Fenwal 35-70 Series User manual

THE TOTAL SOLUTION FOR
GAS IGNITION CONTROL
Fenwal offers a complete range of ignition
control including:
nIgnition Controls
nSpark and Flame Sense Electrodes
nSpark and Flame Sense Cables
nWiring harnesses
Designed, developed and manufactured by Fenwal, these components
integrate seamlessly providing maximum system performance.
Getting Started - Samples
To ensure proper system design and operation, Fenwal provides
sample ignition controls, high-voltage wires and electrodes for trial
and evaluation at no charge. To get you started quickly, Fenwal has
identified our most popular ignition controls, see Page 8. Whether
it is an individual control, complete start-up kit or customized control,
Fenwal is ready to provide your gas ignition solution.
Fenwal Ignition Development Center
Send your equipment to us and we’ll design, install and qualify a
control to meet your exact application requirements. Fully equipped
and staffed with trained technicians, the Fenwal Ignition Development
Center has proven extremely beneficial for many customers focused on
product quality and reducing time-to-market for their appliances.
FEATURES
n 3 Enclosure Configurations
n Case and Cover - dust and foreign object protection
n Open Board with Stand-Off's - saves space and cost
n Potted - protection for washdown and extreme vibration
n 2 Wiring Options – ¼” quick connects and multi-pin connector
n 2 Trial for Ignition Options – 1 and 3 try
n 4 Trial for Ignition Times – 4, 7,10 and 15 seconds
(customized timings available)
n 2 Flame Sense Options –
single spark and sense and remote sense
n 2 Reset Options – thermostat/power off and automatic
(1 hour reset)
n Diagnostic LED – 3 error codes for accurate troubleshooting
n Flame Current Test Pins – instant access to circuit
for troubleshooting
n Polarity Insensitive – reduces chance of miswiring
APPLICATIONS
n
Construction and Agriculture Heaters
n
Crop Dryers
n
Ceramic and Black Body Infrared Heaters
n
Commercial Cooking Equipment
n
Any 120 VAC Gas Burner Application under 400K BTU
The 35-70 is a 120 VAC direct spark ignition control
for controlling a gas valve and igniting LP or natural
gas fired equipment and gas burner applications that
provide a 120 VAC operating signal.
The microprocessor circuit design provides precise,
repeatable timing sequences for ignition times and
purge times (pre- and inter-) as well as multiple tries
for ignition, one hour automatic reset and flame sensing
during pre-purge. The on-board diagnostics with LED
output provide assistance with trouble-shooting to
ensure safe and efficient burner operation.
Agency Certifications
Recognized under the Component Program of Underwriters
Laboratories Inc., UL 372, UL 1998 Software
Design certified by CSA International, CAN C22.2 #199-M89
and ANSI Z21.20 Automatic Ignition Systems
FM Approved as both an ignition device and a flame safeguard.
Restricted to single try models without 1 hour reset.
TFI time must be 15 seconds or less.
35.70.02
Series 35-70, 120 VAC Direct Spark Ignition Control Page 1
www.fenwalcontrols.com 1-800-FENWAL-1
SERIES 35-70
120 VAC Microprocessor Based
Direct Spark Ignition Control
®
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Start up - Heat Mode
120 VAC is supplied to the L1 terminal either from a thermostat
or other control device. When this occurs, the control will power up
and perform a self-check routine, flash the diagnostic LED
for one second, then turn off and begin a pre-purge*, if selected.
Following the pre-purge, the gas valve is energized and sparks com-
mence until flame is detected or the Trial-for-Ignition (TFI)
period expires.
When flame is detected, the spark is shut off and the gas
valve remains energized. The thermostat and burner flame
are constantly monitored to ensure that the system is functioning
properly. When the thermostat is satisfied and the demand for
heat ends, the gas valve is de-energized immediately and the flame
is extinguished.
System Response to Flame Failures
Fenwal controls are configured with several options for managing
loss of flame.
