Robertshaw 780-704 & 780-705 Series Modernization Kit User manual

Brand: Robertshaw

Model: 780-704 & 780-705 Series Modernization Kit

Type: User manual

Robertshaw 780-704 & 780-705 Series Modernization Kit converts “K” Series to “Flame Rectification” ignition systems, replacing ignition control units SP710 and SP730, and the second generation SP710A and SP730A. This kit retains the plug-in wiring harness feature and upgrades the old heat sensing/flame switch system to “Flame Rectification”.

INSTALLATION DATA

780-704 & 780-705

MODERNIZATION KIT

COVERTS “K” SERIES TO “FLAME RECTIFICATION”

The Robertshaw® “K” Series Pilot Ignion System Gas Valve (7000

BKER) was used with two models of ignion control units: SP710

and SP730, and the second generaon SP710A and SP730A. Due to

obsolescence, this modernizaon kit will replace these ignion 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 moderniza-

on kits upgrade the old heat sensing/ame switch system to “Flame

Reccaon”.

PILOT ADAPTORS – ORDER SEPARATELY

GAFFERS AND SATTLER CARRIER/BDP 732 PILOT

ORDER 1751-712 ORDER 1751-716

ORDERING DATA

UNI-LINE

NUMBER TYPE REPLACES

780-704 LOCKOUT

780-711, 780-713

SP730 AND SP730A

780-705 NONLOCKOUT

780-710, 780-712

SP710 AND SP710A

PREINSTALLATION INSTRUCTIONS

The installaon procedures below should be followed in the exact

sequence as outlined in these instrucons.

The gas valve and valve wiring are the same for both generaons and

need not be changed. Do not remove the wiring harness from the gas

valve connector. See gure 1.

Select and use the appropriate modernizaon kit 780-705 nonlockout

or 780-704 lockout. See cross-reference chart above. To determine

ignion unit type, see below.

REMEMBER: You are converng or upgrading the system from heat

sensing to ame sensing (Flame Reccaon).

SYSTEM IDENTIFICATION

IMPORTANT

1. Determine ignion control unit type and factory model number.

The “K” Series Pilot Ignion Systems may be found with one of

two styles of ignion control units: the rst generaon SP710

nonlockout or SP730 lockout (gure 2), or the second generaon

SP710A nonlockout or SP730A lockout (gure 3).

Determine the factory model number by locang the number on the

control’s rang 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 possibilies 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 gure 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.

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.

STEP 1 - REMOVING THE OLD SYSTEM

1. Turn o all electrical power to the furnace being serviced.

2. Double check exisng wiring against wiring method “A” schemac

shown in gure 5. If idencal, then proceed as directed below.

3. Disconnect the orange high voltage wire from the top of the ignion

control unit.

4. Remove the heat sensor/ame switch from the pilot burner. It will

not be reused.

5. Remove the ignion control unit, leaving the wiring harness connect-

ed 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

applicaon: O.E.M. type and retroed type. To determine which

type you have and how to “modernize” it, turn to page 5. Follow the

instrucons given on page 5, then return to this page and connue

to Step 3.

STEP 3 - INSTALLING AND WIRING NEW SYSTEM

1. Install the new ignion control unit using the mounng screws or

double-faced tape included in the modernizaon kit.

2. The new wiring harness in the modernizaon kit should be prewired.

If for any reason it isn’t, connect the harness to the ignion 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 Color Connecon

Green GND

White Two-wire MV/PV

Black Connector TR

Red MV

Blue PV

Gray TH

3. Install the ground terminal included in the modernizaon kit.

Remove

screw holding wire harness connector bracket to the gas valve.

Assemble terminal to valve and bracket using this screw. See gure 6.

4. With the new blue wiring harness aached to the new ignion

control unit, cut the insulated quick connects from the red, white

and blue wires in the new harness. Strip about 1/4” of insulaon

from these wires. The black and gray wires already have the

insulaon separated. Remove this also.

5. At the plug-in connector on the old exisng ignion unit, cut the wire

at terminals “T1” and wire-nut this wire to the gray wire in the new

harness. Refer to wiring diagram gure 7.

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.

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 gure 7 against what

has just been done. If it agrees, then set thermostat heat ancipator

to .7 amp. Set thermostat low. Turn on power. See sequence of

operaon and checkout procedure page 6.

