ignition control

Intermittent PilotIgnition Controls

Features– Benefits:Energy savings can be as much as 16% compared to a 2,000 BTU/hr standing pilot

Microprocessor-based– precise, repeatable

timing sequencesPolarity insensitive– eliminates the chance

of damage by miswiring2 sensing options:– single spark and sense

or remote flame sense· Quick connects

– easy installation

New fromFenwal

· 2 reset options:– by thermostat power off, or– automatic after 1 hour2 packaging options:– enclosed, or

uncovered with standoffsOn-board diagnostics with LED output and flame current test pins– quick troubleshooting– assurance of safe and

efficient operationCustom prepurge and interpurge timingsMultiple trials for ignitionSoftware conforms to UL 1998 requirementsCSA Certified, CE Approved

35-63series

24 VAC

®

The 35-73 is a 120 VAC intermittent pilot ignition control with a two-stage ignitionprocess. After a call for heat fromthe thermostat, the control firstlights and verifies the pilot andthen energizes the main gas valve to light the main burner.Applications for this productinclude commercial cooking,HVAC, infrared heaters and a variety of 120 VAC gas burnerapplications under 400K BTU.

Features– Benefits:Energy savings can be as much as 16% compared to a 2,000 BTU/hr standing pilotMicroprocessor-based– precise, repeatable

timing sequencesPolarity insensitive– eliminates the chance

of damage by miswiring2 sensing options:– single spark and sense

or remote flame sense· Quick connects

– easy installation

· 2 reset options:– by thermostat power off, or– automatic after 1 hour2 packaging options:– potted or uncovered

with standoffsOn-board diagnostics withLED output and flame current test pins– quick troubleshootingSoftware conforms to UL 1998 requirementsCSA Certified, CE Approved

35-73 series

120 VAC

Fenwal Controls

400 Main Street

Ashland, MA 01721

508. 881.2000

www.fenwalcontrols.com

The 35-63 is a 24 VAC intermittent pilot ignition control with a two-stage ignitionprocess. After a call for heat fromthe thermostat, the control firstlights and verifies the pilot andthen energizes the main gas valve to light the main burner.Applications include commercialcooking equipment, commercialgas furnaces, unit heaters andwater heater applications.

Courtesy of Steven Engineering, Inc.-230 Ryan Way, South San Francisco, CA 94080-6370-Main Office: (650) 588-9200-Outside Local Area: (800) 258-9200-www.stevenengineering.com

SERIES 35-5212 VDC Microprocessor-Based Direct Spark Ignition Control

FEATURES� Multiple tries� Custom TFI, prepurge and interpurge timings� Potted Module available� Local Sensing� Safe Start� Software conforms to UL 1998 requirements

APPLICATIONS

� RV gas furnaces� RV water heaters � Construction equipment� Other similar appliances

DESCRIPTIONThe model 35-52 is a 12 VDC Microprocessor Based Direct Spark Ignition Control designed for use in many types of heating applications. The control utilizes a microprocessorto continually and safely monitor, analyze and control the properoperation of the gas burner. Value added features such as safestart and multiple ignition tries highlight the control’s benefits.

Agency Certifications

Design certified to UL372, File MH8817

Design certified to ANSI Z21.20-1997 and CAN/CSAC22.2 No. 199-M89 - Report # C2180012

®

35.52.02

Input Power Control: 9.5 to 15 VDC from a storagebattery or full wave rectified unfiltered 50/60 Hz AC

Input Current Drain 200 mA @ 12 VDC, gas valve relay energized(control only)

Gas Valve Rating 1.0A @ 12 VDC

Operating Temperature -40°F to +167°F-40°C to +75°C

Flame Sensitivity 0.7µA minimum

Flame Failure 0.8 seconds maximumResponse Time

Types of Gases Natural, LP, or manufactured

Spark Rate 10 sparks per second

Size (LxWxH) 4.00 x 2.30 x 1.50 inches10.16 x 5.84 x 3.81 cm

Weight 3.0 ounces nominal (85 grams), uncovered version

Enclosure Uncovered with integralstandoffs or Potted Module

Moisture Resistance Conformal coated to operate to 95% (Uncovered) 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 5.0, 7.0, 10.0, or 25.0 seconds available

Prepurge & Interpurge None, 15 or 25 seconds depending on Timings model. Without prepurge there is a

1 second safe start delay before the first try for ignition

SPECIFICATIONS

Series 35-52, 12 VDC Microprocessor-Based DSI Control Page 1www.fenwalcontrols.com 1-800-FENWAL-1


MOUNTING AND WIRING

The control 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. WARNING: The control uses voltages ofshock hazard potential. Wiring and initial operation must be doneby a qualified service technician.

The control must be secured in an area that will experience a minimum of vibration and remain below the maximum operatingtemperature of 167°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 control to other components in the system.

System Wiring Diagram

SEQUENCE OF OPERATION / FLAMERECOVERY/ SAFETY LOCKOUT

Heat ModeWhen a call for heat is received from the thermostat supplying 12volts to PWR, the control will reset, perform a self check routine, anda prepurge delay begins. Following the pre-purge period the gas valveis energized and sparks commence for the trial for ignition period.

When flame is detected during the trial for ignition, sparks are shut off immediately and the gas valve remains energized. The thermostatand main burner flame are constantly monitored to assure the systemcontinues 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

MULTI TRIAL MODELShould the main burner fail to light, or flame is not detected during the trial for ignition period, the control will go into lockout.The valve will be turned off immediately.

SINGLE TRIAL MODELShould 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 delaybefore another ignition attempt. The control will attempt two additional ignition trials before going into lockout and the valverelay will be de-energized immediately.

Recovery from lockout requires a manual reset by either resetting the thermostat or removing 12 volts for a period of 5 seconds.

Flame Failure - Re-Ignition

If the established flame signal is lost while the burner is 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 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 operationresumes.

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.

Terminal Designations

TERMINAL DESCRIPTION TERMINAL PWR Power 6 Pin Edge ConnectorGND Ground 6 Pin Edge ConnectorNC NC Contact 6 Pin Edge ConnectorVI Gas Valve 6 Pin Edge Connector

WARNING:Operation outside specifications could cause failure of the Fenwalproduct and other equipment resulting in property damage, personalinjury or even death from fire, explosion, and/or toxic gases.

Page 2 Series 35-52, 12 VDC Microprocessor-Based DSI Control www.fenwalcontrols.com 1-800-FENWAL-1


POWER ELECTRODE LOCATION

Proper location of the electrode assembly is important for optimum system performance. It is recommended that electrodeassemblies be mounted temporarily using clamps or other suitable means so that thesystem can be checked before permanently mounting the assembly. The electrode assemblyshould be located so that the tips are inside the flame envelopeand about 1/2 inch above the base of the flame. See Figure 3.