Failure during TFI Period
SINGLE TRIAL MODEL
Should the burner fail to light or flame is not detected
during the TFI period, the gas valve is de-energized and
the control will go into lockout mode.
MULTI TRIAL MODEL
Should the burner fail to light or flame is not detected
during the first TFI period, the gas valve is de-energized
and the control will attempt two additional ignition trials
with inter-purge. If these attempts are unsuccessful,
the control will go into lockout mode.
Failure of Established Flame -Two Options
There are two methods for re-starting the burner after loss
of established flame. The Re-ignition option is the default
configuration for re-establishing flame and does not need to
be specified when ordering. If the Recycle option is desired,
please specify this when ordering so that a special part
number is assigned to the control by Fenwal.
RE-IGNITION
If the established flame signal is lost, the control responds
and begins sparking within 0.8 seconds of loss of flame.
This is considered the first re-ignition attempt. The spark will
be energized for the duration of the TFI period in
an attempt to re-light the burner. If flame is re-established,
normal operation resumes.
SINGLE TRIAL MODEL
If the burner does not light after the first re-ignition
attempt, the control will de-energize the gas valve
and go into lockout mode.
MULTI TRIAL MODEL
If the burner does not light after the first re-ignition
attempt, the inter-purge sequence is completed between
the next two attempts to re-light the burner. If the burner
fails to light after the third attempt, the control will
de-energize the gas valve and go into lockout mode.
RECYCLE
If the established flame signal is lost, the control responds
by shutting off the gas valve within 0.8 seconds.
SINGLE TRIAL MODEL
The control will begin the ignition cycle with the
pre-purge cycle, if a pre-purge cycle is programmed
into the control. Controls without pre-purge immediately
commence sparking for one TFI period. If flame is
re-established, normal operation resumes. If the burner
fails to light after the first try, the control will de-energize
the gas valve and go into lockout mode.
MULTI TRIAL MODEL
The control will begin the ignition cycle with the
inter-purge sequence and attempt three tries for ignition
including inter-purges. If flame is re-established, normal
operation resumes. If the burner fails to light after the
third try, the control will de-energize the gas valve and
go into lockout mode.
NOTE: The Recycle feature option requires a special part
number that is determined by contacting Fenwal.
Lockout Mode (On-Board Safety System)
After single or multiple attempts to light the burner have failed or
flame is not established, the control automatically enters lockout
mode. The control will not open the gas valve unless there is inter-
vention by the user or one hour has passed depending on the
model chosen. See Lockout Recovery.
Lockout Recovery - Two Options
There are two options for recovering from lockout mode.
When selecting the control, please specify one of the following meth-
ods for lockout recovery.
1. Thermostat/ Power Off Reset- requires the user to reset the thermo-
stat below ambient temperature or remove the 120 VAC power supply
for 5 seconds. The control will start the ignition sequence and attempt
to light the burner again.
2. Automatic Reset - After one hour, if the thermostat is still calling for
heat, the control will automatically start the ignition sequence and
attempt to light the burner again.
SEQUENCE OF OPERATION / FLAME RECOVERY/ SAFETY LOCKOUT
* The pre-purge and inter-purge are delays to allow gas to dissipate from the
combustion chamber. This control is not equipped with a combustion blower
relay and therefore does not initiate a fan powered purge.
Page 2 Series 35-70, 120 VAC Direct Spark Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1
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1/4”
3/16”
3/16”
3/16”
1/4”
3/16”
1/4”
Alarm
Valve Power
120 VAC (Neutral)
Valve Neutral
120 VAC Input (Hot)
Burner Ground
Remote Flame Sensor
Flame Sense Test Pins
NC
V1
L2
V2
L1
B. GND
S1*
FC+, FC-
11
10
8
7
6
2
1
Lt. Blue
Brown
White
Yellow
Black
Purple
Gray
MOUNTING AND WIRING
The 35-70 is not position sensitive and can be mounted vertically or
horizontally. The control may be mounted on any surface and fastened
with #6 sheet metal screws. Secure the control in an area that will
experience a minimum of vibration and remain below the maximum
ambient temperature of 80°C (175°F).
