Fenwal 35-60 Series User manual

SERIES 35-60
24 VAC Microprocessor-Based
Direct Spark Ignition Control
FEATURES
 24 VAC microprocessor based DSI control
 System diagnostic LED
 Automatic reset 1 hour after lockout*
 Multiple tries for ignition
 Custom prepurge and interpurge timings**
 Remote or local flame sensing
 Flame sense test pins
DESCRIPTION
The Series 35-60 is a 24 VAC Microprocessor Based Direct Spark
Ignition Control designed for use in all types of heating applications.
The control utilizes a microprocessor to continually and safely,
analyze and control the proper operation of the gas burner. Value
added features such as LED diagnostics, automatic one hour reset,
and flame current test pins highlight the controls benefits.
* US Versions Only
** Prepurge Time Cannot Exceed Interpurge
Time on European Models
Input Power Control: 18-30 VAC 50/60 Hz
(Class 2 Transformer)
Input Current Drain 300 mA @ 24 VAC and
gas valve relay energized
(control only)
Gas Valve Rating 2.0A @ 24 VAC
Operating Temperature -40ºF to +160ºF
-40ºC to +71ºC
Flame Sensitivity .7μA minimum
Flame Failure Response Time 0.8 seconds maximum
Types of Gases Natural, LP, or manufactured
Spark Rate Line frequency (50/60 sparks/ sec.)
Size (LxWxH) 5.69 x 3.94 x 1.87 inches (with cover)
14.45 x 10.0 x 4.75 cm (with cover)
Weight 8 ounces (nominal)
224 grams (nominal)
Enclosure Gray (Noryl N-190) fire retardant plastic
lntegral standoffs optional
Moisture Resistance Conformal coated to operate to 95% R.H.
Care must be taken to protect module from
direct exposure to water
Tries for ignition One or three try versions available
Trial for ignition Periods 4.0, 7.0, 10.0, or 15.0 seconds standard
Contact factory for other settings
Prepurge & Interpurge None, 15, or 30 seconds depending on model.
Without prepurge there is a one second delay
before the first try for ignition
Edge Connect Version Optional Edge connect model for
replacement product
SPECIFICATIONS
APPLICATIONS
 Gas Furnaces
 Boilers
 Water Heaters
 Commercial Cooking and other SimilarAppliances
®
35.60.03
35-60, 24 VAC Direct Spark Ignition Control Page 1
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Agency Certifications
UL Component Recognized System.
Design certified to UL 372, file MH8817.
Software conforms to UL 1998 requirements.
Design certified to ANSI Z21.20, and EN 298
CAN/ CSA C22.2 No. 199-M89
CE Approved to EN 298:2003

begin with pre-purge, allowing single or multiple trials for ignition
depending on model. If burner relights, normal operation
resumes, if burner does not relight, control will go into lockout
as described in “failure to light”.
Fault Conditions
The LED will flash on for 1/4 second, then off for 1/4 second during
a fault condition. The pause between fault codes is 3 seconds.
MOUNTING AND WIRING
The Series 35-60 is not position sensitive and can be mounted
vertically or horizontally. The case may be mounted on any surface
with #6 sheet metal screws.
The control must be secured in an area that will experience
minimum vibration and remain below the maximum operating
temperature of 160°F.
All connections should be made with UL approved 105°C rated
18 gauge, stranded, .054 thick insulated wire. Refer to wiring
diagram when connecting the Series 35-60 to other components
in the system.
CAUTION:
Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation.
A functional checkout of a replacement control is recommended.
Start up - Heat Mode
When a call for heat is received from the thermostat supplying
24 volts to TH, the control will reset, perform a self check
routine, flash the diagnostic LED, and a pre-purge delay begins.
Following the pre-purge period the gas valve is energized and
sparks commence for the trial for ignition period.
When flame is detected during the trial for ignition, sparks are
shutoff immediately and the gas valve remains energized. The
thermostat and main burner flame are constantly monitored to
assure the system continues to operate properly. When the
thermostat is satisfied and the demand for heat ends, the main
valve is de-energized immediately.
Failure to Light - Lockout
SINGLE TRIAL MODEL
Should the main burner fail to light, or flame is not detected
during the trial for ignition period, the control will go into lockout
and the valve will be turned off immediately.
MULTI TRIAL MODEL
Should the main burner fail to light, or flame is not detected
during the first trial for ignition period, the gas valve is
de-energized and the control goes through an interpurge delay
before another ignition attempt. The control will attempt two
additional ignition trials before going into lockout and the valve
relay will be de-energized immediately.
Recovery from lockout requires a manual reset by either
resetting the thermostat for a period of 5 seconds.
If the thermostat is still calling for heat after one hour the control
will automatically reset and attempt to ignite the burner again.
Flame Failure - Re-Ignition
If the established flame signal is lost while the burner is
the control will respond within 0.8 seconds. The HV spark
will be energized for a trial ignition period in an attempt to
relight the burner. If the burner does not light the control
will de-energize the gas valve. Multi-try models will make
two more attempts to relight the burner. If the burner
does not relight the control will go into lockout as noted
above in “Failure to light”. If flame is re-established,
normal operation resumes.
Recycle After Loss Of Flame
The option “recycle after loss of flame” may be selected as a
special feature. With this option, upon loss of flame, the gas
valve is de-energized and the control recycles its sequence of
operation. Controls with no prepurge will begin with the first trial
for ignition period. Multi-try models will allow three tries for
ignition including interpurges. Controls with pre-purge delay will
Error Mode
Internal Control Failure
Flame with No Call for heat
Ignition Lockout
LED Indication
Steady on
2 flashes
3 flashes
TERMINAL DESIGNATIONS
Thermostat Input
System Ground
Valve Power
Valve Ground
Alarm (normally closed contact)
Remote Flame Sensor
Flame Current Test Pins
TH
GND
V1
V2
NC
S1
FC+, FC-
Page 2 35-60, 24 VAC Direct Spark Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1
SEQUENCE OF OPERATION / FLAME RECOVERY/ SAFETY LOCKOUT
WARNING: All wiring must be done in accordance with both local
and national electrical code.
WARNING: The Series 35-60 uses voltages of shock hazard
potential. Wiring and initial operation must be done by a qualified
service technician.