INSTALLATION INSTRUCTIONS - WIRING METHOD “A”

FIGURE 6

FIGURE 7

WIRING AT COMPLETION OF MODERNIZATION

“K” SERIES WIRING

CONVERTED TO FLAME RECTIFICATION

FIGURE 5

WIRING AT THE END OF STEP 1

“K” SERIES (SP710/730) O.E.M. WIRING

R & W ARE JUMPED

STEP 1- REMOVING THE OLD SYSTEM

1. Turn o all electrical power to the furnace being serviced.

2. Double check exisng wiring against wiring method “B” schemac

shown in gure 8. If idencal, then proceed as directed below.

3. Disconnect the orange high voltage wire from the top of the

ignion control unit.

4. Remove the heat sensor/ ame switch from the pilot burner. It will

not be reused.

5. Remove the ignion control unit, leaving the wiring harness con-

nected 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

applicaon: O.E.M. type and retroed type. To determine which type

you have and how to “modernize” it, turn to page 5. Follow the instruc-

ons given on page 5, then return to this page and connue to Step 3.

STEP 3 - INSTALLING AND WIRING NEW SYSTEM

1. Install the new ignion control unit using the mounng screws or

double-faced tape included in the modernizaon kit.

2. The new wiring harness in the modernizaon kit should be prewired.

If for any reason it isn’t, connect the harness to the ignion 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 Color Connecon

Green GND

White Two-wire MV/PV

Black Connector TR

Red MV

Blue PV

Gray TH

3. Install the ground terminal included in the modernizaon kit.

Remove screw holding wire harness connector bracket to the gas

valve.

Assemble terminal to valve and bracket using this screw.

See gure 6.

4. With the new blue wiring harness aached to the new ignion

control unit, cut the insulated quick-connects from the red, white

and blue wires in the new harness. Strip about 1/4” of insulaon

from these wires. The black and gray wires already have the

insulaon

separated. Remove this also.

5. At the plug-in connector on the old exisng ignion unit, cut the

wires at terminals “T1” and “R” and wire-nut these wires together.

Refer to wiring diagram gure 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.

INSTALLATION INSTRUCTIONS - WIRING METHOD “B”

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.

13. Wiring is now complete. Compare wiring in gure 9 against what

has just been done. If it agrees then set thermostat heat

ancipator to .7 amp. Set thermostat low. Turn on power. See

sequence of operaon and checkout procedure page 6.

FIGURE 9

WIRING AT COMPLETION OF MODERNIZATION

“K” SERIES WIRING

CONVERTED TO FLAME RECTIFICATION

FIGURE 8

WIRING AT THE END OF STEP 1

“K” SERIES (SP710/730) O.E.M. WIRING

R & W ARE NOT JUMPED

STEP 1 - REMOVING THE OLD SYSTEM

1. Turn o all electrical power to the furnace being serviced.

2. Double check exisng wiring against wiring method “C” schemac

shown in gure 11. If idencal, then proceed as directed below.

3. Disconnect the orange high voltage wire from the top of the ignion

control unit.

4. Remove the heat sensor/ame switch from the pilot burner. It will

not be reused.

5. Remove the ignion control unit. Leaving the wiring harness con-

nected 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

applicaon: O.E.M. type and retroed type. To determine which

type you have and how to “modernize” it, turn to page 5. Follow the

instrucons given on page 5, then return to this page and connue

to Step 3.

STEP 3 - INSTALLING AND WIRING NEW SYSTEM

1. Install the new ignion control unit using the mounng screws or

double-faced tape included in the modernizaon kit.

2. The new wiring harness in the modernizaon kit should be prewired.

If for any reason it isn’t, connect the harness to the ignion 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 Color Connecon

Green GND

White Two-wire MV/PV

Black Connector TR

Red MV

Blue PV

Gray TH

3. Install the ground terminal included in the modernizaon kit.

Remove screw holding wire harness connector bracket to the gas

valve. Assemble terminal to valve and bracket using this screw.

See gure 6.

4. With the new blue wiring harness aached to the new ignion

control unit, cut the insulated quick connects from the red, white

and blue wires in the new harness. Strip about 1/4” of insulaon

from these wires. The black and gray wires already have the

insulaon separated. Remove this also.

5. At the plug-in connector on the old exisng ignion unit, cut the

wires at terminal “T1.” Wire-nut this wire to the gray wire in the

new wiring harness. Refer to wiring diagram gure 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.

INSTALLATION INSTRUCTIONS - WIRING METHOD “C”

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 gure 11 against what

has just been done. If it agrees, then set thermostat heat ancipator

to .7 amp. Set thermostat low. Turn on power. See sequence of

operaon and checkout procedure page 6.

