780-001 / 780-002 / 780-003 UNIVERSAL IGNITION MODULE ... ??INSTALLATION DATA 780-001 / 780-002 / 780-003 UNIVERSAL IGNITION MODULE REPLACEMENT UNI-KIT  Robertshaw Universal Ignition Control

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  • INSTALLATION DATA780-001 / 780-002 / 780-003

    Universal ignition ModUle replaceMent Uni-Kit

    Robertshaw Universal Ignition Control Uni-Kit is available in both nonlockout (780-001) and lockout (780-002). The 780-003 is lockout with a prepurge function.

    The Universal Ignition Control Uni-Kits feature a flame sense circuit that automatically detects the presence of a remote sense probe (2 rod system) or it switches to local sense (1 rod system) utilizing the pilot assembly as a sensing source. If both systems are provided, failure of one causes automatic reversion to the other.

    780-001 (NONLOCKOUT)The automatic recycle features assure that, in the event of flame failure, main gas is disabled and the spark repetition sequence is restarted until pilot gas is ignited. Only after pilot ignition has been reestablished can main gas be returned to the burner.

    780-002 (LOCKOUT)These kits have a lockout feature to shut off all gas to the furnace, should pilot ignition fail to occur after a predetermined time period. The 780-002 provides 3 tries for ignition. Each ignition period is 60 seconds followed by a 5 minute time delay between ignition attempts. After 3 tries if no pilot flame is sensed, unit goes into lockout and must be reset at the thermostat.

    780-003 (LOCKOUT w/prepUrge)Same features as the 780-002 above, except it has a 45 second prepurge function.

    SpeCIFICATIONS

    Input voltage 24V AC to 50/60 Hz

    Transformer 24V AC / 20 VA

    Safety lockout timing (780-002 only)

    60 seconds*

    Prepurge (780-003 only) 45 seconds*

    Spark rate 3 to 4 sparks per second

    Relay contact ratings

    Pilot valve 1 amp at .5 PF

    Main valve 1 amp at .5 PF

    Combined load 1.5 at .4 PF

    Flame sense current .7 A DC @ 25C / 24 VAC

    Maximum total current load 1.5 amp

    Flame failure reignition time .8 seconds maximum

    Thermostat anticipator setting .7 amp

    Ambient temperature rating - 40F to 175F (- 40C to 80C)

    Relative humidity 95% noncondensing at 104

    *The SP745 lockout ignition control used in the 780-002 and 780-003 Uni-Kit provides 3 tries for ignition. Each ignition period is 60 seconds followed by a 5 minute time delay between ignition attempts. After 3 tries if no pilot flame is sensed, the unit goes into lockout and must be reset at the thermostat.

  • 2

    repLACINg rOBerTSHAw: Sp715 / Sp715A / USI715U / Sp735 / Sp735A / Sp7451. Turn OFF all electrical power to the appliance being serviced.

    2. Remove the old ignition control unit, but leave the wires connected at this time.

    3. Install the new Universal Ignition Control Module in the same location as the old one.

    4. Locate the 'grey or white plug' assembled to the SENSOR terminal. Remove it and discard. It is no longer required.

    5. Remove one wire at a time from the old l.C.U. Reconnect it to the same terminal on the new Universal l.C.U. Example: PV to PV.

    6. The wiring and installation of the new ignition module is now compete.

    7. Restore electrical power to the appliance being serviced. Proceed as directed in SYSTEM CHECKOUT PROCEDURES section.

    780-715*

    Replaces: SP715, SP715A, USI715U

    780-745*

    Replaces: SP735, SP735A, SP745

    *Uni-Line part number for the individual model Intermittent (spark pilot) model only

    JOHNSON CONTrOLSThe Robertshaw 780-001 (nonlockout), 780-002 (lockout) and 780-003 (lockout with prepurge) Universal Replacement Module Uni-Kit is designed to replace the Johnson Controls Spark Ignition System Modules listed on pages 5 and 6. The 780-002 kit must be used whenever a Johnson Controls Y79 Series lockout module is present on the system being serviced.

    The 780-001 and 780-002 Uni-Kit replaces only the existing control module, while utilizing the existing Johnson gas valve, pilot sensor and ignitor. The Uni-Kit includes a special mounting bracket for mounting the new module onto the existing gas valve. A special wiring adaptor, (included with the Uni-Kit) is used whenever the existing system includes a Johnson Controls M15/Y15 Series Vent Damper.

    STep I - IdeNTIFyINg yOUr JOHNSON CONTrOLS MOdULe1. Locate the Johnson Controls part number on the existing

    module.

    2. Find this number in the cross-reference list (pages 5 and 6) to determine which wiring diagram to use.

    Refer to Wiring Diagram Number

    Existing Module (Control Part) Part Number

    3. Over the years Johnson Controls has gone through many different model variations of ignition control units. Along with the many different models, Johnson Controls has also had dozens of different wiring combinations for these controls.

