J&R MANUFACTURING ROTISSERIE Operation manual

Owner's
myriad
ROTISSERIE
OPERATIONS AND SERVICE MANUAL
J&R MANUFACTURING, INC.[phone]
4855 (Texas)
820 W. Kearney (800) 527-
4831 (All 50 States & Canada)
Suite B (972) 289-
0801 (Parts & Service)
Mesquite, TX 75149 [phone] (Fax)
820 W. Kearney [phone] (50 states & Canada)
Suite B [phone] (Parts and Service)
Mesquite, Texas 75149 [phone] (Fax)
READ AND UNDERSTAND THIS OPERATIONS AND SERVICE
MANUAL BEFORE USING THIS MACHINE. FAILURE TO
FOLLOW OPERATING INSTRUCTIONS COULD RESULT IN
PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT.
KEEP THIS MANUAL IN A SAFE LOCATION FOR
FUTURE REFERENCE
J&R MANUFACTURING [phone] (Texas)

ESURE DE SECURITE
Ne pas entreposer ni utiliser deessence ni
autres vapeurs ou liquids inflammables a
proximte de cet appareil ou de tout autre
appareil
<< ATTENTION: Le regulateur de pression fourni avec cet
appareil doit etre utillise. Ce regulateurest regle pour une
pression de sortie de 15 cm. po de colonne deau >>
SN _______________

WARNINGS!
Disposal of Ashes
Ashes should be placed in a metal container with a tight-fitting lid. The closed
container of ashes should be placed on a noncombustible floor or on the ground,
well away from all combustible materials, pending final disposal. If the ashes are
disposed of by burial in soil or otherwise locally dispersed, they should be
retained in the closed container until all cinders have thoroughly cooled.
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
Creosote – Formation and Need for Removal –
When wood is burned slowly, it produces tar and other organic vapors, which
combine with expelled moisture to form creosote. The creosote vapors condense
in the relatively cool chimney flue of a slow-burning fire. As a result, creosote
residue accumulates on the flue lining. When ignited this creosote makes an
extremely hot fire. The chimney connector and chimney should be inspected at
least twice monthly during the heating season to determine if a creosote buildup
has occurred. If creosote has accumulated it should be removed to reduce the
risk of a chimney fire.
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
Exhaust Hood Required
This unit MUST BE INSTALLED under a Class 1 exhaust hood with an approved fire suppression
system
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
DANGER-Risk of Fire or Explosion
Do not burn garbage, gasoline, drain oil or other flammable liquids
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
WARNING-Risk of Fire
Do not operate with fuel loading doors or ash removal drawers open.
Do not store fuel or other combustible material within marked
installation clearances.
Inspect and clean flues and chimney regularly
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
CAUTION-Hot Surfaces
Keep children away
Do not touch during operation

ROTISSERIE
OPERATIONS AND SERVICE
MANUAL
MANUFACTURED BY:
J & R MANUFACTURING
Rev.12-21

CONTENTS
OPERATING INSTRUCTIONS 3
INSTALLATION INSTRUCTIONS 1
PREVENTIVE MAINTENANCE 6
TROUBLESHOOTING – ROTISSERIE 7
TROUBLESHOOTING – INFRARED 8
WIRING SCHEMATIC 10
IGNITION CONTROL INSTRUCTIONS 11
GAS PILOT SAFETY VALVE INSTRUCTIONS 14
ELECTRONIC IGNITION GAS VALVES16
33
34
36
51
42
48
PARTS
INFRARED BURNERS
STAR TURNER ASSEMBLY
CHAIN DRIVE –PARTS DETAIL FOR SN 12000-12489
GEAR DRIVE –PARTS DETAIL FOR SN 12490-12699
GEAR DRIVE – PARTS DETAIL FOR SN 12722 AND UP
WARRANTY

