Heating Line Product Guide 435.0Ignition Controls Section

Product Bulletin G67Issue Date 1098

© 1998 Johnson Controls, Inc. 1Code No. LIT-4350400 www.johnsoncontrols.com

The G67 Intermittent Pilot Ignition(IPI) Control is used toautomatically light a pilot burnerand energize the main burnergas valve of a heating system inresponse to the thermostat’s callfor heat. When the heating load issatisfied, the thermostat opensand the G67 de-energizes thepilot and main burner gas valves.The G67 can be used withequipment with a maximum firingrate of 117 kW (400,000 Btu/hr)Any application over 117 kW(400,000 Btu/hr) must beapproved in advance by theJohnson Controls ApplicationEngineering Department.

Figure 1: G67 Intermittent PilotIgnition Control

Figure 2: EC Approved G67EGIntermittent Pilot Ignition Control

Features and Benefits

❑ Energy Efficient Allows pilot gas to be on only during the runcycle

❑ High Energy Spark Promotes consistent dependable pilot lighting

❑ Compact Size Provides limited space applications

❑ Solid State Components Provides long life

❑ Quick Response to Loss ofPilot Flame

Provides rapid closure of main valve(0.8 second maximum)

❑ G67EG Approved Worldwide Broadens applications to include global markets

G67 Intermittent Pilot Ignition Controls

2 G67 Intermittent Pilot Ignition Controls Product Bulletin

ApplicationThe G67 ignition control may only be used fortwo types of applications:

• well ventilated or outdoor applications

• power vent or induced draft application

The G67 is suitable for operation over a temperaturerange of -40 to 66°C (-40 to 150°F). Considerationmust be given to the temperature of the surface onwhich the G67 is mounted.

Use the G67B( ) only on rooftop, excess air, and powervented gas burning equipment.

When using the G67, the appliance or equipment mustbe approved by a recognized testing agency inaccordance with the applicable American NationalStandards. See Specifications section. No otherapplication is permissible.

The G67 solid-state ignition control lights a pilot burnerby a spark. Pilot gas is ignited and burns during eachrun cycle (intermittent pilot). Main burner and pilot gasare extinguished during the Off cycle. All applicationsmust use a redundant main gas valve.

The main gas valve will not open until the pilot flamehas been proven by the sensing circuit. Should a lossof flame occur, the main valve closes and the sparkrecurs within 0.8 seconds.

Operating Mode DefinitionsThe following definitions describe operating conditions:

Trial for Ignition--Period during which the pilot valveand spark are activated attempting to ignite gas at themain burner.

Run--Main gas valve remains energized and the sparkis turned off after successful ignition.

Flameout--Loss of proven flame. Should a flameoutoccur, the main valve closes and the spark recurswithin 0.8 seconds.

Sequence of OperationFigure 3 illustrates the sequence of operation for theG67.

On a call for heat from the system thermostat, the G67ignition control simultaneously opens the pilot valveand supplies a continuous spark to the pilot burner’selectrode. When the pilot burner gas ignites, the pilotflame sensor detects the pilot flame and signals theG67 to energize the main gas valve and discontinuethe spark. The main gas valve will not be energizeduntil the flame sensor detects the presence of the pilotflame.

If the pilot flame goes out (with the thermostat stillcalling for heat), the G67 will de-energize the main gasvalve and provide a continuous spark at the pilotburner’s electrode. When the pilot flame is re-ignitedand detected by the pilot flame sensor, the main gasvalve is energized and the spark is shut off. The G67ignition control de-energizes the pilot gas valve andmain burner gas valve when the thermostat stopscalling for heat.

MountingChoose a location that provides the shortest, directcable route to the spark electrode, flame sensorassembly. Easy access to the terminals is desired forwiring and servicing. The G67 may be mounted in anyposition.

For G67A and G67B, refer to Figures 4 through 6 forwiring schematics/diagrams and Figure 7 for mountingdimensions. For G67EG, refer to Figures 8 and 9 forwiring schematic/diagram and Figure 10 for mountingdimensions.

G67 Intermittent Pilot Ignition Control Product Bulletin 3

Start ThermostatCall for Heat

FlamePresent?

Trial forIgnition

Energize Main Valve

Flameout? De-energizeMain Valve

No

No

Yes

No

Yes

PilotFlame

Sensed?

Run

No

ThermostatCalling for

Heat?

Yes

De-energize ControlPilot and Main Valves.

End

Yes

Figure 3: Sequence of Operation

4 G67 Intermittent Pilot Ignition Controls Product Bulletin

Q 1 R 324 V A CInput

Q

Therm osta t

S ensingC ircu it

R Flam eS ensor

R 2

R 1

H igh L im itsin th is L ine

Only

Jum per

P ilo tB urnerG round

S parkC ircuit

R W

6

2

1

4

P VM V

3

5

G R

G R

G RG R

Internal W iringExte rn a l W iring

Figure 4: Wiring Schematic for G67 Self-Checking Control

Flam eSensor

Thermostat

PowerSupp ly

24VAC

1 6 2 4 3

H igh Vo ltageCable

H igh Lim itsin th is L ine

O nly

Jum per

P ilo tBurnerG round

G round Term ina ls

W R Y

M V PV

5

Power is w ired directly to R (C omm on) on thetherm ostat and Term ina l 6 on the G 67.