    We have provided for you what we feel are the most accurate wiring schematic(s) that we can. If you encounter problems with your wiring, Robertshaw I.C.U. terminals and their functions are listed below:

    TH = 24 volt signal from wall thermostat

    PV = Pilot valve - pilot gas only

    MV = Main valve - main burner gas

    SENSOR = Flame sensor (2 rod system)

    ACCESSORY TERM E3 = Not used

    MV/PV = Common return for MV and PV (grounded)

    TR = Transformer common (grounded)

    GND. = Ground

    IGNITOR = Spark electrode lead wire

  • 3

    STep II - reMOvINg THe OLd IgNITION MOdULeCAUTION: THIS devICe SHOULd Be INSTALLed By A QUALIFIed

    ServICeperSON wITH dUe regArd FOr SAFeTy AS IMprOper INSTALLATION COULd reSULT IN A HAZArdOUS CONdITION.

    NOTE: The following instructions are based on the premise that the appliance being serviced is in correct operating order except for the failed control module. If other problems are present, they must be corrected or the new module may not perform correctly.

    1. Turn off all electrical power to the appliance being serviced.

    2. Using the wiring tags provided, label each wire with the old terminal designation as you disconnect it. It is not necessary to label the high voltage cable as it is readily identifiable.

    3. If a vent damper wiring harness (not just the "dummy plug") is plugged into the six-pin molex connector, make sure that you use the 1751-724 (G60 Vent Damper Adaptor), included with the Uni-Kit.

    4. Remove and discard the screws that held the ignition module (control part) onto the mounting plate. Discard the old ignition module. See Figure 1.

    Figure 1

    STep III - INSTALLINg THe New IgNITION MOdULe1. Locate the G60 adaptor bracket, 6" green grounding wire and

    using the two #12 x 1/2" sheet metal screws provided, mount the adaptor bracket and 6" ground wire to the gas valve mounting plate as shown in Figure 2. The adaptor bracket fits onto the mounting plate in more than one position. Use the position that gives the easiest access to the mounting screw locations. Actual orientation of the bracket is not important. The screws will accept either a 1/4" flat screwdriver or a 5/16" nut driver. Make sure no wires are pinched between the bracket and mounting plate.

    2. Locate the 'grey or white plug' assembled to the SENSOR terminal. Remove it and discard. It is no longer required.

    3. Remove the protective backing from one side of the double-sided tape. Place the side of the tape with the exposed adhesive on the bottom of the new Robertshaw ignition module.

    4. Referring back to the appropriate wiring instructions, place the wires on the correct terminals.

    5. Remove the remaining protective backing from the double-sided tape on the ignition module. Center the module over the previously installed bracket and press down. See Figure 2.

    3" x 3" Double-sided Tape

    #12 x 1/2 Hex ScrewG60 Adaptor Bracket

    6" Green Grounding Wire

    Existing Gas Valve (Wires Not Shown for Clarification)

    Figure 2

    6. Connect the green ground wire, that was attached in Step 1, to any one of the following terminals that are not already being used; GND, MV/PV or TR.

  • 4

    7. Locate the high voltage cable adaptor included in the kit. Attach it to the IGNITOR terminal on the new ignition module. See Figure 3.

    High Voltage Cable Adaptor

    IGNITOR Terminal

    Figure 3

    8. Attach the existing high voltage cable (from the pilot ignitor) to the high voltage cable adaptor or IGNITOR terminal.

    9. If a vent damper is present in the system, proceed as follows, if not proceed to Step 10.

    A. Locate the orange lead wire on the 1751-724 adaptor, See Figure 4. Wire nut it to the power lead that came off terminal #5 or #6 on the old unit.

    B. Wire nut the red wire on the 1751-724 adaptor to the thermostat wire. This is the wire that was connected to terminal #2 on the old unit.

    C. Connect the gray wire on the 1751-724 to the TH terminal on the new module.

    Figure 4

    10. The wiring and installation of the new ignition module is now complete.

    11. Restore electrical power to the appliance being serviced. Proceed as directed in SYSTEM CHECKOUT PROCEDURES section.

  • 5

    JOHNSON CONTrOLS NUMBer UNI-LINe repL.

    USe wIrINg dIAgrAM NUMBer

    IF A y79 IS preSeNT

    ON SySTeM USe wIrINg

    dIAgrAM

    CSA35A-617R 780-001 3 5

    CSA35A-618R 780-001 3 5

    CSA42A-600R 780-001 3 4

    CSA42A-601R 780-001 3 4

    CSA42A-602R 780-001 3 4

    CSA42A-603R 780-001 3 4

    CSA42A-604R 780-001 3 4

    CSA43A-600R 780-001 3 4

    CSA44A-600R 780-001 3 4

    CSA45A-601R 780-001 3 4

    CSA45A-602R 780-001 3 4

    CSA46A-600R 780-001 3 4

    CSA48A-600R 780-001 3 4

    CSA49A-600R 780-002 3

    CSA49A-601R 780-002 3

    CSA49A-605R 780-002 3

    CSA51A-601R 780-002 3

    CSA52A-600R 780-002 3

    G600AX-1 780-001 3

    G600AX-2 780-002 3

    G600AX-3 780-002 3

    G600AY-1 780-001 5

    G600KX-1 780-002 3

    G600LX-1 780-002 3

    G600LX-2 780-002 3

    G