Robertshaw 780-704 & 780-705 Series Modernization Kit Manual

Robertshaw 780-704 & 780-705 Series Modernization Kit Manual
INSTALLATION DATA
780-704 & 780-705
MODERNIZATION KIT
COVERTS “K” SERIES TO “FLAME RECTIFICATION”
The Robertshaw® “K” Series Pilot Ignition System Gas Valve (7000
BKER) was used with two models of ignition control units: SP710
and SP730, and the second generation SP710A and SP730A. Due to
obsolescence, this modernization kit will replace these ignition control
units without the need to rewire the gas valve. This kit also retains the
plug-in wiring harness feature. The 780-704 and 780-705 modernization kits upgrade the old heat sensing/flame switch system to “Flame
Rectification”.
PILOT ADAPTORS – ORDER SEPARATELY
GAFFERS AND SATTLER
CARRIER/BDP 732 PILOT
ORDER 1751-712
ORDER 1751-716
ORDERING DATA
UNI-LINE
NUMBER
TYPE
780-704
LOCKOUT
780-705
NONLOCKOUT
CAUTION
THIS DEVICE SHOULD BE INSTALLED BY A QUALIFIED SERVICE
TECHNICIAN WITH DUE REGARD FOR SAFETY AS IMPROPER
INSTALLATION COULD RESULT IN A HAZARDOUS CONDITION.
REPLACES
780-711, 780-713
SP730 AND SP730A
780-710, 780-712
SP710 AND SP710A
PREINSTALLATION INSTRUCTIONS
The installation procedures below should be followed in the exact
sequence as outlined in these instructions.
The gas valve and valve wiring are the same for both generations and
need not be changed. Do not remove the wiring harness from the gas
valve connector. See figure 1.
Select and use the appropriate modernization kit 780-705 nonlockout
or 780-704 lockout. See cross-reference chart above. To determine
ignition unit type, see below.
REMEMBER: You are converting or upgrading the system from heat
sensing to flame sensing (Flame Rectification).
SYSTEM IDENTIFICATION
IMPORTANT
1. Determine ignition control unit type and factory model number.
The “K” Series Pilot Ignition Systems may be found with one of
two styles of ignition control units: the first generation SP710
nonlockout or SP730 lockout (figure 2), or the second generation
SP710A nonlockout or SP730A lockout (figure 3).
Determine the factory model number by locating the number on the
control’s rating plate and visually comparing it with the drawings below.
2. Determine system wiring method.
IGNITION CONTROL UNITS (ICU) - SP710 and SP730
There are two types of wiring harness possibilities that can be
encountered on the SP710 and SP730. Locate the terminal plug
that connects to the l.C.U. If it has a seven-wire harness with a
jumper wire as shown in figure 4, use wiring method “A” page 2.
If the connector has nine wires and no jumper wire, use wiring
method “B” page 3.
IGNITION CONTROL UNITS - SP710A and SP730A
Use wiring method “C” page 4.
1
INSTALLATION INSTRUCTIONS - WIRING METHOD “A”
STEP 1 - REMOVING THE OLD SYSTEM
1. Turn off all electrical power to the furnace being serviced.
“K” SERIES (SP710/730) O.E.M. WIRING
R & W ARE JUMPED
2. Double check existing wiring against wiring method “A” schematic
shown in figure 5. If identical, then proceed as directed below.
3. Disconnect the orange high voltage wire from the top of the ignition
control unit.
4. Remove the heat sensor/flame switch from the pilot burner. It will
not be reused.
5. Remove the ignition control unit, leaving the wiring harness connected to the l.C.U. and the gas valve.
STEP 2 - PILOT ELECTRODE/SENSOR ASSEMBLY
There are two types of pilots that may be encountered on your
application: O.E.M. type and retrofitted type. To determine which
type you have and how to “modernize” it, turn to page 5. Follow the
instructions given on page 5, then return to this page and continue
to Step 3.
STEP 3 - INSTALLING AND WIRING NEW SYSTEM
FIGURE 5
WIRING AT THE END OF STEP 1
1. Install the new ignition control unit using the mounting screws or
double-faced tape included in the modernization kit.
7. Cut the wires at terminals “H” and “P.” Wire-nut these two wires to
the blue wire in the new wiring harness.
8. Cut the wires from terminals “TH” and “C.” Wire-nut these two
wires to the white wire in the new wiring harness.
9. Cut the wire at terminal “TR”. Wire-nut this wire to the red wire in
the new wiring harness.
10. In the two-wire red wiring harness connect the orange high voltage
wire to the “IGN” terminal and the white sensor wire to the “SENSE”
terminal.