FLAME CURRENT CHECK

Flame current is the current which passes through the flame fromthe sensor to ground to complete the primary safety circuit. Theminimum flame current necessary to keep the system from lockoutis 0.7µA microamps. To measure flame current, DISCONNECTINPUT VOLTAGE, then insert a 0-50µA DC meter and capacitor inseries with the sensor electrode and wire per Figure 5. Metershould read 0.7µA or higher while flame is established. If meterreads below “0” on scale, meter leads are reversed. Disconnectpower and reconnect meter leads for proper polarity.Ignitor Location

Figure 3

System Flame Current Measurement Circuit

Figure 5

Fenwal Accessory Items

CAUTIONS:

1. Ceramic insulators should not be in or close to the flame to avoid overheating.

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).

3. Exceeding temperature limits can cause nuisance lockouts and premature electrode failure.

TROUBLESHOOTING GUIDE

SYMPTOM1. Dead

2. Valve on, no spark

3. Spark on, no valve

4. Flame okay during TFI, no flame sense (after TFI)

RECOMMENDED ACTIONSA. MiswiredB. Transformer badC. Fuse/Circuit breaker badD. No voltage @ PWRE. Bad control

A. Shorted electrodeB. Open HV cableC. MiswiredD. Bad control

A. Valve coil openB. Open valve wireC. Bad control

(check voltage between V1 & GND)

A. Bad electrodeB. Bad HV wireC. Poor ground at burnerD. Bad control (check flame current)

CAUTIONS:When monitoring flame current, use a 1.5µF \by pass capacitor to protect the meter from damage. See Figure 5.

PART NUMBER DESCRIPTION22-100001-021 Spark Electrode05-127694-448 Edge Connect Wire Harness05125948-1XX Ignition Cable - Quick Connects

on both ends *XX is length of cable in inches

05-125608-6XX* Supression Cable - Quick Connects on both ends *XX is length of cable in inches

05-080224-004 12 VDC Gas Igntion Field Tester

Series 35-52, 12 VDC Microprocessor-Based DSI Control Page 3www.fenwalcontrols.com 1-800-FENWAL-1


A 9 in this location of the part number(i.e. 35-52 5 -113) identifies this configuration as a non-standarddesign. The part number does not follow the part numbering system.The 9XX is a sequential part numberassigned by Fenwal.

Consult factory for operating characteristics of this control.

Trial for Ignition Time (TFI)1 = 5 seconds3 = 7 seconds5 = 10 seconds7 = 25 seconds

Inter-Purge0 = None1 = 15 seconds3 = 25 seconds

Pre-Purge Time0 = None1 = 15 seconds3 = 25 seconds

Number of Ignition Trials and Flame Sense Method 0 = 1 try, Local Sense5 = 3 try, Local Sense

Enclosure5 = Integral Standoffs

Configurations

5 = Standard Model, Recycle on Flame Loss8 = Aftermarket Kit (may consist of control,

high voltage ignition wire, electrode and harness)9 = Non Standard Configuration*

DIMENSIONS

HIGH VOLTAGE TERMINAL(1/4” QC)

6 POSITIONEDGE-

CONNECTOR

Special Options� Potted module� Recycle after flame loss

400 MAIN STREET, ASHLAND, MA 01721TEL: (508) 881-2000 FAX: (508) 881-6729www.fenwalcontrols.com

© 2003 Kidde-Fenwal Printed in U.S.A. TAG

These instructions do not purport to cover all the details or variations in the equipmentdescribed, nor do they provide for every possible contingency to be met in connection withinstallation, operation and maintenance. All specifications are subject to change without notice.Should further information be desired or should particular problems arise which are notcovered sufficiently for the purchaser’s purposes, the matter should be referred toKIDDE-FENWAL, Inc., Ashland, Massachusetts.

P/N 35.52.02 6/20/03

®

Page 4 Series 35-52, 12 VDC Microprocessor-Based DSI Control www.fenwalcontrols.com 1-800-FENWAL-1

901

CONTROL CONFIGURATION

DescriptionX X X35 - 52 5 - X X X

* Non-Standard Configurations


FEATURESOptional combustion blower relay with selectable postpurgeSystem diagnostic LED indicatorMultiple tries for ignition (TFI)Automatic reset 1 hour after lockout Custom TFI, prepurge and interpurge timingsRemote or local flame sensingSoftware conforms to UL 1998 requirementsSafe startHeavy conformal coating

APPLICATIONSRecreational Vehicles (including boats/marine)Infrared Paving Repair Equipment Outdoor Torches and LanternsBattery Powered Furnaces & Appliances

DESCRIPTIONThe Model 35-53 is a 12 VDC Microprocessor Based Direct Spark Ignition Control designed for use in all types of heatingapplications such as RV gas furnaces and other similar appliances.The control utilizes a microprocessor to continually and safely monitor, analyze and control the proper operation of the gas burner. Value added features such as combustion blower control,LED diagnostic output, and multiple ignition tries highlight the control's benefits. Combustion blower versions are fully backwardcompatible with all previous Fenwal 12VDC controls and competitive models. The control determines the unit configurationat the start of the heating sequence and disables the blower func-tion if not required, allowing one part to address all service or OEMneeds.


Design certified to UL372, File MH8817

Design certified to ANSI Z21.20-1998 and CAN/CSA C22.2No. 199-M89 - Report # C2180012

SERIES 35-5312 VDC Microprocessor Based Direct Spark Ignition Control

Series 35-53, 12 VDC DSI Control Page 1www.fenwalcontrols.com 1-800-FENWAL-1

®

35.53.02

INPUT VOLTAGES

Input Power

Input Current Drain

Gas Valve Rating

Combustion Blower RatingOperating Temperatue

Flame Sensitivity

Flame Failure Response Time

Types of Gases

Spark Rate

Size (LxWxH)

Enclosure

Moisture Resistance

Tries for Ignition

Trial for Ignition Period

Prepurge & Interpurge Timings

Postpurge Timings

DESCRIPTION

Control: 9.0 to 15 VDC from a storage batteryor full wave rectified unfiltered 50/60 Hz AC300 mA @ 12 VDC, combustion blower andgas valve relays energized (control only)

1.0A @ 12 VDC

20.0A @ 12 VDC-40°F to +176°F ( -40°C to +80°C)

0.7µA minimum

0.8 seconds maximum

Natural, LP, or manufactured

16 sparks per second

4.25 x 3.25 x 1.80 inches10.80 x 8.25 x 4.57 cm

Uncovered with integral standoffsor optional coverConformal coated to operate to 95% R.H.Always avoid direct exposure to water

One or three try versions available

5.0, 7.0, 10.0, or 25.0 seconds available

None, 15 or 25 seconds depending on model. Without prepurge there is a 1 second start-up delay.

Selectable 45, 90, 130, 150 seconds

SPECIFICATIONS



WARNING: Operation outside specifications could result in failure of the Fenwal product and other equipment with injury or death topeople and damage to property.