All connections should be made with UL approved, 105°C rated, 18
gauge, stranded, .054” thick insulated wire. Refer to the appropriate
wiring diagram when connecting the 35-70 to other components in the
system. High voltage spark cables and control wiring harnesses are
detailed on Pages 5 and 6.
SYMPTOM
Control will not start up
Gas Valve on and no spark
through TFI
Spark on and gas valve off
Flame during trial
for ignition but
no flame sense after
trial for ignition
Input Power
Input Current Drain
Gas Valve Rating
Operating Temperature
Flame Sense Voltage
Flame Sense Current
Flame Failure Response Time
Types of Gas
Spark Rate
Moisture Resistance
Size (LxWxH)
Weight
102 to 138 VAC, 50/60 Hz
350mA @ 120 VAC, 60 Hz
1.5A @ 120 VAC
-40°F to +175°F, -40°C to +80°C
120 VAC
1.0 microamp minimum
0.8 seconds maximum
Natural, LP and manufactured
Line frequency (50/60 Hz)
Conformal coated to operate to 95% R.H.
See drawings on Page 8
Integral stand-offs: 7.1 oz Potted:14.3 oz
Case and Cover: 10.1oz
RECOMMENDED ACTIONS
A. Check wiring
B. No voltage @ L1, check thermostat
C. Check fuse/circuit breaker
D. Faulty transformer on control
E. Faulty control, consult Fenwal
A. Shorted electrode - re-establish 1/8” gap
B. High voltage cable is disconnected
C. Check wiring
A. Valve coil open
B. Valve wire disconnected
C. Faulty control, check voltage @ V1
A. Check electrode position
B. Check high voltage wire and connection
C. Poor ground @ burner
D. Check flame current
E. Check flame current on control
SINGLE SPARK AND SENSE
REMOTE SENSE
TERMINAL DESCRIPTION
MULTI-PIN
CONNECTOR
P/N: AMP 1-644615-1
QUICK
CONNECT
TERMINAL
SIZE
SPECIFICATIONS
TROUBLESHOOTING GUIDE
Terminal Designations
WARNING: Operation outside specifications could result in failure of
the Fenwal product and other equipment with injury or death to people
and damage to property.
PIN
LOCATION
WIRE
COLOR
CAUTION: Label all wires prior to disconnection when servicing the control.
Wiring errors can cause improper and dangerous operation. A functional
checkout of a replacement is recommended.
LED Indication
Steady on
2 Flashes
3 Flashes
Fault Mode
Internal Control Failure
Flame Fault**
Ignition Lockout Fault
The LED will flash on for 0.2 seconds then off for 0.2 seconds to indicate
an error condition. The pause time between error codes will be 2.5 to 3.0
seconds. During power-up, the LED will light for one second and then turn
off to indicate normal operation.
ON-BOARD DIAGNOSTICS
2 Pin Header
(AMP P/N: 640383-2, Molex P/N: 26-60-2020)
PIN LAYOUT
*On controls configured for single spark and sense with quick connects, the
S1 terminal is removed. On controls configured for single spark and sense with
multi-pin connector, leave S1 wire, pin 1, color gray unconnected.
Series 35-70, 120 VAC Direct Spark Ignition Control Page 3www.fenwalcontrols.com 1-800-FENWAL-1
** May indicate either that a flame was detected during pre- or post-purge,
or that there is a flame sensing error.
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HIGH TEMP
MATERIAL
CSA rated at 2500°F
Steel Cu Flashed
Nickel Plated Steel
Nickel Plated Steel
Alumina
Alumina
Spring Steel
Kanthal APM
Kanthal APM
Kanthal APM
ACCESSORIES
Proper Electrode Location
Proper location of the electrode assembly is important for
optimum system perfromance. It is recommended that the
electrode assembly be mounted temporarily using clamps or other
suitable means to check the system 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 (10 mm)
above the base of the flame. See Figures 3a and 3b.