11. Connect the green ground wire to the ground terminal on the gas
valve. NOTE: System must be grounded or severe damage to gas
valve may result.
12. Wiring is now complete. Compare wiring in figure 7 against what
has just been done. If it agrees, then set thermostat heat anticipator
to .7 amp. Set thermostat low. Turn on power. See sequence of
operation and checkout procedure page 6.
2. The new wiring harness in the modernization kit should be prewired.
If for any reason it isn’t, connect the harness to the ignition control
units as follows: NOTE: Two-wire white and black connector may be
connected to any terminal marked GND, MV/PV or TR. The green
wire should be connected to either of the remaining terminals.
Terminal
Wire ColorConnection
Green
GND
White
Two-wire
MV/PV
Black
Connector
TR
Red
MV
Blue
PV
Gray
TH
3. Install the ground terminal included in the modernization kit. Remove
screw holding wire harness connector bracket to the gas valve.
Assemble terminal to valve and bracket using this screw. See figure 6.
“K” SERIES WIRING
CONVERTED TO FLAME RECTIFICATION
FIGURE 6
4. With the new blue wiring harness attached to the new ignition
control unit, cut the insulated quick­connects from the red, white
and blue wires in the new harness. Strip about 1/4” of insulation
from these wires. The black and gray wires already have the
insulation separated. Remove this also.
5. At the plug-in connector on the old existing ignition unit, cut the wire
at terminals “T1” and wire-nut this wire to the gray wire in the new
harness. Refer to wiring diagram figure 7.
6. Cut the wire at terminal “T2.” Wire-nut this wire to the black wire in
the new wiring harness.
FIGURE 7
WIRING AT COMPLETION OF MODERNIZATION
2
INSTALLATION INSTRUCTIONS - WIRING METHOD “B”
STEP 1- REMOVING THE OLD SYSTEM
“K” SERIES (SP710/730) O.E.M. WIRING
R & W ARE NOT JUMPED
1. Turn off all electrical power to the furnace being serviced.
2. Double check existing wiring against wiring method “B” schematic
shown in figure 8. If identical, then proceed as directed below.
3. Disconnect the orange high voltage wire from the top of the
ignition control unit.
4. R
emove the heat sensor/ flame switch from the pilot burner. It will
not be reused.
5. R
emove the ignition control unit, leaving the wiring harness connected to the l.C.U. and the gas valve.
STEP 2 - PILOT ELECTRODE/SENSOR ASSEMBLY
There are two types of pilots that may be encountered on your
application: O.E.M. type and retrofitted type. To determine which type
you have and how to “modernize” it, turn to page 5. Follow the instructions given on page 5, then return to this page and continue to Step 3.
STEP 3 - INSTALLING AND WIRING NEW SYSTEM
1. Install the new ignition control unit using the mounting screws or
double-faced tape included in the modernization kit.
2. The new wiring harness in the modernization kit should be prewired.
If for any reason it isn’t, connect the harness to the ignition control
units as follows: NOTE: Two-wire white and black connector may be
connected to any terminal marked GND, MV/PV or TR. The green
wire should be connected to either of the remaining terminals.
FIGURE 8
WIRING AT THE END OF STEP 1
12. Connect the green ground wire to the ground terminal on the gas
valve. NOTE: System must be grounded or severe damage to gas
valve may result.
Terminal
Wire Color
Connection
Green
GND
White
Two-wire
MV/PV
Black
Connector
TR
Red
MV
Blue
PV
Gray
TH
13. Wiring is now complete. Compare wiring in figure 9 against what
has just been done. If it agrees then set thermostat heat
anticipator to .7 amp. Set thermostat low. Turn on power. See
sequence of operation and checkout procedure page 6.
“K” SERIES WIRING
CONVERTED TO FLAME RECTIFICATION
3. Install the ground terminal included in the modernization kit.
Remove screw holding wire harness connector bracket to the gas
valve. Assemble terminal to valve and bracket using this screw.
See figure 6.
4. With the new blue wiring harness attached to the new ignition
control unit, cut the insulated quick-connects from the red, white
and blue wires in the new harness. Strip about 1/4” of insulation
from these wires. The black and gray wires already have the
insulation separated. Remove this also.
5. At the plug-in connector on the old existing ignition unit, cut the
wires at terminals “T1” and “R” and wire-nut these wires together.
Refer to wiring diagram figure 9.
6. Cut the wire at terminal “T2.” Wire-nut this wire to the black wire in
the new wiring harness.
7. Cut the wire at terminal “W.” Wire-nut this wire to the gray wire in
the new wiring harness.