CAUTION: Label all wires prior to disconnection when servicingthe control. Wiring errors can cause improper and dangerous operation. A functional checkout of a replacement is recommended.

EDGE CONNECT TERMINALS

Page 2 Series 35-53, 12 VDC DSI Control www.fenwalcontrols.com 1-800-FENWAL-1

WARNING: The 35-53 uses voltages of shock hazard potential. Wiring and initial operation must be done by a qualified service technician.

TROUBLESHOOTING GUIDESYMPTOM1. Dead

2. Thermostat on - No blower output

3. Airflow Switch input okay but no trial for ignitionafter purge delay



6. Flame okay during TFI, no flame sense (after TFI)

RECOMMENDED ACTIONSA. MiswiredB. Transformer/battery badC. Fuse/circuit breaker badD. No voltage @ PWR or AIRE. Bad controlA. Miswired or failed air flow switchB. Bad thermostat no voltage @ THC. Bad controlA. MiswiredB. Bad control

A. Shorted electrodeB. Open HV cableC. MiswiredD. Bad controlA. Valve coil openB. Open valve wireC. Bad control

(check voltage between V1 & GND)A. Bad electrodeB. Bad HV wireC. Poor ground at burnerD. Bad control (check flame current)

Start up - Heat ModeWhen a call for heat is received from the thermostat supplying 12 volts toTH, the control will reset, perform a self check routine and verify no flameexists (safe start). After verifying the airflow switch input is open, theBlower is energized and the airflow switch contacts close starting the pre-purge delay. After the pre-purge delay the gas valve is energized andsparks commence for the trial for ignition period.

When flame is detected during the trial for ignition, sparking stops and the gas valve remains energized. The thermostat, airflow switch and mainburner flame are constantly monitored to assure that the system continuesto operate properly. When the thermostat is satisfied and the demand for heat ends, the main valve is de-energized immediately, and after thepost-purge period the blower is turned off.

Failure to Light - LockoutMULTI TRIAL MODELShould the main burner fail to light, or if the 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 ignitionattempt. The control will attempt two additional ignition trials before going into lockout after which the valve relay will remain de-energized and the blower will turn off after a five minute delay.

SINGLE TRIAL MODELShould the main burner fail to light, or flame is not detected duringthe trial for ignition period, the control will go into lockout. The valve

will be turned off immediately and the blower will turn off after a five minute delay.

Recovery from lockout requires a manual reset by either resetting the thermostat or removing 12 volt power 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 FailureIf the established flame signal is lost while the burner is operating, the control will respond within 0.8 seconds. On re-cycle models, the gas valve is de-energized and a new interpurge and TFI sequence will begin. On optional re-ignition models, the gas valve will stay energized and the HV spark will be energized for a trial for ignition period to 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.

Combustion Airflow ProblemsIf the airflow signal is lost, or the hi-limit opens during heat mode, the gas valve is immediately de-energized and the blower stays on. If the switch closes again, a normal ignition sequence will resume. If not and this condition persists for more than five minutes, the control will enter lockout with the blower off.

SEQUENCE OF OPERATION / FLAMERECOVERY/ SAFETY LOCKOUT

MOUNTING AND WIRINGThe 35-53 is not position sensitive and can be mounted vertically or horizontally. The control may be mounted on any surface and fastenedwith #6 sheet metal screws. Secure the control in an area that will experi-ence a minimum of vibration and remain below the maximum ambient tem-perature of 80°C (175°F).

All connections should be made with UL approved, 105°C rated, 18 gauge stranded wire with .054” miniumum insulation thickness, .054”thick insulated wire. Refer to the appropriate wiring diagram when con-necting the 35-53 to other components in the system. High voltage sparkcables and control wiring harnesses are detailed on Page 3.

/SEN

SE

TERMINAL DESCRIPTION TERMINAL TYPE LOC-ATION

WIRECOLOR

PWR * + 12 VDC Power 3/16” Q.C. Terminal - -

BLO * Blower 1/4” Q.C. Terminal - -

AIR * Airflow Switch 6 Pin Edge Connector 1 Red

TH * Thermostat 6 Pin Edge Connector 2 OrangeNC NC Contact 6 Pin Edge Connector 3 BlueV1 Gas Valve 6 Pin Edge Connector 4 Brown

Local Sense Unused 5 -Remote Sense 6 Pin Edge Connector 5 Black

GND Ground 6 Pin Edge Connector 6 Yellow

TEST/SENSE

* Air terminal provides +12 VDC power for models withoutblower control DWR, BLO and TH terminals are not used.


Series 35-53, 12 VDC DSI Control Page 3www.fenwalcontrols.com 1-800-FENWAL-1

CONTROL WIRE HARNESSSelect the proper harness based on the 35-53 control's termination connection. Once the terminal configuration is 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 and 48 inches. Example 05-129927-024 = 24 inches. For other lengths,please contact Fenwal

Part Number: 05-129927-0XX

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-artwire forming and assembly equipment is used to accurately and efficientlyproduce 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 sendthe formed electrode back for Fenwal to detail or send us a print and will provide you with a quote and samples.

ELECTRODE ASSEMBLIES

Part Number: 22-100001-117

Part Number: 22-100001-052


REMOTE FLAME SENSE RODS

Part Number: 22-100001-080

Part Number: 22-100001-110

Local Sense Models

Remote Sense Models


REMOTE SENSE WITH BLOWER RELAY REMOTE SENSE WITHOUT BLOWER RELAY

WIRING DIAGRAMS

INTEGRAL STAND-OFFFigure 2:

DIMENSIONS

CASE AND COVERFigure 1:


Trial for Ignition Time (TFI)1 = 5 seconds 3 = 7 seconds5 = 10 seconds 7 = 25 secondsInter-Purge Time0 = None 1 = 15 seconds3 = 25 secondsPre-Purge Time0 = None 3 = 25 seconds1 = 15 secondsNumber of Ignition Trials and Flame Sense Method 0 = 1 try, local sense1 = 1 try, remote sense 5 = 3 tries, local sense6 = 3 tries, remote senseEnclosure Configurations and Wiring Options0 = Covered Module5 = Integral Standoffs

DescriptionX X X35 - 53 X - X X XBlower Relay0 = None5 = Combustion Blower RelayConfigurations

5 = Standard Model, Recycle on Flame Loss8 = Aftermarket Kit (may consist of control, high voltage ignition wire,electrode and harness)9 = Non Standard Configuration

A 9 in this location of the part number (i.e. 35-53 5 -113)identifies this configuration as a non-standard design. Thepart 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.



These instructions do not purport to cover all the details or variations in the equipment described, nor do theyprovide for every possible contingency to be met in connection with installation, operation and maintenance.All specifications are subject to change without notice. Should further information be desired or shouldparticular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter shouldbe referred to KIDDE-FENWAL, Inc., Ashland, Massachusetts.