FIGURE 11

WIRING AT COMPLETION OF MODERNIZATION

“K” SERIES CONVERSION TO FLAME RECTIFICATION WITH

MODEL SP715 OR SP735 IGNITION CONTROL UNITS

FIGURE 10

WIRING AT END OF STEP 1

“K” SERIES WITH MODEL SP710A

OR SP730A IGNITION CONTROL UNITS

STEP 2 - PILOT ELECTRODE/SENSOR ASSEMBLY

There are two types of pilots that may be encountered on your applicaon:

O.E.M. type and retroed type. Compare your pilot with the drawings

below (gure 12 and gure 13). Follow the appropriate instrucons

given for your pilot type, then return to Step 3.

O.E.M. TYPE PILOT

A. The pilot has a small hole with a nerman 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 modernizaon kit.

Insert it into the nerman clip as shown below.

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 protecve sheath.

C. Connect the white or clear sensor wire to the base of the ame sensor.

D. Locate the high voltage cable adaptor included in the kit. Aach it to

the “IGNITOR” terminal on the new ignion control unit.

(See Figure 10.)

E. Locate the orange high voltage wire that is aached to the electrode

on the pilot frame. Connect it to the adaptor on the “IGNITOR”

terminal on the new ignion control unit.

RETROFITTED TYPE PILOT

A. The exisng 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 gure 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.

B. Locate the twin electrode/sensor assembly included in the

modernizaon kit. Assemble it to the pilot burner frame as

shown below.

C. The electrode/sensor assembly can now be posioned for correct

sparking and sensing. Because the leads are idencal, you can select

either to be the electrode.

D. Posion the electrode so that the electrode wire can be bent and

posioned to spark to the pilot hood. Cut o excess wire and posion

the p of the electrode wire for a 1/8” maximum spark gap. Be sure

sparking will occur in the path of the gas ow.

E. Next, posion the ame sensor and bend this wire so that the pilot

ame fully envelops the sensor wire. This sensor wire can be cut to

length also. Tighten the bolt rmly so that the bracket assembly will

not move or change posion 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. Aach the orange wire to

the electrode and the white wire to the sensor.

G. Reinstall the pilot in its exact previous locaon. 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.

FIGURE 12

O.E.M. TYPE

FIGURE 12

O.E.M. TYPE

FIGURE 13

RETROFITTED TYPE

HIGH VOLTAGE

CABLE ADAPTOR

“IGNITOR

TERMINAL”

FIGURE 10

Customer Service Telephone 1.800.304.6563

Customer Service Facsimile 1.800.426.0804

[email protected]

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.

For Technical Service

Telephone 1.800.445.8299

Facsimile 1.630.260.7294

[email protected]

www.uni-line.com

www.robertshaw.com

10/14 –1-406 RevD

SYSTEM CHECKOUT PROCEDURES

The inial installaon poron is now complete and ready for nal

system checkout. The checkout procedures listed below must be

followed. While there are redundant safety features built into the

system, it is imperave that you follow the steps outlined below to

ensure proper and safe operaon.

1. ❏ Check all wiring connecons.

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 ame on sensor, main burner on.

7. ❏ With main burner on, cycle thermostat o then on.

A. Nonlockout system will turn o and immediately on again.

B. Lockout system will turn o. Sparking will not begin for 5 seconds.

8. ❏ With the main burner on, turn the manual gas valve to o posion.

Wait unl all ame is out. Turn manual gas valve on again.

A. Sparking will begin as soon as the pilot ame is out.

B. Pilot ignion takes place when gas ow is restored.

9. ❏ If this is a lockout system, with main burner on, turn manual gas

valve o. Sparking will begin when the pilot ame goes out.

Aer 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

(thermostacally controlled) through at least three complete

heang cycles. Set thermostat to a temperature slightly higher

than the exisng ambient. Allow appliance to cycle ON and run

through a normal cycle. Do not manually shorten the cycle.

12. ❏ The inial checkout procedures have been completed. If the

system has funconed normally, return thermostat seng to its

normal seng. The qualied installing agency must completely

ll out and apply the yellow appliance conversion scker to the

front of the appliance. Leave these and all other instrucons with

the homeowner.

Robertshaw 780-704 & 780-705 Series Modernization Kit User manual

Robertshaw 780-704 & 780-705 Series Modernization Kit User manual

Robertshaw 780-704 & 780-705 Series Modernization Kit User manual

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