8. Cut the wires from terminals “H” and “P.” Wire-nut these two wires
to the blue wire in the new wiring harness.
9. Cut the wires at terminal “TH” and “C.” Wire-nut these two wires to
the white wire in the new wiring harness.
10. Cut the wire at terminal “TR.” Wire-nut this wire to the red wire in
the new wiring harness.
11. In the red two-wire wiring harness connect the orange high
voltage wire to the “IGN” terminal and the white sensor wire
to the “SENSE” terminal.
FIGURE 9
WIRING AT COMPLETION OF MODERNIZATION
3
INSTALLATION INSTRUCTIONS - WIRING METHOD “C”
STEP 1 - REMOVING THE OLD SYSTEM
“K” SERIES WITH MODEL SP710A
OR SP730A IGNITION CONTROL UNITS
1. Turn off all electrical power to the furnace being serviced.
2. Double check existing wiring against wiring method “C” schematic
shown in figure 11. If identical, then proceed as directed below.
3. Disconnect the orange high voltage wire from the top of the ignition
control unit.
4. Remove the heat sensor/flame switch from the pilot burner. It will
not be reused.
5. Remove the ignition control unit. Leaving the wiring harness connected to the l.C.U. and the gas valve.
STEP 2 - PILOT ELECTRODE/SENSOR ASSEMBLY
There are two types of pilots that may be encountered on your
application: O.E.M. type and retrofitted type. To determine which
type you have and how to “modernize” it, turn to page 5. Follow the
instructions given on page 5, then return to this page and continue
to Step 3.
FIGURE 10
WIRING AT END OF STEP 1
STEP 3 - INSTALLING AND WIRING NEW SYSTEM
1. Install the new ignition control unit using the mounting screws or
double-faced tape included in the modernization kit.
9. C
ut the wire at terminal “TR”. Wire-nut this wire to the red wire in
the new wiring harness.
2. The new wiring harness in the modernization kit should be prewired.
If for any reason it isn’t, connect the harness to the ignition control
units as follows. NOTE: Two-wire white and black connector may be
connected to any terminal marked GND, MV/PV or TR. The green
wire should be connected to either of the remaining terminals.
10. In the two-wire red wiring harness connect the orange high voltage
wire to the “IGN” terminal and the white sensor wire to the
“SENSE” terminal.
Terminal
Wire ColorConnection
Green
GND
White
Two-wire
MV/PV
Black
Connector
TR
Red
MV
Blue
PV
Gray
TH
11. C
onnect the green ground wire to the ground terminal on the gas
valve. NOTE: System must be grounded or severe damage to gas
valve may result.
12. W
iring is now complete. Compare wiring in figure 11 against what
has just been done. If it agrees, then set thermostat heat anticipator
to .7 amp. Set thermostat low. Turn on power. See sequence of
operation and checkout procedure page 6.
3. Install the ground terminal included in the modernization kit.
Remove screw holding wire harness connector bracket to the gas
valve. Assemble terminal to valve and bracket using this screw.
See figure 6.
“K” SERIES CONVERSION TO FLAME RECTIFICATION WITH
MODEL SP715 OR SP735 IGNITION CONTROL UNITS
4. With the new blue wiring harness attached to the new ignition
control unit, cut the insulated quick­connects from the red, white
and blue wires in the new harness. Strip about 1/4” of insulation
from these wires. The black and gray wires already have the
insulation separated. Remove this also.
5. At the plug-in connector on the old existing ignition unit, cut the
wires at terminal “T1.” Wire-nut this wire to the gray wire in the
new wiring harness. Refer to wiring diagram figure 11.
6. Cut the wire at terminal “T2.” Wire-nut this wire to the black wire in
the new wiring harness.
7. Cut the wires at terminals “H” and “P.” Wire-nut these two wires to
the blue wire in the new wiring harness.
8. Cut the wires from terminals “TH” and “C.” Wire-nut these two wires
to the white wire in the new wiring harness.
FIGURE 11
WIRING AT COMPLETION OF MODERNIZATION
4
RETROFITTED TYPE PILOT
STEP 2 - PILOT ELECTRODE/SENSOR ASSEMBLY
A. The existing ignitor is not riveted to the pilot frame but is held in
place by metal tabs bent to hold it in place, as shown in figure 13.
If you have this type of pilot, remove the pilot assembly from the
furnace. Disassemble and remove the ignitor sensor from the pilot
frame.
There are two types of pilots that may be encountered on your application:
O.E.M. type and retrofitted type. Compare your pilot with the drawings
below (figure 12 and figure 13). Follow the appropriate instructions
given for your pilot type, then return to Step 3.