P/N 35.53.02 3/21/05

®

Page 4 Series 35-53, 12 VDC DSI Control www.fenwalcontrols.com 1-800-FENWAL-1

901

LOCAL SENSE WITH BLOWER RELAY LOCAL SENSE WITHOUT BLOWER RELAY


SERIES 35-6024 VAC Microprocessor-Based Direct Spark Ignition Control

FEATURES24 VAC microprocessor based DSI controlSystem diagnostic LED

Automatic reset 1 hour after lockout*Multiple triesCustom prepurge and interpurge timings**Remote or local sensingFlame sense test pins

DESCRIPTIONThe Series 35-60 is a 24 VAC Microprocessor Based Direst SparkIgnition 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. Valueadded 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 andgas valve relay energized(control only)

Gas Valve Rating 2.0A @ 24 VACOperating Temperature -40ºF to +160ºF

-40ºC to +71ºCFlame Sensitivity .7µA minimumFlame Failure Response Time 0.8 seconds maximum


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 retardent plastic

lntegral standoffs optionalMoisture Resistance Conformal coated to operate to 95% R.H.

Care must be taken to protect module fromdirect 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 availablePrepurge & Interpurge None, 15, or 30 seconds depending on model.

Without prepurge there is a 3.5 second delay before the first try for ignition.

Edge Connect Version Optional Edge connect model for replacement product

SPECIFICATIONS

APPLICATIONSGas FurnacesBoilersWater HeatersCommercial Cooking and other Similar Appliances

®

35.60.03

35-60, 24 VAC Direct Spark Ignition Control Page 1www.fenwalcontrols.com 1-800-FENWAL-1


Software conforms to UL 1998 requirements

Design certified to ANSI Z21.20, and EN 298CAN/ CSA C22.2 No. 199-M89


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 duringa fault condition. The pause between fault codes is 3 seconds.

MOUNTING AND WIRINGThe Series 35-60 is not position sensitive and can be mounted vertically or horizontally. The case may be mounted on any surfacewith #6 sheet metal screws.

The control must be secured in an area that will experience a minimum of vibration and remain below the maximum operatingtemperature 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 ModeWhen a call for heat is received from the thermostat supplying 24 volts to TH/W, the control will reset, perform a self check routine, flash the diagnostic LED for up to four seconds, and a prepurge 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.


SINGLE TRIAL MODELShould 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 MODELShould 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.


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 operating, 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, gas valve is de-energized and controller 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 prepurge delay will begin with pre

Error ModeInternal Control FailureFlame with No Call for heatIgnition Lockout

LED IndicationSteady on2 flashes3 flashes

TERMINAL DESIGNATIONSThermostat InputSystem GroundValve PowerValve GroundAlarmRemote Flame Sensor

TH/WGNDV1V2NCS1

Page 2 35-60, 24 VAC Direct Spark Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1

SEQUENCE OF OPERATION / FLAME RECOVERY/ SAFETY LOCKOUT

WARNING: All wiring must be done in accordance with both localand national electrical code.

WARNING: The Series35-60 uses voltages of shock hazard potential. Wiring and initial operation must be done by a qualified service technician.


WARNING: Operation outside specifications could result in failure of the Fenwal product and other equipment with injury to people and property.

High Voltage CableFenwal Part Number 05-129608-624 Suppression Cable (or equivalent)must be used for proper operation of control.


SYMPTOM RECOMMENDED ACTIONS1. Dead A. Miswired

B. Transformer badC. Fuse/Circuit breaker badD. Bad control (check LED for steady on)

2. Thermostat on- no spark A. MiswiredB. Bad thermostat no

voltage@ terminal W

3. Valve on, no spark A. Shorted electrodeB. Open HV cableC. MiswiredD. Bad control

4. Spark on, no valve A. Valve coil openB. Open valve wireC. Bad control (check voltage

between V1 & V2)

5. Flame okay during TFI, A. Bad electrodeno flame sense (after TFI) B. Bad S1 or HV wire

C. Poor ground at burnerD. Poor flame (check flame current)

FLAME SENSOR CURRENT CHECK

Series 35-60

SERVICE CHECKSFlame current is the current which passes through the flame fromthe sensor to ground. The minimum flame current necessary tokeep the system from lockout is .7 microamps. To measure flamecurrent, connect ananalog DC microammeter to the FC-FC+ terminals per figure. Meter should read .7 uA or higher. If themeter reads below “0” on scale, meter leads are reversed.Disconnect power and reconnect meter leads for proper polarity.

PROPER ELECTRODE LOCATIONProper location of the electrode assembly is important for optimumsystem performance. It is recommended that electrode assembly bemounted temporarily using clamps or other suitable means so thatthe system can be checked before permanently mounting theassembly. The electrode assembly should be located so that thetips are inside the flame envelope and about 1/2 inch (1 cm) abovethe 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 mustbe 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

35-60, 24 VAC Direct Spark Ignition Control Page 3www.fenwalcontrols.com 1-800-FENWAL-1


SERIES 35-605 X X X -X X XTrial for Ignition1= 4 Seconds3= 7 Seconds5= 10 Seconds7= 15 Seconds

Inter-Purge0= None (Single Try Only)1= 15 Seconds2= 30 Seconds

Pre-Purge0= None1= 15 Seconds2= 30 Seconds

Tries for Igntion and Methods for Flame Sense0= Single Try - Local Sense1= Single Try - Remote Sense5= Three Tries - Local Sense6= Three Tries - Remote Sense

Enclosure0= Noryl Gray Enclosure1= Integral Standoffs2= HHVT w/Enclosure Edge Connect Version Only)3= HHVT No Enclosure (Edge Connect Version Only)5= Mate-N-Lock W/Enclosure6= Mate-N-Lock W/Standoffs

Product Designation 2= Standard European Version3= Special European Version*5= Standard6= Edge Connector8= Aftermarket Kit9= Non-Standard**

DIMENSIONS

Special OptionsNo CoverNo DiagnosticsRecycle after Loss of Flame

*Special European VersionDiagnostics and test pins are not available on European version.

**Non-Standard Configurations

9 = Non Standard Configuration

A 9 in this location of the part number (i.e. 35-60 5 -113) identifies this configuration as a non-standard design. The part number does not follow the part numbering system. The 9XX is a sequentialpart number assigned by Fenwal. Consult factory for operating characteristics of thiscontrol.

901


Page 4 35-60, 24 VAC Direct Spark Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1

FENWAL400 MAIN STREET, ASHLAND, MA 01721TEL: (508) 881-2000 FAX: (508) 881-6729www.fenwalcontrols.com

© 2003 Fenwal Printed in U.S.A. TAG

These instructions do not purport to cover all the details or variations in the equipmentdescribed, nor do they provide for every possible contingency to be met in connection withinstallation, operation and maintenance. All specifications subject to change without notice.Should further information be desired or should particular problems arise which are not coveredsufficiently for the purchaser’s purposes, the matter should be referred to KIDDE-FENWAL,Inc., Ashland, Massachusetts.

