Fenwal 35-60 Series User manual

F-35-60
October 2018
1
FEATURES
• Safe start with DETECT-A-FLAME®flame sensing
technology
• Custom pre-purge and inter-purge timings*
• Single or three trials for ignition
•SystemdiagnosticLED
• Flame current test points
• Local or remote flame sensing
•Automaticreset**
• Alarm output (normally closed contact)
APPLICATIONS
• Commercial cooking
• Gas furnaces
•Boilers
•Waterheaters
• Other gas-fired appliances
DESCRIPTION
The 35-60 is a 24 VAC direct spark ignition (DSI) control
designed for use in all types of gas-fired appliances. The control
uses a microprocessor circuit to provide precise, repeatable
timing and operating sequences. On-board diagnostics with LED
output makes troubleshooting easy and ensures safe and
efficient operation.
Export Information (USA)
Jurisdiction: EAR
ECCN: EAR99
Agency Certifications
* Pre-purge time cannot exceed inter-purge time on CE
Approved models.
** Automatic reset is not allowed for CE Approved models.
*** EMC emission requirements shall be verified after
incorporation of the burner control system into the end use
appliance.
SPECIFICATIONS
Recognized under the UL component program, UL
372. Software certified to ANSI/UL 1998. UL File
MH8817
Design Certified to ANSI Z21.20,
CAN/CSA C22.2 No. 199-M89
CE Approved to EN 298-2012
Code Compliant to:
AS 4625 - 2008
AS 4622 - 2004
Input Power Control: 18-30 VAC 50/60Hz
(Class 2 transformer)
Input Current 300 mA @24 VAC with gas valve
relay energized (control only)
Gas Valve 2.0A max @ 24 VAC
Operating Temperature -40°F to +176°F
(-40°C to +80°C)
Storage Temperature -40°F to +185°F
(-40°C to +85°C)
Flame Sensitivity 0.7 µA minimum
Flame Failure Response 0.8 seconds maximum
Flame Detector Self-check
Rate
Once per second minimum
Gas Types Natural, LP, or manufactured
Spark Rate:
Remote
Local
50/60 sparks/sec
25/30 sparks/sec
Size (LxWxH)
with enclosure
5.69 x 3.94 x 1.87 inches
(14.45 x 10.01 x 4.75 cm)
Moisture Resistance Conformal coated to operate non-
condensing to 95% R.H. Module
should not be exposed to water
Ingress Protection Not rated, protection provided by
appliance in which it is installed
Tries for Ignition One or three try versions available
Trial for Ignition Periods 4, 7, 10, 15 seconds available
Pre-purge and
Inter-purge Timings
0, 15 or 30 seconds available
SERIES 35-60
24 VAC Microprocessor-Based
Direct Spark Ignition Control
R

Effective: October 2018
2F-35-60
SEQUENCE OF OPERATION / FLAME
RECOVERY / SAFETY LOCKOUT
Start Up - Heat Mode
When a call for heat is received from the thermostat supplying
24VAC to TH/W, the control will reset, perform a self-check
routine, flash the diagnostic LED and begin a pre-purge delay.
Following the pre-purge period, the gas valve is energized and
sparking commences for the Trial For Ignition (TFI) period.
When flame is detected during the TFI, the sparking process is
terminated and the gas valve remains energized. The
thermostat and burner flame are constantly monitored to assure
proper system operation. When the thermostat is satisfied and
the demand for heat ends, the gas valve is immediately de-
energized.
Failure to Light - Lockout
SINGLE TRIAL MODEL
Should the burner fail to light, or a flame is not detected during
the TFI period, the gas valve will de-energize and the control will
go into lockout. The LED will indicate the fault code for ignition
lockout.
MULTI TRIAL MODEL
Should the burner fail to light or the flame is not detected during
the TFI period, the gas valve will de-energize. The control will
then go through an inter-purge delay before an additional
ignition attempt. The control attempts two additional ignition
trials before de-energizing the gas valve and entering lockout.
The LED will indicate the fault code for ignition lockout.
FLAME FAILURE - RE-IGNITION MODE
If the established flame signal is lost while the burner is
operating, the control will respond within 0.8 seconds by
immediately energizing the H.V. spark for the TFI period in an
attempt to relight the flame. If the burner does not light within
the TFI, the gas valve will immediately de-energize and single
try models will enter lockout. On multi-try models, a new TFI
sequence will begin after an inter-purge delay. Multi-try models
perform two additional attempts to light the burner before de-
energizing the gas valve and entering lockout. If the burner
relights, normal operation resumes.
FLAME FAILURE-RECYCLE MODE
With the “Recycle After Loss of Flame" option, upon loss of
flame, the gas valve is de-energized and the control proceeds to
inter-purge before attempting to relight the flame. Multi-try
models permit three tries for ignition including inter-purges. If
the burner relights, normal operation resumes. If the burner
does not relight, the control will enter lockout.
Lockout Recovery
Recovery from lockout requires a manual reset by either
resetting the thermostat, or removing 24 VAC for a period of 5
seconds. On models with automatic reset, if the thermostat is
still calling for heat after one hour, then the control will
automatically reset and attempt to ignite the burner.