INSTALLATION INSTRUCTIONS
SHIPPING
The Custom Rotisserie will be shipped fully assembled. The spits will be packed inside
the cooking compartment.
HANDLING
The unit can be handled with a forklift with a 6,000 pound capacity. The extra
capacity is necessary due to the size of the unit.
There is an optional drain connection on the left or right hand side of the unit. This
drain is used for draining grease and/or water and for cleaning the cooking
compartment. The unit’s drain should be piped into a floor drain.
ELECTRICAL REQUIREMENTS
OPTIONAL DRAIN CONNECTION (Not applicable to all solid fuel fired units)
GAS PIPING (Not applicable to all solid fuel fired units)
Back and sides: 0
Front: 48
From non-combustible walls:
From combustible walls:
If this appliance is to be used with casters, please note the following:
The gas connection must be made with a connector that complies with the Standard for
Connectors for Movable Gas Appliances, ANSI Z21.69: CSA 6.16, and a quick-disconnect
device that complies with the Standard for Quick-Disconnect Devices for Use With Gas
Fuel, ANSI Z21.41; CSA 6.9. Adequate means must be provided to limit the movement
of the appliance without depending on the connector and quick-disconnect device or
its associatedpiping to limit the appliance movement. Use the hole provided in the base
frame of the unit to attach a movement limitationdevice (for example, a steel cable secured
to the building structure).
The unit requires a 115 volt, 1 phase, 15 amp electrical service. A switch or circuit
breaker should be installed near the unit. It will be necessary during certain
maintenance procedures to shut off the electrical supply. At these times, it is a good
safety procedure to tag the switch to guard against someone re-energizing the
circuit. Your electrician should extend a conduit from the unit’s junction box to
a 115 volt supply in your building using a grounded circuit. Please refer to your
local electrical code for any other requirements. Connect at junction box only.
the gas supply (including a gas line supply valve) to the gas connection on the
unit. Use a UL approved pipe joint compound. Check for leaks with a soap solution
(do not use a flame). If there are no leaks, light any standing pilot burners by following
the instructions on the gas safety valve. Turn on the burners and check all piping
connections for leaks.
Connect
CLEARANCES:The installation must conform to the following min.clearances (inches):
Back and sides: With no upper enclosure panels: 48
With upper enclosure panels: 2
Front: 48
Page 1
The unit can only be installed on a non-combustible floor.

D. Exhaust hood volume should be based on the specifications from the
2009 (or later) International Mechanical Code Section 507.
VENTING INFORMATION
B. For Canopy-type commercial cooking hoods the inside edge thereof shall
overhang or extend a horizontal distance of not less than six (6) inches
beyond the edge of the cooking surface on all open sides, and the vertical
distance between the lip of the hood and the cooking surface shall not
exceed four (4) feet.
C. A grease duct serving a Type 1 Hood shall be constructed of at least 0.054
inch thick (No. 16 Manufacturer’s Standard Gauge)steel or at least
0.043inch thick stainless steel (No. 18 MSG). Duct enclosures for grease
duct shall be constructed as the Building Code requires. Duct
enclosures shall be of at least one-hour fire-resistive construction in
all buildings and shall be of 2-hour fire-resistive construction in
buildings with four or more stories.
Listed, Type 1 hoods with automatic fire
suppression systems and conform to NFPA 96 requirements.
A. Exhaust hoods should be
Page 2
In all cases, it is imperative to obtain the approval of the AHJ (Authority Having
Jurisdiction). This will typically be the mechanical inspection department of the
local municipality’s building inspection division and/or the local fire marshal.
Notes :
1. Exhaust volume should be determined by the exhaust hood
manufacturer based on their products listing and local code
requirements. States such as California, Oregon, Washington, and
Connecticut all have code driven maximum exhaust volumes for specific
equipment. For example: California mandates that solid fuel exhaust
hoods for a wall mounted application can use NO MORE than 385 cfm/lf
for solid fuel.
2. Spark arrestor type filters are required for solid fuel equipment.
3. A hood serving our solid fuel equipment must be dedicated to our
equipment only and must have its own dedicated fire protection system.