P/N 35.60.03 11/10/03

®


SERIES 35-6124 VAC Microprocessor Based Direct SparkIgnition Control with Combustion Blower Relay

FEATURES� 24 VAC Microprocessor Based DSI Control� System Diagnostic LED� Automatic reset 1 hour after lockout� Custom prepurge and interpurge timings� Flame sense test pins

DESCRIPTIONThe Series 35-61 is a 24 VAC Microprocessor Based Direct SparkIgnition Control designed for use in all types of heating applications. The control utilizes a microprocessor to continually and safely monitor, analyze and control the proper operation of the gas burner.Value added features such as combustion blower control, LEDdiagnostics, automatic one hour reset, and flame current test pinshighlight the controls benefits.

®

35.61.02

Input Power Control: 18-30 VAC 50/60 Hz (Class 2 Transformer)Line: 120/240 VAC(L1, IND contacts only)

Input Current Drain 300 mA @ 24 VAC, combustionblower relay and gas valve relay energized (control only)

Gas Valve Rating 2.0A @ 24 VAC

Combustion Blower 3.0 FLA @ 120 VAC (6.0 LRA)Rating 1.5 FLA @ 240 VAC (3.0 LRA)

1/4 H.P. Motor

Operating Temperature -40ºF to +160ºF-40ºC to +71ºC

Flame Sensitivity .7µA minimum

Spark Rate Line frequency (50/60 sparks/ sec.)

Enclosure Gray (Noryl N-190) fireretardent plastic

Moisture Resistance Conformal coated to operateto 95% R.H. Care must betaken to protect module fromdirect exposure to water

Tries for Ignition One or three try versionsavailable

Trial for Ignition Periods 4.0,7.0,10.0, or 15.0 secondsavailable

Prepurge & Interpurge None, 15, or 30 secondsdepending on model. Withoutprepurge there is a 3.5second delay before the firsttry for ignition.

SPECIFICATIONS

APPLICATIONS� Gas Furnaces� Boilers� Water Heaters� Other Similar Appliances


Software conforms to UL 1998 requirements

Design certified to ANSI Z21.20, CAN/CSA C22.2 No. 199-M89

35-61, 24 VAC DSI Control with Blower Relay Page 1www.fenwalcontrols.com 1-800-FENWAL-1


MOUNTING AND WIRINGThe Series 35-61 is not position sensitive and can be mounted vertically or horizontally. The case may be mounted on any surfacewith #6 sheet metal screws. All wiring must be done in accordancewith both local and national electrical code.

Power Up / Stand ByUpon applying power (24 volts) to 24VAC/R, 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 ModeWhen a call for heat is received from the thermostat supplying 24 volts to TH/W, the control will check the pressure switch for normally open contacts. The combustion blower is then energized and once th pressure switch contacts close, a prepurge delay begins. Following the pre-purge period the gas valve is energized and sparks commence for the trial forignition period.

When flame is detected during the trial for ignition, sparks are shutoff immediately and the gas valve combustion blower remains energized. The thermostat, pressure switch, 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 immed-iately, the control senses the loss of flame signal and initiates a post-purge period (optional) before de-energizing the combustion blower.


SINGLE TRIAL MODELShould the main burner fail to light, or flame is not detected during the trial for ignition period, the control will go into lockout. The valve will be turned off immediately, and the combustion blower will be turned off following the optional post purge period.

MULTI TRIAL MODELMulti-try Models will attempt two additional ignition trials before going into lockout. The valve relay will be de-energized immed-iately, and the combustion blower will be turned off following the optional post purge period.

Recovery from lockout requires a manual reset by either resetting the thermostat or removing 24 volts for aperiod 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-IgnitionIf the established flame signal is lost while the burner is operating, 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 lock out as noted above in “Failure to Light”. If flame is re-established, normal operation resumes.

Combustion Airflow Problems - Lockout

Combustion air flow is continually monitored during an ignition sequence by the air flow switch (PSW). If during the initial call forheat the pressure contacts are in the closed position for 30 seconds without an output to the Combustion Blower, an air flow fault will be declared and the control will remain in this mode withthe combustion blower off.

If the air flow switch remains open for more than 30 seconds after the combustion blower output (L1 & IND) is energized, an air flow fault will be declared and the control will stay in this mode with the combustion blower on, waiting for the air flow switch to close.

When proper air flow is detected from the air flow switch input (PSW) the control begins the prepurge period with a normal ignition sequence following.

If the air flow signal is lost while the burner is firing, the control will immediately de-energize the gas valve and the combustion blower will remain on. If the call for heat remains, the control will wait for proper air flow to return. If proper air flow is not detected after 30 seconds an air flow fault signal will be declared. If properair flow is detected at any time, a normal sequence will begin with the prepurge period.

Flame Fault

If at any time the main valve fails to close completely and maintains a flame, the full time flame sense cir cuit will detectit and energize the combustion blower. Should the main valve later close completely removing the flame signal, the combustion blower will power off following the optional post purge period.

Fault Conditions

The LED will flash on for 1/4 second, then off for 1/4 second duringa fault condition. The pause between fault codes is 3 seconds.

SEQUENCE OF OPERATION / FLAME RECOVERY / SAFETY LOCKOUT

Error ModeInternal Control FailureAir Flow FaultFlame with No Call for heatIgnition Lockout

LED IndicationSteady on1 flash2 flashes3 flashes

Page 2 35-61, 24 VAC DSI Control with Blower Relay www.fenwalcontrols.com 1-800-FENWAL-1

WARNING: The Series 35-61 uses voltages of shock hazard potential. Wiring and initial operation must be done by a qualified service tech-nician. The control must be secured in an area that will experience a minimum of vibration and remain below the operating temperature of160ºF. All connections should be made with UL approved 105ºC rated 18 gauge, stranded, .054 thick insulated wire. Refer to wire diagram whenconnecting the Series 35-61 to other components in the system.


PROPER ELECTRODE LOCATIONProper location of the electrode assembly is important for optimumsystem performance. It is recommended that electrode assembly bemounted temporarily using clamps or other suitable means so thatthe system can be checked before permanently mounting theassembly. The electrode assembly should be located so that thetips are inside the flame envelope and about 1/2 inch (1 cm) abovethe base of the flame. See Figure 3 below.

TERMINAL DESIGNATIONS

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.


Electrodes should have a gap spacing of 0.125± 0.031 in (3.12± 0.81 mm). If this spacing is not correct, the assemblymust be replaced. Electrodes are NOT field adjustable.


WARNING:Operation outside specifications could result in failure of the Fenwalproduct and other equipment with injury to people and property.

TROUBLESHOOTING GUIDESYMPTOM RECOMMEDED ACTIONS


SERVICE CHECKSFlame current is the current which passes through the flame from the sensor to ground. The minimum flame current necessary to keepthe system from lockout is .7 microamps. To measure flame current,connect ananalog DC microammeter to the FC-FC+ terminals perfigure. 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.