Figure 5: Wiring Diagram for G67A( )

G67 Intermittent Pilot Ignition Control Product Bulletin 5

5: <

Y75Flam eSensor

Thermostat

PowerSupply

24VAC

1 2 4 3

H igh VoltageCable

H igh Lim itsin this L ine

Only

Jumper

P ilotBurnerGround

GroundTerm inals

MV PV

5

Pow er is w ired d irectly to R (C om m on) on the therm osta t.Term inals 1 and 2 on th e G 67 are tied together in tern ally.

Figure 6: Wiring Diagram for G67B( )

562.21

50.82 .00

8 .890 .35

5 .330 .21

5 .580 .22

55.62 .19

1154.53

104.94 .13

22.60 .89

6 .350 .25

Q uick C onnectTerm ina ls

Two Ho les fo rM ounting S crews

67.562 .66

Spark Term ina lfo r Ra jah Connector

22.30 .88

4 .110 .162

Figure 7: G67(A and B) Mounting Dimensions, mm (in.)

6 G67 Intermittent Pilot Ignition Controls Product Bulletin

K1a K2c2 4 V A CInput

K1

Thermostat

Sens ingCircuit

K2F lameSensor

K2bK2a

High Limits inthis Line Only

Jumper

BurnerGround

SparkCircuit

Internal Wir ingExternal Wir ing

SparkG a pChass is

6

2WR

1

3

4

PVM V

7

7

5

Figure 8: Wiring Schematic for G67EG Self-Checking Control

Transformer

Thermostat

Limits inThermostatLine Only

Main BurnerGround

PowerSupply

Pi lot Burner/Spark Igni ter

F lameSensor

G 6 7 E GIgnit ion Control

SENSE 4

T H S

M.V.

24V 6P.V. 1

2

3

Pi lot GasSupply

C H A S S I S5

724VC O M

M V P V

Figure 9: Wiring Diagram for G67EG

G67 Intermittent Pilot Ignition Control Product Bulletin 7

56.382 .22

66.82 .63

57.912 .28

50.82 .00

77.723 .06

33.781 .33

5 .580 .22

5 .580 .22

19.550 .77

7 .870 .31

107.954 .25

1164.57

119.384 .70

4 .10 .162

6.350 .25

Spade Term inals

Two H olesfo r No. 8 M ach ineor No. 6 Sheet M etalM ounting S crews

Figure 10: G67EG Mounting Dimensions, mm (in.)

8 G67 Intermittent Pilot Ignition Controls Product Bulletin

Ordering InformationG 67 _ _ - _ _

Customer-specific Requirements

1stLetter Trial Time

OtherFeatures

2ndLetter Volta ge

A Non-100% Lockout Self Checking G 24V 60 Hz

B Non-100% Lockout Non-Self Checking

E Non-100% Lockout Self Checking/EC Approval

The presence of a particular construction in this information does not guarantee its availability.Consult Johnson Controls for available constructions.

G67 Intermittent Pilot Ignition Control Product Bulletin 9

Notes

10 G67 Intermittent Pilot Ignition Controls Product Bulletin

Notes

G67 Intermittent Pilot Ignition Control Product Bulletin 11

Notes

12 G67 Intermittent Pilot Ignition Controls Product Bulletin

SpecificationsProduct G67 Non-100% Lockout Intermittent Pilot Ignition Control

Ignition Type Indirect

Ignition Source High voltage spark, capacitive discharge

Maximum High VoltageCable Length

1,220 mm (48 in.) recommended

Flame Detection Means Flame rectification

Flame Detection Types Remote sensing

Minimum Flame Current 0.2 microampere

Flame Failure ResponseTime

0.8 second, maximum

Spark Gap 2.5 mm (0.1 in.) nominal

Ignition Trial Time Infinite

Power RequirementsControl

Operation Current24 VAC, 50/60 Hz, nominal0.15A nominal + valves

Contact RatingsMain ValvePilot Valve

2A continuous, 5A inrush2A continuous, 5A inrush

Ambient Operating andStorage Temperature

-40 to 66°C (-40 to 150°F)

Humidity 95% RH non-condensing

Types of Gas Natural, Liquefied Petroleum (LP), manufactured, mixed, or LP gas-air mixture may be used in awell-vented or outdoor application.

Packaging Bulk pack supplied to original equipment manufacturer (individual pack options).

Bulk Pack Quantity 50

Bulk Pack Weight 12 kg (27 lb)

Agency Listing IAS (AGA, CGA) Certificate Number C2154020EN/EC Type Examination Certificate Number 115687 (G67EG only)

Specification Standards ANSI Standard Z21.20CSA C22.2-No. 199EN 298 (G67EG only)

The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond t hesespecifications, consult the local Johnson Controls office. Johnson Controls, Inc. shall not be liable for damages resulting fro mmisapplication or misuse of its products.

Refer to the G67 Series Technical Bulletins (LIT-121190 and LIT-121191) for necessary information on the installation, use, and servicing of thisproduct.

Controls Group www.johnsoncontrols.com507 E. Michigan Street FAN 435.0P.O. Box 423 Heating Line Product GuideMilwaukee, WI 53201 Printed in U.S.A

ApplicationOperating Mode DefinitionsSequence of OperationMountingOrdering InformationSpecifications