OPERATING INSTRUCTIONS
PRIOR TO COOKING
Wash and clean all spits and forks thoroughly. Wipe down the interior of the unit.
If the unit has standing pilots, verify that all pilots are lit. If not, locate the safety
valve associated with the pilot. Turn the arrow to Pilot and press down while an
assistant holds a flame to the pilot light adjacent to the burner. The button should
remain depressed at least 60 seconds to ensure lighting.
If the unit has a water pan, verify that there is at least ¼” of water in the bottom of the
cooking compartment. This will greatly simplify cleaning the unit at the end of the
day.
BUILDING A FIRE
Make sure that the exhaust hood is operating before building a fire.
Never use charcoal lighter fluid, gasoline, grease, etc. or any volatile chemicals
to start or aid the fire.
PROTECTING THE INFRARED BURNERS
If there is a solid fuel firebox under the rotisserie spits a shield is provided with the
unit. If the infrareds are not in use and there is a fire below (even if it is just
smoldering) the shield must be in place. Otherwise the infrareds will become clogged
and rendered inoperative.
LOADING AND UNLOADING THE CHICKEN
Each spit has one end that has been rounded off and one end that is hex shaped. To
install a spit, insert the rounded end of spit into the hexagonal spring loaded socket
until the opposite end of the spit can be inserted into its opposing hexagonal socket.
Make sure that each end is seated securely into its respective socket.
To unload the spits the procedure is reversed.
Never try to install or remove a spit while the rotisserie is turning. Never reach into
the rotisserie area while it is moving. Serious injury may result.
There is an on/off switch for the rotisserie on the front of the unit, which can be used
to stop the rotisseries motion so that a spit in front can be loaded or unloaded.
sure that it will not fall over the retainer grating and into the water of the cooking
For units with rear fire boxes, load the wood through the side fuel loading door making
Start the fire by using kindling or safe (low volatility) solid fire starting aids.
compartment. On some units wood is loaded below the spits from the front through the
front fuel loading door(s).
Page 3

STARTING TO COOK
Before starting to cook it is necessary to turn on either the gas control knob (for
standing pilots) or a switch where spark ignition is used.
The infrared heaters should all come on when the gas control knob is turned on.
Visually verify that all the infrared burners are burning. If not, turn the gas control
knob or the switch off. Wait 5 minutes before turning the gas back on. Verify that all
the infrared burners are burning before proceeding to cook.
WARNING: Do not use the rotisserie unless all the infrared burners are operational.
END OF THE DAY CLEANUP
At the end of the day the unit should be cleaned to remove all grease. Where
applicable this work is expedited by draining the water from the unit and cleaning
with a commercial degreaser.
If grease is allowed to build up in the unit a grease fire may occur.
Wipe or wash down the upper works of the unit as needed and at the end of the day.
However, care must be taken not to splash water or any fluid on the infrareds. They
may still be hot and this could cause a burner face to crack.
The exhaust hood should operate at all times when the burners are in use or when
wood is burning or smoldering. Ashes should be removed from the ash drawers.
Remove the wood ashes from the unit. Place wood and coals into a tightly sealed
metal container, which is stored in a safe location away from combustibles. Do not
dump ashes into a dumpster until you are sure that no embers remain (sometimes
they can remain live for several days).
Page 4

OPERATING INSTRUCTIONS
COMBO BROILER – ALL SOLID FUEL MODELS
1. Place charcoal or wood fuel carefully onto the fuel grates and/or in the
firebox. Make sure the exhaust hood is in operation. Ignite the fuel with
kindling or a commercially available solid fire starting aid. When more fuel is
required, carefully add it to the fuel bed by either raising the top (if movable)
meat grating or opening one of the fuel loading doors (if the unit is so
equipped). Only add the minimum fuel required for each cooking session (don’t
over stoke). If your unit has gas burners, turn the gas valve(s) on when needed
after checking to be sure that the pilot flames are burning.
2. Adjust the cooking grates/or fuel grates (if applicable) to a suitable position
for the type of cooking and for the state and size of the fire.
3. Keep all spits in place in the rotisserie at all times (even when empty) when
the rotisserie is turning. Keep the tension on the non-springloaded side of the
rotisserie adjusted, so that each time a spit “spoked turner” contacts the fixed
arm, it only turns 120 degrees. It should not “spring” back or forward after
separating from the arm. See Figure 1. If your rotisserie has the “star tuner”
on the same side as the compression spring, you do not have to keep all spits
in place at all times. If your rotisserie has no “star turner” it utilizes our
“Spinnin-Spitz” design. In this case a concealed chain and sprocket assembly
does all spit turning.
4. To install a spit, insert one end of the spit into the hexagonal spring loaded
socket and push against the spring’s tension until the opposite end of the spit
can be inserted into the opposing hexagonal socket. Make sure each end is
seated securely into its socket. Rotate the rotisserie to ensure that each spoked
turner properly engages the fixed arm for the first revolution of the rotisserie.
Thereafter, they will stay properly aligned as long as the tension is in
adjustment (as described in item 3 above). To remove a spit, reverse the above
procedure.
5. Remove ashes from the ash drawers daily. Discard them into a tightly
sealed metal ash bin and don’t dump stored ashes into a dumpster until you
are sure that no embers remain (sometimes they can remain live for several
days).
6. Wipe or wash down the upper works of the unit as needed and at the end of
each cooking shift.
7. Never try to install or remove a spit while the rotisserie is turning – Never
reach into the rotisserie area while it is turning – Never reach a part of your
body into the fuel area or under a movable grate. Keep anything that might
ignite away from the fire area (this especially includes clothing).
Page 5

