Fenwal 35-62 Series User manual

SERIES 35-62
24 VAC Microprocessor Based Dual Point
Direct Spark Ignition Control
FEATURES
 24 VAC microprocessor based DSI control
 System diagnostic LED
 Multiple tries
 Custom prepurge and interpurge timings
 Remote flame sensing
 Full time flame sensing
 Flame sense test pins
 Software conforms to UL 1998 requirements
DESCRIPTION
The Series 35-62 is a 24 VAC Microprocessor Based Dual Point
Direct Spark Ignition Control continually and safely monitors,
analyzes and controls the proper operation of two gas burners.
Value added features such as LED diagnostics, automatic one hour
reset, and flame current test pins highlight the controls benefits.
®
35.62.03
Input Power Control:20-28 VAC 50/60 Hz
(Class 2 Transformer)
Input Current Drain 300 mA @ 24 VAC and
gas valve relay energized
(control only)
Gas Valve Rating 1.5A @ 24 VAC
(Inrush 3,0A maximum)
Operating Temperature -40°F to +160°F
-40°C to +71°C
Flame Sensitivity >1.0uA minimum
Flame Failure 0.8 seconds
Response Time
Types of Gases Natural, LP, or manufactured
Spark Rate Line frequency
(50/60 sparks/sec)
Enclosure Gray (Noryl N-190) fire
retardant plastic integral
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 4.0,7.0,10.0,15.0 or 21.0
seconds available
Prepurge & Interpurge None,15, or 30 seconds
depending on model.
APPLICATIONS
 Gas furnaces
 Boilers
 Water heaters
 Commercial cooking
 Other similar appliances
SPECIFICATIONS
Series 35-62, 24 VAC Dual Point DSI Control Page 1
www.fenwalcontrols.com 1-800-FENWAL-1
Agency Certifications
Design certified to ANSI Z21.20-1993 and
CAN/CSA C22.2 No. 199-M89

MOUNTING AND WIRING
CAUTIONS:
1. Ceramic insulators should nor be in or close to the flame.
2. Electrode assemblies should not be adjusted or disassem bled.
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.
SEQUENCE OF OPERATION / FLAME
RECOVERY / SAFETY LOCKOUT
Power Up/Stand-By
• Upon applying power (24 VAC) to 24V terminal, the control will
reset, perform a self check routine, initiate full time flame sensing,
flash the diagnostic LED for up to four seconds, and enter the
thermostat scan state.
Heat Mode
• When a call for heat is received from the thermostat supplying 24
volts to TH/W, a pre-purge delay begins, then the gas valve is
energized and the sparks commence at both burners 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 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 either 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 of immediately.
MULTI TRIAL MODEL
Should either 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 or removing 24 volts for a period of 5 seconds.
FLAME FAILURE- RE-IGNITION
If the established flame signal is lost from either burner while the
burners are operating, the control will respond within 0.8 seconds.
The HV spark will be energized for a trial for ignition period in an
attempt to relight the burners. If either burner does not light the
control will de-energize the gas valve. Multi-try models will make
two more attempts to relight the burners. If either 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.
Flame Fault
If at any time the main valve fails to close completely and main
tains a flame, the full time flame sense circuit will detect it and
flash an error code of 2.
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.
WARNING:
Operation outside specifications could result in failure of the
Fenwal product and other equipment with injury to people
and product.
TERMINAL DESIGNATIONS
TH/W THERMOSTAT INPUT
GND SYSTEM GROUND
V1 VALVE POWER
V2 VALVE GROUND
NC ALARM
S1 REMOTE FLAME SENSOR
S2 REMOTE FLAME SENSOR
FC1 FLAME CURRENT TEST PIN
FC2 FLAME CURRENT TEST PIN
24V 24 VAC INPUT (FULL TIME)
WARNING:
The Series 35-62 uses voltages of shock hazard potential. Wiring
and initial operation must be done by a qualified service technician.
The Series 35-62 is not position sensitive and can be mounted
vertically or horizontally. The control may be mounted on any
surface with #6 sheet metal screws.
All wiring must be done in accordance with both local and
national electrical code. The control must be secured in a area
that will experience a minimum of 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 35-62 to other components
in the system.
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.
Page 2 Series 35-62, 24 VAC Dual Point DSI Control www.fenwalcontrols.com 1-800-FENWAL-1

ERROR MODE LED INDICATION
Internal Control Failure Steady on
Flame with No Call for Heat 2 flashes
Ignition Lockout 3 flashes
FAULT CONDITIONS
The LED will flash on for 1/4 seconds, then off for 1/4 second
during a fault condition, the pause between fault codes is
3 seconds.
TROUBLESHOOTING GUIDE
SYMPTOMS 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 t’stat no voltage@ terminal W
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 okay 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)
6. Flame with no call for heat A. Stuck valve (check LED for 2 flashes)
FLAME CURRENT CHECK
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.
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.
HIGH VOLTAGE CABLE
Fenwal Part Number 05-129608-624 Suppression Cable
(or equivalent) must be used for proper operation of control.
IGNITOR LOCATION
Figure 3
WIRING DIAGRAM
Series 35-62, 24 VAC Dual Point DSI Control Page 3
www.fenwalcontrols.com 1-800-FENWAL-1

The Series 35-62 series direct spark ignition controller
is a custom manufactured control. Consult factory with
operational requirements.
Variable Options:
Pre-purge time
Single or multiple tries for ignition
Trial for ignition time
Inter-purge time
The Series 35-62 is only available
with remote flame sensing
CONTROL CONFIGURATION
SERIES 35-625 X X X - X X X Description
DIMENSIONS
FENWAL
400 MAIN STREET, ASHLAND, MA 01721
TEL: [phone] FAX: [phone]
www.fenwalcontrols.com
© 2003 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 35.62.03 10/30/03
®
Page 4 Series 35-62, 24 VAC Dual Point DSI Control www.fenwalcontrols.com 1-800-FENWAL-1
Non-Standard Configurations
9 = Non Standard Configuration
A 9 in this location of the part number
(i.e. 35-62 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