CAUTIONS:
1. Ceramic insulators should not be in or close to the flame.
2. Electrodes should have a gap spacing of 0.125± 0.031 inch
(3.12 ± 0.81 mm). If this spacing is not correct, the assembly
must be replaced or adjusted (see troubleshooting)
3. Exceeding the temperature limits can cause
nuisance lockouts and premature electrode failure.
4. Electrodes must be placed where they are not exposed
to the appliance user in normal operation.
Flame Sensing
Flame sensing is achieved using the principal of flame
rectification. Flame rectification relies on current passing
from ground through the flame to the sense rod. The minimum
flame current necessary to keep the system operating is
1.0 DC microamperes.
SINGLE SPARK AND SENSE
Figure 3a
REMOTE FLAME SENSE
Figure 3b
ITEM
#
1
2
3
4
5
6
7
8
9
DESCRIPTION
Mounting Bracket
1/4” Q.C. High Voltage Terminal
3/16” Q.C. Flame Sense Terminal
Spark, H.V. Ceramic Tube
Sense Electrode Ceramic Tube
Press Ring
Flame Sense Electrode
Ground Rod
Spark Electrode, High Voltage
STANDARD
MATERIAL
CSA rated at 1800°F
Steel Cu Flashed
Nickel Plated Steel
Nickel Plated Steel
L-3 Steatite
L-3 Steatite
Spring Steel
Kanthal D
Kanthal D
Kanthal D
1
2
3
4
6
7
5
8
9
TYPICAL SPARK ELECTRODE
WITH INTEGRAL REMOTE FLAME SENSE
Figure 4
FLAME CURRENT CHECK: SINGLE SPARK & SENSE AND
REMOTE SENSE
To measure flame current, disconnect the input voltage, and attach
the leads from a multi-meter with a DC microampere scale to FC+
and FC- terminals to the 35-70 flame sense test pins per Figure 4.
Reconnect the input voltage and initiate a call for heat. After spark-
ing is complete and the flame is established, the meter should read
1.0 DC microamperes or higher. If meter reads below "0" on the
scale, meter leads are reversed. Disconnect power and reconnect
meter leads for proper polarity.
+
-
Page 4 Series 35-70, 120 VAC Direct Spark Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1
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Electrode Assemblies
With over 1,000 configurations of spark electrodes and flame sense rods, Fenwal has a design for almost any application. The latest
state-of-the-art wire forming and assembly equipment is used to accurately and efficiently produce high quality electrodes that deliver
the hottest spark. The "Universal" electrodes depicted below are just a sampling of the 1,000 electrode styles available. These electrodes
are designed for on-site customization. Cut and bend these to fit your application and then send the formed electrode back for Fenwal to
detail or send us a print and we will provide you with a quote and samples.
Part Number: 22-100000-593
Part Number: 22-100001-076
Part Number: 22-100001-117
Part Number: 22-100001-052
SPARK ELECTRODE WITH INTEGRAL REMOTE FLAME SENSE ROD
SINGLE SPARK AND SENSE ELECTRODES
Series 35-70, 120 VAC Direct Spark Ignition Control Page 5
www.fenwalcontrols.com 1-800-FENWAL-1
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Electrode Assemblies continued
REMOTE SENSE
Part Number: 05-129864-6XX
Part Number: 05-129864-5XX
Part Number: 22-100001-110
Part Number: 05-129864-0XX Part Number: 05-129864-1XX
SINGLE SPARK AND SENSE
REMOTE FLAME SENSE ROD
To make your own harness select AMP connector housing P/N: 1-770849-1 and AMP housing terminal P/N: 770522-1
1/4” FEMALE Q.C. -
FULLY INSULATED
To make your own harness select AMP connector housing P/N: 1-770849-1 and AMP housing terminal P/N: 770522-1
1/4” FEMALE Q.C. -
FULLY INSULATED
Control Wire Harness
Select the proper harness based on flame sense option. Once the terminal configuration is determined, complete the part number by replac-
ing the last two digits (“XX”) with the length in inches (“L” dimension). Standard wire lengths are 12, 18, 24, 30, 36, 48, and 60 inches.
