UTC Fire and Security Fenwal 35-63J Series User manual

June 2011
06-237172-001 Rev AA
SERIES 35-63J
INSTALLATION INSTRUCTIONS FOR REPLACING JOHNSON CONTROLS G77X
AND OTHER MODELS WITH FENWAL SERIES 35-63J IP IGNITION CONTROL
APPLICATIONS
The Fenwal 35-63J series Intermittent Pilot Ignition Control (35-
63J) is a microprocessor based ignition control suitable for
replacing many existing intermittent pilot ignition controls from
various manufacturers.
The 35-63J is a direct form, fit, and functional replacement for
the discontinued Johnson G77x series controls. The 35-63J is
available in a number of timing configurations that match popu-
lar G77x applications providing a better solution than a univer-
sal type aftermarket control. The most common applications are
listed in “Control Cross Reference” on page 2.
The 35-63J is suitable for many types of heating applications
including commercial cooking, furnaces, boilers, and water
heaters that require intermittent pilot ignition, burner supervi-
sion through flame rectification, and safety shutoff. It is
designed for use with Natural, LP, and mixed gases used in
gas-fired appliances.
The microprocessor circuit design of the 35-63J provides pre-
cise, repeatable timing and operating sequences. High energy
spark output and excellent flame sense characteristics provide
reliable burner operation. The on-board diagnostics with LED
output make troubleshooting easy and ensure safe and efficient
operation.
FEATURES
• Safe start and full-time flame sensing
• Wide variety of prepurge and interpurge timings
• Single or three trials for ignition
• Diagnostic LED with Fenwal error codes
• Three ground terminals for ease of wiring
• Remote or local flame sense options
• Automatic 5 min or 1 hour reset after lockout options
AGENCY CERTIFICATIONS
CSA Design certified to ANSI Z21.20,
CAN/CSA C22.2 No. 199-M99
SPECIFICATIONS
Input Power Control: 18-30 VAC 50/60 Hz
(Class 2 Transformer)
Input Current Drain 200 mA @ 24 VAC with gas and
pilot relays energized (Control
only)
Main Gas Valve 2.0A max (continuous)
Pilot Gas Valve 2.0A max (continuous)
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 0.3 μA minimum
Flame Failure Response or
Reignition Time
0.8 seconds minimum
Flame Detector Self-check Rate Once per second minimum
Flame Failure Lockout Time Varies by model, 500 seconds
maximum
Types of Gas Natural, LP, or manufactured
Spark Rate Remote sense (50/60 Hz)
Local sense (25/30 Hz)
Size (LxWxH) 4.70 x 3.10 x 2.50 inches
(11.94 x 7.87 x 6.35 cm)
Moisture Resistance Conformal coated to operate non-
condensing to 95% R.H.
Tries for Ignition One or three try versions available
Trial for Ignition Periods 8, 25, 50, 85, and 120 seconds
available
Pre-purge Timings None, 4,15, or 30 seconds
available
Inter-purge Timings None, 15, 30, or 45 seconds avail-
able