B. Locate the twin electrode/sensor assembly included in the
modernization kit. Assemble it to the pilot burner frame as
shown below.
FIGURE 12
FIGURETYPE
12
O.E.M.
O.E.M. TYPE
FIGURE 13
RETROFITTED TYPE
O.E.M. TYPE PILOT
A. The pilot has a small hole with a tinerman clip and the electrode is
riveted to the pilot frame. If you have this type of pilot assembly,
locate the new “Flame Sensor” included in the modernization kit.
Insert it into the tinerman clip as shown below.
C. The electrode/sensor assembly can now be positioned for correct
sparking and sensing. Because the leads are identical, you can select
either to be the electrode.
D. Position the electrode so that the electrode wire can be bent and
positioned to spark to the pilot hood. Cut off excess wire and position
the tip of the electrode wire for a 1/8” maximum spark gap. Be sure
sparking will occur in the path of the gas flow.
E. Next, position the flame sensor and bend this wire so that the pilot
flame fully envelops the sensor wire. This sensor wire can be cut to
length also. Tighten the bolt firmly so that the bracket assembly will
not move or change position once the pilot is installed.
CAUTION: The electrode must not spark to the sensor wire.
F. Locate the red two-wire harness in the kit. Attach the orange wire to
the electrode and the white wire to the sensor.
G. Reinstall the pilot in its exact previous location. NOTE: Pilot is not to
be relocated or altered. If replacing the pilot becomes necessary; due
to damage, an exact replacement should be used. Return to step 3.
HIGH VOLTAGE
CABLE ADAPTOR
B. Locate the red two-wire harness that is included in the kit. Pull the
orange wire out and discard it. Leave only the white or clear sensor
wire in the red protective sheath.
C. Connect the white or clear sensor wire to the base of the flame sensor.
D. Locate the high voltage cable adaptor included in the kit. Attach it to
the “IGNITOR” terminal on the new ignition control unit.
(See Figure 10.)
E. Locate the orange high voltage wire that is attached to the electrode
on the pilot frame. Connect it to the adaptor on the “IGNITOR”
terminal on the new ignition control unit.
“IGNITOR
TERMINAL”
FIGURE 10
5
SYSTEM CHECKOUT PROCEDURES
The initial installation portion is now complete and ready for final
system checkout. The checkout procedures listed below must be
followed. While there are redundant safety features built into the
system, it is imperative that you follow the steps outlined below to
ensure proper and safe operation.
1. ❏ Check all wiring connections.
2. ❏ Turn on main gas supply and manual valve on the gas valve.
3. ❏ Turn on electrical power.
4. ❏ Thermostat set high.
5. ❏ Sparking begins, pilot gas ignites.
6. ❏ Pilot flame on sensor, main burner on.
7. ❏ With main burner on, cycle thermostat off then on.
A. Nonlockout system will turn off and immediately on again.
B. Lockout system will turn off. Sparking will not begin for 5 seconds.
8. ❏ With the main burner on, turn the manual gas valve to off position.
Wait until all flame is out. Turn manual gas valve on again.
A. Sparking will begin as soon as the pilot flame is out.
B. Pilot ignition takes place when gas flow is restored.
9. ❏ If this is a lockout system, with main burner on, turn manual gas
valve off. Sparking will begin when the pilot flame goes out.
After 60 seconds the system will lockout and sparking will cease.
10. ❏ To restart the system turn thermostat low for 5 seconds.
Then set high again. Sparking will begin in 5 seconds.
11. ❏ It is absolutely necessary that the system be cycled normally
(thermostatically controlled) through at least three complete
heating cycles. Set thermostat to a temperature slightly higher
than the existing ambient. Allow appliance to cycle ON and run
through a normal cycle. Do not manually shorten the cycle.
12. ❏ The initial checkout procedures have been completed. If the
system has functioned normally, return thermostat setting to its
normal setting. The qualified installing agency must completely
fill out and apply the yellow appliance conversion sticker to the
front of the appliance. Leave these and all other instructions with
the homeowner.
Customer Service Telephone 1.800.304.6563
Customer Service Facsimile 1.800.426.0804
HVACCustomerService@robertshaw.com
For Technical Service
Telephone 1.800.445.8299
Facsimile 1.630.260.7294
TechnicalService@robertshaw.com
6
Robertshaw®, Ranco®, Paragon® and Uni-Line® are
trademarks of Robertshaw its subsidiaries and/or
affiliated companies. All other brands mentioned
may be the trademarks of their respective owners.
www.uni-line.com
www.robertshaw.com
©2014 Robertshaw
10/14 –1-406 RevD
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