Example: 05-129864-518 = 18 inches. For other lengths, please contact Fenwal.
SPECIFICATIONS: Voltage Rating Agency Rating Temperature Rating Diameter Jacket Material
All Wires 600 V UL/CSA Listed 105°C (221°F) 18 gage stranded PVC
Gray Only 600 V UL/CSA Listed 200°C (392°F) 18 gage stranded PVC
Page 6 Series 35-70, 120 VAC Direct Spark Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1
“L” “L”
“L” “L”
Part Number: 22-100001-080
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1. SILICONE RUBBER SUPRESSION TYPE: Resistive carbon coated fiberglas core prevents spark energy radiation from interfering with
other electronic systems. Select this wire type for applications where wire lengths are less than 36” and noise is a major concern.
SPECIFICATIONS: Voltage Rating Agency Rating Temperature Rating Diameter Jacket Material
25K VDC SAE J2031 200°C (392°F) 7mm (.27”) Silicone Rubber
over Fiberglas Braid
Part Number: 05-129608-0XX Part Number: 05-129608-2XX Part Number: 05-129608-6XX
1/4” FEMALE Q.C. WITH SILICONE RUBBER BOOT
RIGHT ANGLE SPARK PLUG
WITH SILICONE RUBBER BOOT
2. SILICONE RUBBER COPPER CONDUCTOR TYPE: Low resistance copper conductor transmits maximum spark energy. Select this
type when maximum energy or longer wire lengths are required and noise is not a major concern.
SPECIFICATIONS: Voltage Rating Agency Rating Temperature Rating Diameter Jacket Material
25 KVDC UL Type 3257 250°C (482°F) 7mm (.27”) Silicone Rubber
High Voltage Ignition Wire - 3 Types
Part Number: 05-127613-2XX Part Number: 05-129865-0XX Part Number: 05-125948-0XX
Part Number: 05-129887-0XX
Delivering the 15K to 25K volts of spark energy from the ignition control to the electrode is a vital element of an ignition system.
There are 3 material options and multiple terminal configurations available. Shown are the most popular versions offered by Fenwal.
To ensure maximum spark energy, it is recommended that the ignition wires not be longer than 36”. Longer lengths are available and should
be evaluated on the appliance to determine if there is sufficient spark energy to consistently light the burner under all conditions. Once the
wire type and terminal configurations are determined, complete the part number by replacing the last two digits (“XX”)
with the length in inches (“L” dimension). Standard wire lengths are 12, 18, 24, 30, 36, 48 and 60 inches.
Example: 05-129608-018 = 18 inches. For other lengths, please contact Fenwal.
1/4” FEMALE Q.C. -
FULLY INSULATED
BOTH ENDS
1/4” FEMALE Q.C.
BOTH ENDS
RIGHT ANGLE SPARK PLUG WITH
SILICONE RUBBER BOOT
1/4” FEMALE Q.C.
3. TEFLON INSULATED TYPE: Low resistance copper conductor transmits maximum spark energy. Select this type
for applications that have tight clearances and sharp bend radii.
SPECIFICATIONS: Voltage Rating Agency Rating Temperature Rating Diameter Jacket Material
25 KVDC UL Type 1911 250°C (482°F) 2mm (.08”) Teflon
TERMINATIONS SAME AS TYPE 1
4. FLAME SENSE WIRES: Spark electrodes with integral remote sense rod, i.e. 22-100001-076, have a 3/16” male q.c..
Please choose flame sense wire 05-129866-0XX. For remote flame sense rods , i.e. 22-100001-080 choose flame sense
wire part number 05-129866-1XX.