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June 2011 06-237172-001 Rev AA
CONTROL CROSS REFERENCE
INSTALLATION GUIDELINES
MOUNTING AND WIRING
The 35-63J is not position sensitive and can be mounted verti-
cally or horizontally. The case may be mounted on any surface
with #6 sheet metal screws.
HIGH VOLTAGE TERMINAL CONNECTION
The Fenwal 35-63J uses a Rajah (spark plug) type HV connec-
tion which is common to most controls. If the control being
replaced does not utilize a Rajah connection, the HV spark
cable will need to be replaced or re-terminated using a Rajah
style female mating connector.
Manufacturer/ Model Number
Johnson Controls Fenwal Replacement
G770KGA-1,3 35-63J101-011
G770KHA-2 35-63J101-011
G770LGA-1,2 35-63J103-013
G770LGC-1,2,3,4,10 35-63J103-013
G770LHA-1,2 35-63J103-013
G770LHC-1 35-63J103-013
G770MGA-1,2,5 35-63J101-015
G770MHA-2 35-63J101-015
G770MGC-1,3 35-63J101-415
G770MHC-1 35-63J101-415
G770NGA-1 35-63J103-017
G770NGC-4,5,6,7 35-63J103-017
G770NHA-1 35-63J103-017
G770NHC-1 35-63J103-017
G770RHA-2 35-63J103-017
G77RJA-1 35-63J103-017
G775RGA-1,2,3 35-63J103-017
G775RHA-1,2 35-63J103-017
G775RJD-1,2,13,14,15 35-63J103-117
G776RGD-11,14 35-63J303-117
G775LHA-1
(remote flame sense)
35-63J103-013
G779LHA-1 “Universal”
(set-up for Remote flame sense)
35-63J103-013
G779LHA-1 “Universal”
(set-up for Local flame sense)
35-63J102-013
CAUTION
Label all wires prior to disconnection when
servicing or replacing controls. Wiring errors
can cause improper and dangerous
operation. A functional checkout of a
replacement control should always be
performed.
WARNING
The control must be mounted and located in
a manner which protects components from
exposure to water (dripping, condensate,
spraying, rain). Any control that has been
exposed to water must be replaced.
WARNING
All wiring must be done in accordance with
both local and national electrical code.
Wiring must be at least #18 AWG rated for
105°C or higher.
WARNING
The 35-63J uses voltages of shock hazard
potential. Wiring and initial operation must
be done by qualified service technician.
WARNING
Operation outside specifications could result
in failure of the Fenwal product and other
equipment with injury to people and
property.
Wiring Terminal Names
JCI G77x Fenwal
35-63J Description
2 THS THS Thermostat Input
1 PV PV Pilot Valve Power
3 MV MV Main Valve Power
Ground Plate _GND Valve Ground
Ground Plate GND_ Valve Ground
Ground Plate GND System Ground
BLIND BLIND No Connection
4 SENSE SENSE Remote Flame Sensor

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06-237172-001 Rev AA June 2011
ROLLOUT SWITCH
Some control applications may have a separate rollout switch
directly connected to the old ignition control. In this case, the
rollout switch (normally closed) should be connected directly to
the THS terminal on the 35-63J. Verify the rollout switch is wired
in series (downstream) with the thermostat signal. The old THS
wire should be left unconnected and insulated to prevent the
possibility of a short-circuit.
VENT DAMPER CONNECTIONS
The 35-63J does not include an integral vent-damper connec-
tor. When replacing an older control (in applications using a
vent damper) that has a standard 6-pin vent damper plug, the
vent damper wires from the plug must be re-terminated and
connected as follows:
Note: If the old control has a vent damper plug (with a
jumper between pins 2 and 3), but the heating appli-
ance has no vent damper, then ignore this section.
• To connect the Vent Damper, the wire from Pin 1 should be
connected to 24VAC Hot from the supply transformer.
• The wire from pin 2 should be connected to the Thermostat
input (THS) on the 35-63J control. This should be the only
wire attached to the THS terminal.
• The wire from Pin 4 connects directly to the 24VAC Com-
mon.
• The wire from pin 5 should be connected directly to the
Thermostat (call for heat signal) and not to the 35-63J
control.
Figure 1. Wire Sideview of Plug
Figure 2. Vent Damper Wiring Diagram
VENT DAMPER CHECKOUT
During the checkout of the new control, you must confirm the
proper operation of the vent damper as follows:
• With the system in standby (no call for heat) the vent
damper should be driven closed by the 24 VAC power.
• When the Thermostat calls for heat, the vent damper starts
to open. After the damper is fully open, the 35-63J then
sees the 24 VAC call for heat at the THS input and begins
the normal ignition sequence.
Pin # on
Damper Plug System Connection
1 Full-time 24VAC Hot
2 Call for Heat signal (from damper)
3 Fused 24 VAC (not used)
4 24VAC Common
5 24 VAC from Thermostat
6NotUsed
24 VAC Common
Full -time 24 VAC Hot
Call for Heat signal (from damper)
24 VAC from Thermostat
Fused 24 VAC (Not Used)
Not Used
4 1
5 2
6 3
Vent Damper
24 VAC
5
4
2
1
Thermostat
Pilot Gas Valve
Main Gas
Valve
Pilot
H.V.
Sense
Blind_Term
GND
_GND
GND_
THS
PV
MV
35-63J

