INSTALLATION DATA
780-704 & 780-705
MODERNIZATION KIT
COVERTS “K” SERIES TO “FLAME RECTIFICATION”
The Robertshaw® “K” Series Pilot Ignion System Gas Valve (7000
BKER) was used with two models of ignion control units: SP710
and SP730, and the second generaon SP710A and SP730A. Due to
obsolescence, this modernizaon kit will replace these ignion 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
Reccaon”.
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 installaon procedures below should be followed in the exact
sequence as outlined in these instrucons.
The gas valve and valve wiring are the same for both generaons and
need not be changed. Do not remove the wiring harness from the gas
valve connector. See gure 1.
Select and use the appropriate modernizaon kit 780-705 nonlockout
or 780-704 lockout. See cross-reference chart above. To determine
ignion unit type, see below.
REMEMBER: You are converng or upgrading the system from heat
sensing to ame sensing (Flame Reccaon).
SYSTEM IDENTIFICATION
IMPORTANT
1. Determine ignion control unit type and factory model number.
The “K” Series Pilot Ignion Systems may be found with one of
two styles of ignion control units: the rst generaon SP710
nonlockout or SP730 lockout (gure 2), or the second generaon
SP710A nonlockout or SP730A lockout (gure 3).
Determine the factory model number by locang the number on the
control’s rang 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 possibilies 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.
1
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.
2
STEP 1 - REMOVING THE OLD SYSTEM
1. Turn o all electrical power to the furnace being serviced.
2. Double check exisng wiring against wiring method “A” schemac
shown in gure 5. If idencal, then proceed as directed below.
3. Disconnect the orange high voltage wire from the top of the ignion
control unit.
4. Remove the heat sensor/ame switch from the pilot burner. It will
not be reused.
5. Remove the ignion 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
applicaon: O.E.M. type and retroed type. To determine which
type you have and how to “modernize” it, turn to page 5. Follow the
instrucons given on page 5, then return to this page and connue
to Step 3.
STEP 3 - INSTALLING AND WIRING NEW SYSTEM
1. Install the new ignion control unit using the mounng screws or
double-faced tape included in the modernizaon kit.
2. The new wiring harness in the modernizaon kit should be prewired.
If for any reason it isn’t, connect the harness to the ignion 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 Connecon
Green GND
White Two-wire MV/PV
Black Connector TR
Red MV
Blue PV
Gray TH
3. Install the ground terminal included in the modernizaon 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 aached to the new ignion
control unit, cut the insulated quick connects from the red, white
and blue wires in the new harness. Strip about 1/4” of insulaon
from these wires. The black and gray wires already have the
insulaon separated. Remove this also.
5. At the plug-in connector on the old exisng ignion 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 ancipator
to .7 amp. Set thermostat low. Turn on power. See sequence of
operaon 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
3
STEP 1- REMOVING THE OLD SYSTEM
1. Turn o all electrical power to the furnace being serviced.
2. Double check exisng wiring against wiring method “B” schemac
shown in gure 8. If idencal, then proceed as directed below.
3. Disconnect the orange high voltage wire from the top of the
ignion control unit.
4. Remove the heat sensor/ ame switch from the pilot burner. It will
not be reused.
5. Remove the ignion 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
applicaon: O.E.M. type and retroed 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 connue to Step 3.
STEP 3 - INSTALLING AND WIRING NEW SYSTEM
1. Install the new ignion control unit using the mounng screws or
double-faced tape included in the modernizaon kit.
2. The new wiring harness in the modernizaon kit should be prewired.
If for any reason it isn’t, connect the harness to the ignion 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 Connecon
Green GND
White Two-wire MV/PV
Black Connector TR
Red MV
Blue PV
Gray TH
3. Install the ground terminal included in the modernizaon 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 aached to the new ignion
control unit, cut the insulated quick-connects from the red, white
and blue wires in the new harness. Strip about 1/4” of insulaon
from these wires. The black and gray wires already have the
insulaon
separated. Remove this also.
5. At the plug-in connector on the old exisng ignion 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
ancipator to .7 amp. Set thermostat low. Turn on power. See
sequence of operaon 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
4
STEP 1 - REMOVING THE OLD SYSTEM
1. Turn o all electrical power to the furnace being serviced.
2. Double check exisng wiring against wiring method “C” schemac
shown in gure 11. If idencal, then proceed as directed below.
3. Disconnect the orange high voltage wire from the top of the ignion
control unit.
4. Remove the heat sensor/ame switch from the pilot burner. It will
not be reused.
5. Remove the ignion 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
applicaon: O.E.M. type and retroed type. To determine which
type you have and how to “modernize” it, turn to page 5. Follow the
instrucons given on page 5, then return to this page and connue
to Step 3.
STEP 3 - INSTALLING AND WIRING NEW SYSTEM
1. Install the new ignion control unit using the mounng screws or
double-faced tape included in the modernizaon kit.
2. The new wiring harness in the modernizaon kit should be prewired.
If for any reason it isn’t, connect the harness to the ignion 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 Connecon
Green GND
White Two-wire MV/PV
Black Connector TR
Red MV
Blue PV
Gray TH
3. Install the ground terminal included in the modernizaon 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 aached to the new ignion
control unit, cut the insulated quick connects from the red, white
and blue wires in the new harness. Strip about 1/4” of insulaon
from these wires. The black and gray wires already have the
insulaon separated. Remove this also.
5. At the plug-in connector on the old exisng ignion 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 ancipator
to .7 amp. Set thermostat low. Turn on power. See sequence of
operaon 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
5
STEP 2 - PILOT ELECTRODE/SENSOR ASSEMBLY
There are two types of pilots that may be encountered on your applicaon:
O.E.M. type and retroed type. Compare your pilot with the drawings
below (gure 12 and gure 13). Follow the appropriate instrucons
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 modernizaon 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 protecve 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. Aach it to
the “IGNITOR” terminal on the new ignion control unit.
(See Figure 10.)
E. Locate the orange high voltage wire that is aached to the electrode
on the pilot frame. Connect it to the adaptor on the “IGNITOR”
terminal on the new ignion control unit.
RETROFITTED TYPE PILOT
A. The exisng 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
modernizaon kit. Assemble it to the pilot burner frame as
shown below.
C. The electrode/sensor assembly can now be posioned for correct
sparking and sensing. Because the leads are idencal, you can select
either to be the electrode.
D. Posion the electrode so that the electrode wire can be bent and
posioned to spark to the pilot hood. Cut o excess wire and posion
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, posion 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 posion 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. Aach the orange wire to
the electrode and the white wire to the sensor.
G. Reinstall the pilot in its exact previous locaon. 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
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
www.uni-line.com
www.robertshaw.com
©2014 Robertshaw
10/14 –1-406 RevD
6
SYSTEM CHECKOUT PROCEDURES
The inial installaon poron 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 imperave that you follow the steps outlined below to
ensure proper and safe operaon.
1. ❏ Check all wiring connecons.
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 posion.
Wait unl all ame is out. Turn manual gas valve on again.
A. Sparking will begin as soon as the pilot ame is out.
B. Pilot ignion 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.
Aer 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
(thermostacally controlled) through at least three complete
heang cycles. Set thermostat to a temperature slightly higher
than the exisng ambient. Allow appliance to cycle ON and run
through a normal cycle. Do not manually shorten the cycle.
12. ❏ The inial checkout procedures have been completed. If the
system has funconed normally, return thermostat seng to its
normal seng. The qualied installing agency must completely
ll out and apply the yellow appliance conversion scker to the
front of the appliance. Leave these and all other instrucons with
the homeowner.
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