PREVENTIVE MAINTENANCE
Inspect the spit bushings and springs for wear or fatigue and replace if necessary.
Check for refractory damage and arrange to patch if necessary. A service agency can
perform these checks and can also perform a general check at this time.
DAILY
Bearings: Lubricate the rotisserie pillow block bearings with the same grease.
Chain: Lubricate the chains with the same grease and check their tension.
Flue: Clean the exit flue thoroughly. If this flue is not kept clean the accumulations of
solids will corrode the flue, cause soot, and retard the exhaust flow through this flue.
Burners: Check the infrared burners for proper operation. They should burn with a
bright orange or red color. Clean the orifices and venturi tubes if necessary (especially
if any whistling noises are present or if there are blue or rolling flames).
If a burner face is damaged or a “popping” sound is heard, or if flames
appear anywhere except below the ceramic faces, discontinue use of the infrareds
immediately and call a service company.
MONTHLY
Keep the unit clean. Wipe off after each use and clean thoroughly at the
end of the day. Do not splash water or any cleaner on or wipe the
burners since water or a cleaner will damage the ceramic burner faces.
If applicable, remove all ashes and place in a tightly sealed metal container
away from all combustibles. Dispose of ashes only after you are certain that no live
coals remain.
If applicable, clean the pipe burner (log lighter) and ensure that no holes are
plugged. Daily removal of ashes will reduce the need to clean the pipe burner.
Clean between the springs to remove grease buildup and any food residue.
Lubricate the springs by spraying a food grade oil such as olive or vegetable oil onto
the springs.
EVERY 90 DAYS
Lubricate every bushing (associated with each spit drive-side socket) with a high
temperature (rated to 450 degrees) grease with a Teflon additive via the
grease fittingsand a cartridge type automotive grease gun. One such
grease is Super Lube (a cartridge is shipped out with each unit along with a
grease gun). Note, some unitsmanufactured between 2006 and 2010 do not have
greased bushings so no lubrication is required. Units with greased bushings will have a
lubrication access point on the front of the stainless steel guard over the drive-side
rotisserie wheel. This access point will have a pivoting cover with a note to grease
weekly.
Page 6
WEEKLY

TROUBLESHOOTING
ROTISSERIE
ROTISSERIE NOT TURNING
Is the access door completely closed? If not, a safety switch prevents the unit from
operation.
Is the Motor Running?
YES – Then check the chain connection between the motor sprocket and the upper
sprocket on the rotisserie shaft. If the chain is broken, then either repair the chain
(usually with a master link) or replace the chain. If the chain is okay, then check the
connector between the upper sprocket and the shaft. The upper sprocket is connected
or secured to the shaft with a key and a keyway with a set screw.
NO – Check the electrical supply panel for a tripped circuit breaker. If tripped, then
reset. Then check the motor overload contact assembly. This is located inside a gray
ROTISSERIE MOTION IS NOT SMOOTH
Make sure that the load on the rotisserie is balanced.
If equipped with star turners, check the tension on the star turners (see separate page
which follows). New disc springs may be required.
If equipped with a planetary gear action, check the chain tension on the individual
spits. There is an idler sprocket that can be used to take up slack in the chain.
If the motion still does not smooth out then replace the bushings on the drive side.
SPITS DO NOT SNAP INTO PLACE
Replace the compression springs.
electrical enclosure near the motor. Push the reset button to reset the motor. If the
motor still does not turn, call a service technician to troubleshoot the wiring and
the motor.
Page 7