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June 2011 06-237172-001 Rev AA
WIRING DIAGRAMS
Figure 3. Local Sense Wiring
Figure 4. Remote Sense Wiring
CHECKOUT
Test the gas control system after any service or component
changes to the appliance using the following method:
1. Perform a visual check of all piping, burners, and venting.
Check all wiring for integrity and proper electrical and
ground connections. Verify the pilot burner is properly
grounded.
2. With the gas supply and thermostat off, turn on power to
the appliance.
3. Turn the thermostat to a setting high enough to initiate a
call for heat. Verify the ignition control proceeds through
the operating sequence to a safety shutoff (lockout) condi-
tion. (The burner will not light because the gas is shut off)
4. Turn off the thermostat.
5. Turn on the gas supply, and purge the gas lines of air.
Check for gas leaks on all joints upstream of the gas valve
with a soap solution.
6. Turn the thermostat to a setting high enough to initiate a
call for heat. Verify the ignition control proceeds through
the operating sequence to a normal run (burner lit) condi-
tion. Confirm there are no gas leaks downstream of the
gas valve using a soap solution.
7. Turn the thermostat setting down below the room temper-
ature. Verify the main and pilot burner flames go out.
WARNING
Risk of Explosion or Fire
Verify there are no gas leaks by using a rich
soap and water solution on all joints and
pipe connections. Never use a match or
lighter to test for the presence of gas. Fail-
ure to test properly before operation can
lead to explosion or fire and may result in
severe injury or death.

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06-237172-001 Rev AA June 2011
SEQUENCE OF OPERATION / FLAME
RECOVERY / SAFETY LOCKOUT
START UP - HEAT MODE
When a call for heat is received from the thermostat supplying
24 volts to THS the following sequence occurs in the order
listed:
1. The control resets and then performs a self check routine,
flashing the diagnostic LED once in the first two seconds.
2. The control begins a pre-purge delay.
3. Following the pre-purge period, the control energizes the
pilot gas valve. The main gas valve remains de-energized
until the pilot flame is detected.
4. The control enables the high voltage spark output for the
trial for pilot ignition period.
5. When the control detects the presence of pilot flame dur-
ing the trial for ignition, the control terminates the sparking
process and energizes the main gas valve.
6. The thermostat and pilot burner flame are constantly mon-
itored to assure the system continues to operate properly.
7. When the thermostat is satisfied and the demand for heat
ends, both the pilot and main gas valves are de-energized
immediately.
FAILURE TO LIGHT - LOCKOUT
SINGLE TRIAL MODEL
Should the pilot burner fail to light, or if the pilot flame is not
detected during the trial for ignition period, the control performs
the following actions:
1. The control enters ignition lockout.
2. Both the pilot and main gas valves are de-energized
immediately.
3. The LED indicates the fault code for ignition lockout.
MULTI TRIAL MODEL
Should the pilot burner fail to light, or if the pilot flame is not
detected during the first trial for ignition period, the control per-
forms the following actions:
1. The pilot and main gas valves are de-energized.
2. The control then goes through an interpurge delay before
another ignition attempt.
3. The control attempts two additional ignition trials before
going into lockout and the pilot and main gas valve relays
are de-energized immediately.
4. The LED indicates the fault code for ignition lockout.
LOCKOUT RESET
Recovery from lockout requires a manual reset by either recy-
cling the thermostat or removing 24 volts for a period of 5 sec-
onds. On models with automatic reset, if the thermostat is still
calling for heat after 5 minutes the control will automatically
reset and attempt to ignite the burner.
FLAME FAILURE RESPONSE
RECYCLE MODE (STANDARD)
With "recycle after loss of flame", upon loss of pilot flame, both
the pilot and main gas valves are de-energized immediately.
After the flame recycle delay, the control attempts to relight the
pilot flame. Multi-try models allow three tries for ignition includ-
ing inter-purges. If the pilot burner relights, normal operation
resumes. If the pilot burner does not relight, the control will go
into lockout as described in “Failure to Light - Lockout” on
page 5.
RE-IGNITION MODE (OPTIONAL)
If the established pilot flame signal is lost while the burner is
operating, the control will respond within 0.8 seconds by de-
energizing the main gas valve. The control then energizes the
HV spark for the programmed TFI period in an attempt to relight
the pilot burner. If the pilot burner does not light within the TFI,
the pilot gas valve is de-energized immediately and on multi-try
models a new TFI sequence begins.
If the pilot burner does not relight, the control will lockout as pre-
viously described in “Failure to Light - Lockout” on page 5.
Multi-try models will make 2 more attempts to light the burner. If
the pilot flame is re-established, normal operation resumes.