24 VAC Supply to ProcessorThermostat InputPressure Switch InputSystem GroundValve PowerValve Ground120/240 VAC Input (Hot)Inducer Blower OutputAlarmRemote Flame Sensor

24VAC/RTH/WPS/WGNDV1V2L1

INDNCS1

1. Dead

2. Thermostat on - no blower output

3. Pressure switchinput okay but no Trial-for-Ignition after purge delay



6. Flame ok during TFI,no flame sense (after TFI

A. MiswiredB. Transformer badC. Fuse/Circuit breaker badD. Bad control (check LED for

steady on)A. MiswiredB. Bad thermostat no voltage @ terminal WC. Bad control (check LED for steady on)A. Miswired (check psw terminal voltage)B. Flame sense problem(existing flame-check

LED -2 flashes)C. Bad control (check voltage between L1 & IND)A. Shorted electrodeB. Open HV cableC. Bad controlA. Valve coil openB. Open valve wireC. Bad control (check voltage between V1 & V2)A. Bad electrodeB. Bad S1 or HV wireC. Poor ground at burnerD. Poor flame (check flame current)

Series 35-61 Module

35-61, 24 VAC DSI Control with Blower Relay Page 3www.fenwalcontrols.com 1-800-FENWAL-1

Figure 3


SERIES 35-61 X X X - X X XTrial for Ignition Time (TFI)1= 4 Seconds3= 7 Seconds5= 10 Seconds7= 15 Seconds

Inter-PurgeTime

0= NONE (SINGLE TRY MODELS ONLY)1= 15 Seconds2= 30 Seconds

Pre-Purge Time0= NONE1= 15 Seconds2= 30 Seconds

Number of Ignition Tries and Methods of Flame Sensing0= Single Try - Local Sense1= Single Try - Remote Sense5= Three Tries - Local Sense6= Three Tries - Remote Sense

Inducer Control0= No Post-Purge (w/input only)1= No Post-Purge2= 30 Second Post-Purge3= 60 Second Post-Purge

Product Designation5= Standard8= Aftermartet Kit (may consist of control,

high voltage ignition wire,electrode and harness)9= *Non-Standard Configuration

Special Options� No Cover� No Diagnostics� Recycle after Loss of Flame

DIMENSIONS


Description

Page 4 35-61, 24 VAC DSI Control with Blower Relay www.fenwalcontrols.com 1-800-FENWAL-1

*Non-Standard Configurations


A 9 in this location of the part number (i.e. 35-61 5 -113) identifies this configuration as a non-standard design. The part number does not follow the part numbering system. The 9XX is a sequentialpart number assigned by Fenwal. Consult factory for operating characteristics of this control.

901




P/N 35.61.02 6/20/03

®


SERIES 35-6224 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

DESCRIPTIONThe Series 35-62 is a 24 VAC Microprocessor Based Dual PointDirect 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 hourreset, 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 andgas 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 secondsResponse Time


Spark Rate Line frequency(50/60 sparks/sec)

Enclosure Gray (Noryl N-190) fireretardant plastic integralstandoffs optional

Moisture Resistance Conformal coated to operateto 95% R.H. Care must betaken to protect module fromdirect exposure to water

Tries for Ignition One or three try versionsavailable

Trial for Ignition Periods 4.0,7.0,10.0,15.0 or 21.0seconds available

Prepurge & Interpurge None,15, or 30 secondsdepending on model.

APPLICATIONS

Gas furnaces Boilers Water heaters Commercial cooking Other similar appliances

SPECIFICATIONS

Series 35-62, 24 VAC Dual Point DSI Control Page 1www.fenwalcontrols.com 1-800-FENWAL-1


Design certified to ANSI Z21.20-1993 andCAN/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.



SEQUENCE OF OPERATION / FLAMERECOVERY / SAFETY LOCKOUTPower 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 isde-energized immediately.


SINGLE TRIAL MODELShould either burner fail to light, or flame is not detected during thetrial for ignition period, the control will go into lockout and the valvewill be turned of immediately.MULTI TRIAL MODELShould 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.


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 maintains 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 theFenwal product and other equipment with injury to people and product.

TERMINAL DESIGNATIONSTH/W THERMOSTAT INPUTGND SYSTEM GROUNDV1 VALVE POWERV2 VALVE GROUNDNC ALARMS1 REMOTE FLAME SENSORS2 REMOTE FLAME SENSOR

FC1 FLAME CURRENT TEST PINFC2 FLAME CURRENT TEST PIN24V 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 areathat will experience a minimum of vibration and remain below themaximum 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 electrodeassembly be mounted temporarily using clamps or other suitablemeans so that the system can be checked before permanentlymounting the assembly. The electrode assembly should be located so that the tips are inside the flame envelope and about1/2 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 INDICATIONInternal Control Failure Steady onFlame with No Call for Heat 2 flashesIgnition Lockout 3 flashes

FAULT CONDITIONS

The LED will flash on for 1/4 seconds, then off for 1/4 secondduring a fault condition, the pause between fault codes is 3 seconds.


SYMPTOMS RECOMMENDED ACTIONS1.Dead A. Miswired

B. Transformer badC. Fuse/Circuit breaker badD. Bad control (check LED for steady on)

2. Thermostat on- no spark A. MiswiredB. Bad t’stat no voltage@ terminal W

3. Valve on, no spark A. Shorted electrodeB. Open HV cableC. MiswiredD. Bad control

4. Spark on, no valve A. Valve coil openB. Open valve wireC. 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 wireC. Poor ground at burnerD. Poor flame (check flame current)

6. Flame with no call for heat A. Stuck valve (check LED for 2 flashes)

FLAME CURRENT CHECKFlame current is the current which passes through the flame from the sensor to ground. The minimum flame current necessary to keepthe 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” onscale, meter leads are reversed. Disconnect power and reconnectmeter 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 LOCATIONFigure 3

WIRING DIAGRAM

Series 35-62, 24 VAC Dual Point DSI Control Page 3www.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 timeSingle or multiple tries for ignitionTrial for ignition timeInter-purge timeThe Series 35-62 is only available with remote flame sensing


SERIES 35-625 X X X - X X X Description

DIMENSIONS




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


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 sequentialpart number assigned by Fenwal. Consult factory for operating characteristics of this control.

901


SERIES 35-6324 VAC Microprocessor Based Intermittent Pilot Ignition Control

FEATURES

System diagnostic LEDAutomatic reset 1 hour after lockout optionSafe Start and full time flame sensingRemote flame sense optionFlame sense test pinsCustom prepurge and interpurge timingsMultiple trials for ignition

APPLICATIONS

Commercial cooking equipment Commercial gas furnaces Unit heaters Water heaters

DESCRIPTIONThe 35-63 is a 24 VAC intermittent pilot ignition control. The microprocessor circuit design provides precise, repeatable timing and operating sequences. The on-board diagnostics with LED output provide assistance with troubleshooting to ensure safe and efficient operation.