WARNING:
Operation outside specifications could result in failure of
the Fenwal product and other equipment with injury to
people and property.
High Voltage Cable
Fenwal Part Number 05-129608-624 Suppression Cable (or equivalent)
must be used for proper operation of control.
TROUBLESHOOTING GUIDE
SYMPTOM RECOMMENDED ACTIONS
1. Dead A. Miswired
B. Transformer bad
C. Fuse/Circuit breaker bad
D. Bad control (check LED for steady on)
2. Thermostat on- no spark A. Miswired
B. Bad thermostat
C. No voltage at terminal TH
3. Valve on, no spark A. Shorted electrode
B. Open HV cable
C. Miswired
D. Bad control
4. Spark on, no valve A. Valve coil open
B. Open valve wire
C. Bad control (check voltage
between V1 & V2)
5. Flame OK during TFI, A. Bad electrode
no flame sense after TFI B. Bad S1 or HV wire
C. Poor ground at burner
D. Poor flame (check flame current)
FLAME SENSOR CURRENT CHECK
Series 35-60
SERVICE CHECKS
Flame current is the current which passes through the flame from
the sensor to ground. The minimum flame current necessary to
keep the system from lockout is .7 microamps. To measure flame
current, connect an analog DC microammeter to the FC-FC+
terminals per figure. Meter should read .7 uA or higher. If the
meter reads below “0” on scale, meter leads are reversed.
Disconnect power and reconnect meter leads for proper polarity.
PROPER ELECTRODE LOCATION
Proper location of the electrode assembly is important for optimum
system performance. It is recommended that electrode assembly be
mounted temporarily using clamps or other suitable means so that
the system can be checked before permanently mounting the
assembly. The electrode assembly should be located so that the
tips are inside the flame envelope and about 1/2 inch (1 cm) above
the base of the flame. See Figure 3.
CAUTIONS:
1. Ceramic insulators should not be in or close to the flame.
2. Electrode assemblies should not be adjusted or disassembled.
Electrodes should have a gap spacing of 0.125± 0.031 in
(3.12± 0.81 mm). If this spacing is not correct, the assembly must
be replaced. Electrodes are NOT field adjustable.
3. Exceeding the temperature limits can cause nuisance lockouts
and premature electrode failure.
4. Electrodes must be placed where they could not be
exposed to the appliance user in normal operation.
Ignitor Location
Figure 3
35-60, 24 VAC Direct Spark Ignition Control Page 3
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SERIES 35-605 X X X -X X X Trial for Ignition
1= 4 Seconds
3= 7 Seconds
5= 10 Seconds
7= 15 Seconds
Inter-Purge
0= None (Single Try Only)
1= 15 Seconds
2= 30 Seconds
Pre-Purge
0= None
1= 15 Seconds
2= 30 Seconds
Tries for Igntion and Methods for Flame Sense
0= Single Try - Local Sense
1= Single Try - Remote Sense
5= Three Tries - Local Sense
6= Three Tries - Remote Sense
Enclosure
0= Noryl Gray Enclosure
1= Integral Standoffs
2= HHVT w/Enclosure (Edge Connect Version Only)
3= HHVT No Enclosure (Edge Connect Version Only)
5= Mate-N-Lock W/Enclosure
6= Mate-N-Lock W/Standoffs
Product Designation
2= Standard European Version*
3= Special European Version*
5= Standard
6= Edge Connector
8= Aftermarket Kit
9= Non-Standard**
DIMENSIONS
Special Options
No Cover
No Diagnostics
Recycle after Loss of Flame
No Automatic Reset
*European Versions
Diagnostics and test pins are not
available on European version.
**Non-Standard Configurations
9 = Non Standard Configuration
A 9 in this location of the part number
(i.e. 35-60 5 -113) identifies this
configuration as a non-standard design.
The part number does not follow the part
numbering system. The 9XX is a sequential
part number assigned by Fenwal. Consult
factory for operating characteristics of this
control.
901
CONTROL CONFIGURATION
Page 4 35-60, 24 VAC Direct Spark Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1
FENWAL
400 MAIN STREET, ASHLAND, MA 01721
TEL: [phone] FAX: [phone]
www.fenwalcontrols.com
© 2006 Fenwal Printed in U.S.A. TAG
These instructions do not purport to cover all the details or variations in the equipment
described, nor do they provide for every possible contingency to be met in connection with
installation, operation and maintenance. All specifications subject to change without notice.
Should further information be desired or should particular problems arise which are not covered
sufficiently for the purchaser’s purposes, the matter should be referred to KIDDE-FENWAL,
Inc., Ashland, Massachusetts.
P/N 35.60.03 11/7/06
®