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June 2011 06-237172-001 Rev AA
TROUBLESHOOTING
Before troubleshooting the system, check the following items:
• Verify all mechanical and electrical connections are secure
and tight.
• Verify all system wiring is correct.
• Verify there is a proper system ground. The igniter, flame
sensor, and ignition module must share a common ground
with the burner. Nuisance shutdowns are often caused by a
poor or erratic ground.
• Perform the instructions in “Checkout” on page 4, as the
first step in any troubleshooting.
• Verify that the system is powered and that the thermostat is
calling for heat.
• If the control proceeds to an error code on the red
diagnostic LED, troubleshoot per the Fault Conditions table
below:
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.
INTERNAL CONTROL FAILURE
If the control detects an error in its software or hardware, all out-
puts are turned off and the LED displays a steady ON condition.
If this condition persists after an attempt to restart then the con-
trol must be replaced.
PROPER ELECTRODE LOCATION
Proper location of the electrode assembly is important for
optimal 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.
• Ceramic insulators should not be in or close to the flame.
• Electrode assemblies should not be adjusted or disassem-
bled. Electrodes should have a gap spacing of 0.125±
0.031 inch (3.12± 0.81 mm), unless otherwise specified by
the appliance manufacturer. If this spacing is not correct,
the assembly must be replaced. Electrodes are NOT field-
adjustable.
• Exceeding the temperature limits can cause nuisance lock-
outs and premature electrode failure.
• Electrodes must be placed where they are not exposed to
the appliance user in normal operation.
WARNING
Risk of Explosion or Fire
The 35-63J ignition control cannot be ser-
viced by the user. If any control faults are
detected, the 35-63J control module must
be replaced by qualified service personnel.
Risk of explosion or fire can result if the con-
trol module has been opened or with any
attempts to repair it, and the warranty is
void.
Fault Conditions
LED
Indication Fault Mode
Off Normal Operation
2 Flashes Pilot flame without call for heat
3 Flashes Ignition Lockout
Steady On Internal Control Failure
Troubleshooting Guide
Symptom Probable Cause
1. Control
does not start
A. Mis-wired
B. 24 VAC Transformer bad
C. Fuse/Circuit breaker bad (no power)
D. Bad control, check LED for steady on
or flashing codes.
2. Thermostat
on - no spark
A. Mis-wired
B. Bad thermostat, no voltage at ther-
mostat terminal THS
C. Bad control, check LED for steady on
or flashing codes.
3. Valve on -
no spark dur-
ing TFI
A. Shorted electrode
B. Verify 1/8th inch spark gap.
C. Check high voltage cable.
4. Spark on -
valve off
A. Gas Valve coil open
B. Valve wire disconnected
C. Bad control, check voltage between
gas valve terminals PV or MV and
GND.
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

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06-237172-001 Rev AA June 2011
STANDARD PART NUMBER CONTROL CONFIGURATION
35–63 J XX X X X X–
TRIES FOR IGNITION & METHOD OF FLAME SENSE
0 = Single Try - Local Sense
1 = Single Try - Remote Sense
2 = Single Try - Local Sense with 5 Minute Automatic Reset
3 = Single Try - Remote Sense with 5 Minute Automatic Reset
5 = Three Tries - Local Sense
6 = Three Tries - Remote Sense
7 = Three Tries - Local Sense with 5 Minute Automatic Reset
8 = Three Tries - Remote Sense with 5 Minute Automatic Reset
PRE-PURGE
0 = None
1 = 15 Seconds
2 = 30 Seconds
4 = 4 Seconds
INTER-PURGE (RECYCLE DELAY)
0 = None (Single try models only)
1 = 15 Seconds
2 = 30 Seconds
3 = 45 Seconds
TRIAL FOR PILOT IGNITION
1 = 8 Seconds
3 = 25 Seconds
5 = 50 Seconds
7 = 85 Seconds
8 = 120 Seconds
ENCLOSURE
0 = Noryl Gray Enclosure
1 = Integral Stand-Offs
2 = Board Only
OPTIONS
1 = Recycle After Loss of Flame (Standard)
3 = 1 Hour Auto Reset (in place of 5 minutes)
5 = Re-Ignition After Flame Loss
9 = Special OEM Configuration
Description

Fenwal Controls, Kidde-Fenwal Inc.
A UTC Fire & Security Company
400 Main Street
Ashland, MA 01721
Tel: 800-FENWAL-1 Fax: [phone]
www.fenwalcontrols.com
06-237172-001 Rev AA ©2011 Kidde-Fenwal, Inc.
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DIMENSIONS
Figure 5. Control Dimensions with Cover