Component recognized system. Software conforms to UL1998 requirements

Design certified to ANSI Z21.20, CAN/CSA C22.2 No. 199-M99

CE Approved to EN298 (Pending)

®

35.63.01

SPECIFICATIONS

Series 35-63, 24 VAC Intermittent Pilot Igntion Control Page 1www.fenwalcontrols.com 1-800-FENWAL-1

Input Power Control: 18-30 VAC 50/60 Hz (Class 2 Transformer)

Input Current Drain 300 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 -40ºF to +176ºF (-40ºC to +80ºC)

Storage Temperature -40ºF to +185ºF (-40ºC to +85ºC)

Flame Sensitivity 0.7 uA minimum

Flame FailureResponse Time 0.8 seconds maximum


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)

Moisture ResistanceConformal coated to operate non-condensing 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 IgnitionPeriods 15, 30, 60, 90 seconds available

Prepurge Timings None, 15, 30 45 seconds available

Interpurge Timings None, 15, 30 seconds, or 4 minutes available


MOUNTING AND WIRING

CAUTIONS: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.

SEQUENCE OF OPERATION / FLAMERECOVERY / SAFETY LOCKOUTStart Up - Heat Mode

When a call for heat is received from the thermostat supplying 24 voltsto TH/W, the control will reset, perform a self check routine, flash thediagnostic LED once in the first two seconds, and a pre-purge delaybegins. Following the pre-purge period, the pilot gas valve is energizedand sparks commence for the trial for ignition period. The main gasvalve is de-energized until the pilot flame is detected.

When the pilot flame is detected during the trial for ignition, the sparking process is shutoff immediately and the main gas valve is energized. The thermostat and pilot 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 pilot and main valves are de-energized immediately.


SINGLE TRIAL MODELShould the pilot burner fail to light or the pilot flame is not detected during the trial for ignition period, the control will go into lockout.The valves are de-energized immediately. The LED will indicate the code for ignition lockout.

MULTI TRIAL MODELShould the pilot burner fail to light, or pilot flame is not detected during the first trial for ignition period, the pilot and main gas valves are de-energized. The control then goes through an interpurge delay before another ignition attempt. The control will attempt two additional ignition trials before going into lockout and the valve relays 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. On models with automatic reset, if the thermostat is still calling for heat after one hourthe control will automatically reset and attempt to ignite the burner.

FLAME FAILURE- RE-IGNITION MODEIf the established pilot flame signal is lost while the burner is operating, the control will respond within 1 second by de-energizing the main gas valve and energizing the HV spark in an attempt to relight the pilot burner for the programmed TFI period. 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 previously described in the "Failure to Light - Lockout" section. Multi-try models will make 2 more attempts to light the burner. If pilot flame is re-established, normal operation resumes.

FLAME FAILURE- RECYCLE MODEThe option "recycle after loss of flame" may be selected as a special feature. With this option, upon loss of pilot flame, gas valves are de-energized and the controller proceeds to interpurge before attempting to relight the pilot flame. Multi-try models will allow three tries for ignition including inter-purges. If pilot burner relights, normal operation resumes, if pilot burner does not relight, control will go into lockout as described in "failure to light".

TABLE 1 - FAULT CONDITIONS

LED INDICATION FAULT MODE2 Flashes Pilot flame without call for heat3 Flashes Igntion LockoutSteady On Internal Control Failure

Page 2 Series 35-63, 24 VAC Intermittent Pilot Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1

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 outputs are turned off and the LED displays a steady ON condition.

TERMINAL DESCRIPTION QUICK CONNECT

TH/W Thermostat Input 1/4 inch

PV1 Pilot Valve Power 3/16 inch

MV1 Main Valve Power 1/4 inch

V2 Valve Ground 3/16 inch

GND System Ground 3/16 inch

S1 Remote Flame Sensor (Optional) 1/4 inch

HV High Voltage Output 1/4 inch

WARNING:Operation outside specifications could result in failure of the Fenwalproduct and other equipment with injury to people and property

WARNING:All wiring must be done in accordance with both local and national electrical code.

WARNING:The Series 35-63 uses voltages of shock hazard potential. Wiring and initial operation must be done by a qualified service technician.

The Series 35-63 is not position sensitive and can bemounted vertically or horizontally. The case may be mounted on any surface with #6 sheet metal screws.

TABLE 2 - WIRING TERMINALS


LOCAL SENSEFigure 1

Series 35-63, 24 VAC Intermittent Pilot Ignition Control Page 3www.fenwalcontrols.com 1-800-FENWAL-1

REMOTE SENSEFigure 2

Proper Electrode Location Proper location of the electrode assembly is important for optimumsystem 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 mountingthe assembly. The electrode assembly should be located so thatthe tips are inside the flame envelope and about 1/2 inch (1 cm)above the base of the flame. See Figure 3 below.

SYMPTOM RECOMMENDED ACTIONS

1. Control does not start A. MiswiredB. 24 VAC Transformer badC. Fuse/Circuit breaker badD. Bad control, check

LED for steady on or flashing code (see Table 1)

2. Thermostat on - no spark A. MiswiredB. Bad thermostat, no voltage

at thermostat terminal WC. Bad control, check LED

for steady on or flashing codes

3. Valve on - no spark during TFI

A. Shorted electrode - establish 1/8th inch gap

B. Check high voltage cableC. Miswired

4. Spark on - valve off A. Valve coil openB. Valve wire disconnectedC. Bad control, check voltage at

gas valve terminals PV1 or MV1 and V2

5. Flame okay during TFI - no flame sense after TFI

A. Check electrode positionB. Check high voltage wireC. Poor ground at burnerD. Poor flame, check flame current

Flame Sensor Current CheckFlame current is the current that passes through the flamefrom the sensor to ground. The minimum flame current necessary to keep the system from lockout is 0.7 microamps. To measure flame current, connect analog DC microammeter to the FC-, FC+ terminals per figure. Meter shouldread 0.7 microamps or higher. If the meter reads below "0"on scale, meter leads are reversed. Disconnect power andreconnect meter leads for proper polarity.


Electrodes should have a gap spacing of 0.125± 0.031 in (3.12± 0.81 mm), unless otherwise specified by the appliancemanufacturer. If this spacing is not correct, the assembly must be replaced. Electrodes are NOT field adjustable.



