Johnson Control G775 wiring question

OPH

I have a customer with a Burnham steam boiler with a 30+ year old Johnson Controls G775 RHA-1. The control has failed and after talking to Burnham I acquired a conversion kit to swap over to a S8610m that includes the new ignition module and a small wiring harness and a pilot assembly that has a combination spark and flame sensors instead of the old style with the separate spark and sense. The kit does not include any wiring diagram and I’m looking for some help with wiring aspect of the conversion, thanks in advance.

OPH

109A_5

I kind of wonder if the S8610M is the best match, the trial time is different, damper connector ? There is the Baso Gas Products C664FGA-1C which the supplyhouse.com listing for the Johnson Controls G775 RHA-1 claims it to be a direct replacement for the Johnson Controls G775 RHA-1.

https://www.supplyhouse.com/Baso-Gas-Products-C664FGA-1C-24V-Intermittent-Pilot-Ignition-Control-85-Sec-Trial

https://www.baso.com/wp-content/uploads/2021/10/baso-ins-e34qrg_rev-.pdf

The Baso PDF above has some terminal definitions that may be helpful.

Anyway it seems if the wires are swapped from the old to the new unit function for function it should work. The spark and the ground may be the only exceptions and some wiring modifications may be needed to make those connections. Does the boiler have a damper ? Does your S8610M have the connector for the damper ?

Another idea is find the oldest Burnham steam boiler I/O manual (on-line) that uses the Honeywell S86xx series Ignition Control Module and use that wiring diagram for a reference.

OPH

No damper on the boiler. The pilot assembly is in poor shape as well and no replacement part number could be found by me or tech support at Burnham/U.S.Boiler. I opted for the the conversion offered by Burnham that includes the S86 control and new pilot assembly. After taking another look today the only things I see different would be the ground connections on the old control which would have nowhere to land on the new control.(The old control has a metal bracket behind it that grounds to the control.) Also changing to a pilot that does not have separate speak/sense.

109A_5

If it was not included with the kit, you need to purchase or fabricate a ground wire to connect to the 1/4 inch male spade connector on the S8610m (Green annotation below) to the jacket of the boiler. I believe a 1/4 inch female spade terminal, some appropriate wire and possibly a ring terminal to go under the head of a nearby screw. Good quality ground connections are important for the flame detection functionality.

It appears the Johnson Controls G775 RHA-1 simply used the mounting screws, and rivets connecting to the metal plate on the back of the module and provided a few terminals to ground the module and other things to. Or there was another wire that connected the 3 remaining terminals to a better grounding point elsewhere on the boiler.

As a grounding connection method for the actual module circuitry the short white wire was used. If anything else was grounded there too it will have to grounded also.

OPH

Can I use that connection to ground right onto the burner/pilot?

109A_5

As far as the flame detection part of the situation that may be the best place. However you still need the connection to the low side (grounded side) of the 24 VAC power that powers the control circuitry. Without seeing the actual wiring and the original ground bonding it is hard to say. Sticking as close to what worked before maybe the easiest option.