Effective: October 2018
F-35-60 3
MOUNTING AND WIRING
The Series 35-60 control 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 also
supports direct mounting to a standard NEC 4-in. junction box.
Note: NC terminal is not available on CE Approved
models.
Wiring Diagrams - 35-605
Figure 1. Local Sense
Figure 2. Remote Sense
Wiring Diagrams - 35-602
Figure 3. Smaller Footprint Wiring Diagram
High Voltage and Remote Sense Cable
Requirements
The HV Ignition Cable must meet a voltage rating of 25 KV and
an insulation rating of 200 °C. Recommend length of 3ft (.9m)
or less. Consult factory for longer lengths.
Remote flame sense cable must meet a voltage rating of 250V
and an insulation rating of 200 °C. Recommended length of 10ft
(3m) or less. Consult Factory for longer lengths.
CAUTION
All wiring must be performed in accordance with
both local and national electrical codes.
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors may cause
improper and dangerous operation. A functional
checkout of a replacement control should always
be performed.
WARNING
This product uses voltages of shock hazard
potential. Wiring and initial operation must be
performed by a qualified service technician.
WARNING
Operation outside specifications could result in
failure of the Fenwal product and other
equipment with potential for injury to people and
property.
Terminal Designations
Terminal Description Quick Connect (inch)
TH/W Thermostat Input 1/4”
V1 Valve Power (output) 3/16”
NC Alarm
(normally closed contact)
1/4”
V2 Valve Ground 3/16”
GND System Ground 1/4”
S1 Remote Flame Sensor 3/16”
H.V. High Voltage Output Varies by model
FC+, FC- Flame Current Test Points Varies by model
TH/W
THERMOSTAT
Not on
CE Models
THERMOSTAT
TH/W
Not on
CE Models
REMOTE FLAME SENSE
MODELS ONLY

Effective: October 2018
4F-35-60
TROUBLESHOOTING
Note: During a fault condition, the LED will flash on for
1/4 second and off for 1/4 second as needed to
indicate the fault code. The code will repeat every
3 seconds. Removing power from the control will
clear the fault code.
Internal Control Failure
If the control detects a software or hardware error, all outputs
are turned off and the LED displays a Steady On condition. If this
condition persists after an attempt to restart, then the control
must be replaced.
Proper Electrode Location
Proper location of electrode assembly is important for optimum
system performance. The electrode assembly should be located
so that the tips are inside the flame envelope and about 1/2-inch
(1.2 cm) above the base of the flame as shown:
Notes:
• Ceramic insulators must not be in or close to the flame.
• Electrode assemblies must not be adjusted or
disassembled. Electrodes are NOT field adjustable.
• Electrodes should have a gap spacing of 0.125± 0.031
in (3.12± 0.81 mm), unless otherwise specified by the
appliance manufacturer. If spacing is not correct, the
assembly must be replaced.
• Exceeding temperature limits can cause nuisance
lockouts and premature electrode failure.
• Electrodes must be located where they are not exposed
during normal operation.
Flame Current Measurement
Flame current is the current that passes through the flame from
sensor to ground. To measure flame current, connect a True
RMS or analog DC micro-ammeter to the FC+ and FC- terminals.
Readings should be 1.0 µA DC or higher. If the meter reads
negative or below "0" on scale, meter leads are reversed. Re-
connect leads with proper polarity.
Alternately, a Digital Voltmeter may be used to measure DC
voltage between FC+ and FC- terminals. Each micro-amp of
flame current produces 1.0 VDC. For example, 2.6 VDC equates
to 2.6 µA.
A good burner ground that matches the control ground is critical
for reliable flame sensing.
Troubleshooting Guide
Symptom Recommended Actions
1. Control does not start A. Miswired
B. 24 VAC transformer fault
C. Fuse circuit breaker fault
D. Faulty control, check LED
for fault codes
2. Thermostat on - no spark A. Miswired
B. Faulty thermostat, no
voltage at thermostat
terminal TH/W
C. Faulty control, check LED
for fault codes
3. Valve on - no spark during
TFI
A. Shorted electrode -
establish 1/8-inch gap
B. Check high voltage cable
C. Miswired
4. Spark on - valve off A. Valve coil open
B. Valve wire disconnected
C. Faulty control, check
voltage at gas valve
terminal V1
5. Flame okay during TFI - no
flame sense after TFI
A. Check electrode position
B. Check high voltage wire
C. Poor ground at burner
D. Poor flame, check flame
current
Fault Conditions
LED Indication Fault Mode
Steady On Internal Control Failure
2 Flashes Flame without call for heat
3 Flashes Ignition Lockout