TROUBLESHOOTING
INFRAREDS
INFRAREDS ARE PRODUCING A HIGH-PITCHED WHISTLING NOISE.
Deburr the infrared orifice with a scratch all or ice pick, or replace orifice.
INFRAREDS ARE NOT A BRIGHT ORANGE-RED COLOR
Check the ceramic face of the burner. If cracked, replace the infrared burner. Also
check to verify that the gasket that seals the infrared is in place. If not, replace.
Finally, if the holes in the ceramic appear to be clogged, blowing compressed air down
the burner’s venturi tube may clean the face.
Check gas pressure at the 1/3” plug taping in the gas manifold. For natural gas the
minimum manifold gas pressure is 5” w.c., for LP gas it is 10” w.c.
If gas pressure is OK the main burner orifice may be partially clogged. Clean with a
round toothpick so as not to damage the orifice.
A final possibility is that the burner is not receiving enough primary combustion air at
the top of the unit through the expanded metal screen or there is not enough
secondary combustion air at the burner face. Your hood installer should be
consulted.
INPUT POLARITY
If a spark is present and the gas valve opens, but the system shuts down after the trial
period, check input voltage at Terminals A (L1), normally black, and L2, normally
white, for proper polarity. Terminal A (L1) should be the hot side of the line and L2
neutral.
IMPROPER GROUNDING
If a spark is present and the gas valve opens, but the system shuts down after the trial
period, check to make sure the system is properly grounded to the burner and that the
burner is properly grounded. This is the most common – and most easily avoided –
problem you might face. Proper grounding is essential for the proof of flame safety
device. If the system is not grounded to the burner, it cannot determine the presence
of flame and will lock out. A restart will initiate the trial-for-ignition period, but the
system will continue to go into lockout and the thermal reset timer will trip.
HIGH RESISTANCE
Check all terminals to make sure good contact is made. Clean any corrosion that
might interfere with good electrical contact.
Page 8

HIGH VOLTAGE MALFUNCTION
Remove the electrode from burner.
Check the spark gap and adjust to 1/8” ± 1/32”.
Check the ceramic housing for cracks.
Check the electrode lead wires for cracks or breaks.
Check Terminals E1 and E2 for grounding (Local sensing). They should be no closer
than 1/2” from metal objects, which can cause arcing to ground. If the electrode or
electrode lead wires are faulty, replace the defective parts.
If remote sensing is used, be sure sensor wire is connected to S1, and the E2 terminal
is grounded.
VALVE MALFUNCTION
If the board is powered and there is a spark during the trial-for-ignition period, but the
valve will not open, check the valve for an open coil or other malfunctions. Also check
the voltage rating of the valve (24, 120 or 240VAC) and the B(V1), V2 voltage of the
Fenwal 05-14 being used. Use a voltage tester or voltmeter at Terminals B (V1) and
V2. The voltage here should be the same as the valve. Refer to the manufacturer’s
specifications and replace either the valve or the Fenwal 05-14 so voltage ratings are
compatible.
ERRATIC OPERATION
If the system operates properly for a while but randomly shuts down during the duty
cycle, or won’t operate during “cold” start, check the flame proving circuit with a DC
microamp meter. Typical flame current is 2-20 microamps.
If you have low or marginal flame current, it is possible to get nuisance tripping of the
thermal reset timer. If this is the case, you should relocate the electrodes or flame
sensor into the flame to increase the flame current.
Ignitors that begin with the designation 05-142 are designed to be reset by switching
the thermostat off rather than having to press the thermal reset timer button in the
event of a lockout.
If the ignitor is switched off and on several times in succession, the thermal reset
timer will trip, and it will have to be reset.
NOTE: If ignition is not achieved after the first two or three attempts, check to insure
that the other components in the system are functioning correctly.
Page 9

Page 10

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
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
Page 11

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-
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.
Page 12

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
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