SPECIFICATIONS: Voltage Rating Agency Rating Temperature Rating Diameter Jacket Material
600 V UL/CSA Listed 200°C (392°F) 18 gage stranded PVC
Part Number: 05-129866-0XX Part Number: 05-129866-1XX
Series 35-70, 120 VAC Direct Spark Ignition Control Page 7
www.fenwalcontrols.com 1-800-FENWAL-1
3/16”FEMALE Q.C.
FULLY INSULATED
1/4”FEMALE Q.C.
FULLY INSULATED
1/4” FEMALE Q.C. FULLY INSULATED
BOTH ENDS
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Case
l
l
l
l
Multi-
Pin
Auto
MOST COMMON CONFIGURATIONS
Fenwal offers any option variation listed in the above part number scheme along with customized configurations to meet your exact
application requirements. Because of the numerous options available, models not listed in the table below are made to order.
For quick-ship samples and quick-ship orders, please select a model from the table below.
HOW TO ORDER
Assemblies
8 = Assemblies (may consist of control, high voltage ignition wire,
electrode and harness)
Non-Standard Configurations
9 = Non Standard Configuration
A 9 in this location of the part number (i.e. 35-705 -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
Enclosure Configurations
and Wiring Options
2 = Potted Multi-Pin Connector (Figure 4)
3 = Case and Cover Multi-Pin Connector (Figure 6)
4 = Integral Stand-off’s Multi-Pin Connector (Figure 5)
5 = Case and Cover Quick Connect (Figure 3)
6 = Integral Stand-off’s Quick Connect (Figure 2)
7 = Potted Quick Connect (Figure 1)
Trial for Ignition
Time (TFI)
1 = 4 seconds
3 = 7 seconds
5 = 10 seconds
7 = 15 seconds
Pre-Purge
Time
0 = None
1 = 15 seconds
2 = 30 seconds
5 = 5 seconds
Inter-Purge
Time
0 = None
1 = 15 seconds
2 = 30 seconds
Number of Ignition Trials,
Flame Sense Method and Lock Out Reset Method
0 = 1 try, single spark and sense Thermostat / power off reset
1 = 1 try, remote sense Thermostat / power off reset
2 = 1 try, single spark and sense Automatic reset
3 = 1 try, remote sense Automatic reset
5 = 3 try, single spark and sense Thermostat / power off reset
6 = 3 try, remote sense Thermostat / power off reset
7 = 3 try, single spark and sense Automatic reset
8 = 3 try, remote sense Automatic reset
X 0 X
35 - 70 5 - X X X
400 MAIN STREET, ASHLAND, MA 01721
TEL: [phone]
FAX: [phone]
www.fenwalcontrols.com
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 35-70-02 6/20/03
or
POTTED INTEGRAL STAND-OFF
Ignition Control
Part Number
Enclosure Type Wiring Number of
Ignition Trials
Flame Sense
Method
Trial for Ignition
Time (seconds)
Lockout Reset
Method
Pre-purge Time
(seconds)
Stand
Off
Potted
l
l
Q.C.
l
l
l
l
l
l
1
l
l
l
l
3
l
l
Single
l
l
l
Remote
l
l
l
Thermostat/
Power - off
l
l
l
l
l
l
0
l
l
15
l
l
l
30 5
l
4
l
l
7
l
10
l
l
l
15
35-705700-001
35-705701-505
35-705500-001
35-705501-105
35-705505-113
35-705506-115
Figure 1 Figure 2
CASE AND COVER
Figure 3
or
0
l
l
l
l
15
l
l
30
Inter-purge
Time (seconds)
Figure 4 Figure 5 Figure 6
© 2003 Kidde-Fenwal, Inc, Printed in U.S.A. TAG
Page 8 Series 35-70, 120 VAC Direct Spark Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1
®
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