Effective: October 2018
F-35-60 5
DIMENSIONS
Quick Connect Models
Figure 4. Standard Enclosure
Figure 5. 35-602 Special Small Footprint Configuration
4.875 [123.83]4.875 [123.83]
4.23 [107.37]4.23 [107.37]
1.12 [28.32]1.12 [28.32]
1.04 [26.42]1.04 [26.42]
4.00 [101.60]4.00 [101.60]
5.38 [136.53]5.38 [136.53]
1.04 [26.37]1.04 [26.37]
2.25 [57.09]2.25 [57.09]
1
FS
NC
GND
V2
TH/PWR
V1
1
FS
NC
GND
V2
TH/PWR
V1
.190±.005.190±.005
[4.82±.13][4.82±.13]
DIA (2 HOLES)DIA (2 HOLES)
.25 [6.35].25 [6.35]
2.53 [64.21]2.53 [64.21]
1.79 [45.44]1.79 [45.44]
1.27 [32.10]1.27 [32.10]
1
NC
GND
V2
TH/PWR
V1
Remote Flame Sense
(6 Pin)
Local Flame Sense
(5 Pin)
Note: All dimensions are in inches and [millimeters]

This literature is provided for informational purposes only.
KIDDE-FENWAL, INC. assumes no responsibility for the prod-
uct’s suitability for a particular application. The product must be
properly applied to work correctly. If you need more informa-
tion on this product, or if you have a particular problem or
question, contact KIDDE-FENWAL, INC., Ashland, MA 01721.
© 2018 Kidde-Fenwal Inc. P/N F-35-60 Rev AE
Fenwal Controls, Kidde-Fenwal Inc.
400 Main Street
Ashland, MA 01721
Tel: 800-FENWAL-1
Fax: [phone]
www.fenwalcontrols.com
PART NUMBER CONFIGURATION
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 Ignition 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
3 = HHVT No Enclosure
Product Designation
*
*
2 = Standard CE Approved Model
3 = Special CE Approved Model
5 = Standard
6 = Edge Connector
8 = Aftermarket Kit
9 = Special Configuration
*On CE Approved models, pre-purge
time cannot exceed inter-purge time and
automatic reset is not permitted.
A 3, 8 or 9 in this location
(i.e. 35-60 5 901 -113)
indicates a special configuration.
9XX is a sequentially assigned
part number and does not follow
the standard part numbering
configuration.
Consult Fenwal for operating
characteristics of this control.
SERIES 35-602 X X X - X X X
Special small footprint configuration - consult Fenwal
EXPORT INFORMATION (USA)
Jurisdiction: EAR
Classification: EAR99
This document contains technical data subject to the EAR.

Fenwal Controls
400 Main Street
Ashland, MA 01721
Tel. [phone]
© Kidde-Fenwal Inc. 06-237657-001 Rev AC
EU DECLARATION OF CONFORMITY
We
Company Name: Kidde-Fenwal Inc.
Postal Address: 400 Main Street
City and Post Code: Ashland, MA 01721
Tel: [phone]
Declare that the DoC is issued under sole responsibility and belongs to the following product:
Apparatus Model(s) Series 35-40, 35-53, 35-60, 35-61, 35-63, 35-608, 35-65, 35-66, 35-9X
Type: Fitting
Batch Number Date code and Revision Level Assigned per production lot, (YYWW RR)
Object of the Declaration:
Series 35-40, 12/24Vdc Direct Spark Automatic Gas Ignition Controllers
Series 35-53, 12Vdc Direct Spark Automatic Gas Ignition Controllers
Series 35-60, 35-61, 35-63, 35-608 24Vac Direct Spark Automatic Gas Ignition
Series 35-65 & 35-66 24Vac Hot Surface Automatic Gas Ignition Controllers
Series 35-9X Platform Ignition Module
SERIES 35-40 SERIES 35-53 SERIES 35-60/61/63/608 SERIES 35-65/66
SERIES 35-9X
The object of the declaration described above is in conformity within the relevant union
harmonization legislation:
Gas Appliance Regulation: (EU) 2016/426 Low Voltage Directive: 2014/35/EC
EMC Directive: 2014/30/EC Rohs 2011/65/EU
The following harmonized standards and technical specifications have been applied:
EN298:2012: Automatic Burner Control systems for Burners and appliances burning gaseous or liquid fuels.
EN13611:2007_A2:2011: Safety and control devices for Gas Burners and Gas burning appliances – General Requirements.
Name of Notified Body & Number: BSI Group, 0086, EU Type Examination Certification
Notified Body Certificate No.: Series 35-40: CE682407
Series 35-53 CE682404
Series 35-60/61/63/608 CE682405
Series 35-65/66 CE682406
Series 35-9x CE690652
Surveillance Audit Notified Body: BSI Group
For copies of the Installation Instructions and the EU DoC, got to www.fenwalcontrols.com, - Document Library - Data sheets.
Paul Finn
Kidde-Fenwal, Inc. Ashland, MA USA 01 Oct 2018 Paul Finn, Certification Engineer
Place of Issue: Date of Issue Name