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Johnson Controls G861 Series, Technical Bulletin, Page: 12 / 12

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

If the system does not function properly, check the following:

•

 

Are all mechanical and electrical connections tight?

•

 

Is the system wired correctly?

•

 

Is gas inlet pressure per manufacturer’s specifications?

•

 

Is the system powered?

•

 

Is the thermostat calling for heat?

Table 2: LED Flash Code Summary

Flash Code

Flash Code Description

Slow Flash

Normal operation, no call for heat

Fast Flash

Normal operation, call for heat

Flash Two

Failed to detect or sustain flame

Flash Three

Pressure switch open or closed

Flash Four

High limit open

Flash Five

Flame sensed and gas valve not energized

Steady On

Internal failure (microcontroller self-check
failure)

!

 CAUTION: Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and
dangerous operation.

Do not attempt field repairs to the ignition control. Use only an exact or
recommended replacement control. For a replacement control or
accessories, contact the original equipment manufacturer or the nearest
Johnson Control distributor.

Service
Procedures

Flash Codes

Repairs and
Replacement

Controls Group

www.johnsoncontrols.com

507 E. Michigan Street

FAN 121

P.O. Box 423

Installation Sheets Manual

Milwaukee, WI  53201

Printed in U.S.A.

Summary of Contents for G861 Series

Page 1: ...nsor 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...

Page 2: ...ontrol 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 L...

Page 3: ...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 s...

Page 4: ...No Postpurge No End Thermostat calls for m anual fan G No Run manual fan speed Thermostat call for heat Pressure switch open Yes Retry mode 60 m inute delay No Yes Pressure switch closed Third trial Trial for ignition Sixteenth flameout Flam e sensed Circulator Blower on delay Thermostat satisfied Circulator Blower off delay field selectable Figure 2 G861 Sequence of Operation ...

Page 5: ...ill 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 t...

Page 6: ...rmostat 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 e...

Page 7: ... 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 ro...

Page 8: ... 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...

Page 9: ...rm e r 24 V L in e 2 4 V C o m m o n S p ark Tra n s fo rm er 24 VA C H o t G ro u nd F lam e S e n se P S W P re s s u re S w itc h H ig h L im it In H igh L im it O ut R o llo u t In B lo w e r O ff D e la y S etting H igh L im it S w itc h R o llo ut S w itc h T he rm o s ta t 3 1 6 in ch Te rm in a l W G R S e nso r N ote A ll term in a ls are 1 4 in ch u n less o the rw ise spe cified P re ss...

Page 10: ...nd 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...

Page 11: ...draw of the heating system at the thermostat location Measuring this current can be accomplished by opening the thermostat contacts lowering the setpoint and installing an AC ammeter across the terminals or by using a clamp on ammeter with a 10 turn multiplier attached to the terminals See Figure 4 Ten Turns Clamp on Ammeter Divide reading by ten W R W R AC Ammeter Low Scale Setting To Heating Sys...

Page 12: ...ash Three Pressure switch open or closed Flash Four High limit open Flash Five Flame sensed and gas valve not energized Steady On Internal failure microcontroller self check failure CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Do not attempt field repairs to the ignition control Use only an exact or recommended repl...

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