Figure 4

Figure 3

TABLE 3 - TROUBLESHOOTING GUIDE

/w

/w


DIMENSIONS




P/N 35.63.01 3/21/05

®

Page 4 Series 35-63, 24 VAC Intermittent Pilot Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1


Enclosure Configurations and Wiring Options0 = Noryl Gray Enclosure1 = Integral Standoffs2 = Board Only


Inter-Purge Time0 = None (Single Try

Models Only)1 = 15 seconds2 = 30 seconds3 = 45 seconds4 = 4 minutes

Number of Ignition Trials,Flame Sense Method and Lock Out Reset Method0 = Single Try, Local Sense Thermostat / power off reset1 = Single Try, Remote Sense Thermostat / power off reset2 = Single Try, Local Sense Automatic Reset3 = Single Try, Remote Sense Automatic Reset5 = Three Tries, Local Sense Thermostat / power off reset6 = Three Tries, Remote Sense Thermostat / power off reset7 = Three Tries, Local Sense Automatic Reset8 = Three Tries, Remote Sense Automatic Reset

X X X35 - 63 0 - X X X

Pre-Purge Time0 = None1 = 15 seconds2 = 30 seconds3 = 45 seconds4 = 4 minutes

Options1 = Recycle after Loss of Flame5 = Re-ignition after Loss of Flame9 = Special OEM Configuration

Figure 5:Uncovered with standoffs

Figure 6:With cover


FEATURES� Safe start and full-time flame sensing� 120/240 field selectable line voltage for use

with 120 VAC ignitor option� 24/120/240 VAC hot surface ignitor models available� Blower control and airflow switch monitoring option� Diagnostic LED� Multiple trials for ignition� Automatic reset option� Local or remote flame sensing� Flame current test pins� Dual speed blower option for LoNox applications� Fail-safe gas valve control (35-66 only)� CE models available

APPLICATIONS� Pool and spa heaters� Gas furnaces� Water heaters� Any 24 VAC gas burner application under 400K BTU

DESCRIPTIONThe Series 35-65 and 35-66 controls are designed to perform manygas-fired 24 VAC appliance functions in a single control, resulting in lower system cost. This series monitors the demand for heat, controls the combustion blower, monitors proper airflow, ignites andmaintains the flame during heating, and provides diagnostic support.The on-board diagnostics with LED output provide assistance withtroubleshooting and ensures safe and efficient burner operation.

The microprocessor circuit design provides precise, repeatable timing sequences for ignition and purge times (pre-, inter-, and post-)as well as multiple tries for ignition. The optional 120/240 VAC fieldselectable line voltage capability provides additional field service efficiency and lower inventory costs.


Design certified by CSA International to CAN C22.2 #199-M89 and ANSI Z21.20 for Automatic Ignition Systems, including UL1998 software review. FM approvaland CE pending on selected models.

SERIES 35-65 & 35-6624 VAC Microprocessor Based HSI Control with 120/240 Field Selectable Line Voltage Capability

www.fenwalcontrols.com 1-800-FENWAL-1 Series 35-65, -66 HSI Control with 120/240 Field Selectable Line Voltage Page 1

35-65,-66.02

INPUT POWER

Voltage

Current

OUTPUT (CONTACT RATINGS)

Gas Valve

Combustion Blower

(Model 35-66 only)

Hot Surface Element

OPERATING TEMPERATURE

FLAME SENSITIVITY

TYPES OF GAS

IGNITOR

ENCLOSURE

MOISTURE RESISTANCE

SIZE WITH ENCLOSURE

WEIGHT

Control: 18 to 30 VAC 50/60 Hz(Class 2 Transformer)

Line: 24, 120 or 240 VAC (L1 & L2 only)

300 mA max @ 24 VAC with blower and gasvalve relay energized (Control only)

2.0A max @ 24 VAC

3.0 FLA max @ 120 VAC (1/4 hp) 1.5 FLA max @ 240 VAC (1/4 hp)

5.0A max @ 120/240 VAC

-40ºF to +176ºF (-40ºC to +80ºC)

0.7 microamps minimum


24 VAC, 120 VAC, or 240 VAC

mini-ignitors and silicon carbide ignitors

depending on model

Gray (Noryl N-190)

Conformal coated to operate non-condensing

to 95% R.H. Care must be taken to protect

module from direct exposure to water

See Figures on Page 7

8 oz including cover

SPECIFICATIONS

®


POWER-UP / STANDBY

35-66 with Full-Time Power (R Models only):Upon applying power (24 volts) to the R terminal, the control willreset, perform a self-check routine, flash the diagnostic LED for asecond and enter the thermostat scan state.

CALL FOR HEAT

35-65 & 35-66 without Full-Time Power (R Terminal):When a call for heat is received from the thermostat supplying 24volts to the W terminal, the control will perform a self-check routine,flash the diagnostic LED for a second and begin the safety timingsequence. After an optional "pre-purge" period, the hot surface ignitor is energized for a heat-up period, followed by the gas valve for the "trial for ignition" (TFI) period.

Call for Heat - 35-66 Models:In addition to the self-check routine described above, when a call for heat is received from the thermostat supplying 24 volts to the W terminal, the control will check the pressure switch for normallyopen contacts. The combustion blower is then energized and, once the pressure switch contacts close, an optional "pre-purge"period begins. After pre-purge, the hot surface ignitor is energizedfor a heat-up period, followed by the gas valve for the "trial for ignition" (TFI) period.

Ignition - 35-65 Models:When the flame is detected during the TFI period, the ignitor is de-activated and the gas valve remain energized. The thermostatand main burner flame are constantly monitored to assure that thesystem operates properly. When the thermostat is satisfied and thedemand for heat ends, the gas valve is immediately de-energized.

Ignition - 35-66 Models:When the flame is detected during the TFI period, the ignitor is de-activated and the gas valve and combustion blower remains on. The thermostat, pressure switch and main burner flame are constantly monitored to assure that the system operates properly.When the thermostat is satisfied and the demand for heat ends, the gas valve is immediately de-energized, the control senses theloss of flame signal and initiates an optional "post-purge" periodbefore de-energizing the combustion blower.

FAILURE TO LIGHT - LOCKOUT

Single Try Models:Should the main burner fail to light or the flame is not detected during the TFI period, the control will lockout. The gas valve will be turned off immediately. For 35-66 models, the combustionblower will be turned off following an optional "post-purge" period. With the 1 hour reset option, if the thermostat is still calling for heat, the control will automatically reset and attempt a new TFI sequence after one hour.

FAILURE TO LIGHT - LOCKOUT (continued):

Multi-try Models:Should the main burner fail to light or the flame is not detected during the first TFI period, the gas valve is de-energized and the control performs an optional "inter-purge" delay before attempting another TFI period. The control will attempt 2 additional TFI's periods before locking out. In lockout, the gas valve will be turned off immediately. For 35-66 models, the combustion blower will be turned off following an optional"post-purge" period. With the 1 hour reset option, if the thermostat is still calling for heat, the control will automatically reset and attempt a new TFI sequence after one hour.

Lockout Recovery:Recovery from lockout requires a manual reset by either resetting the thermostat or by removing the 24 volts for a period of 5 seconds.

Loss of Flame - Re-igntion:If the established flame signal is lost while the burner is operating,the control will respond within 0.8 seconds. The gas valve is de-energized immediately and a new TFI sequence begins. If the burner does not relight, the control will lockout as previouslydescribed in the "Failure to Light - Lockout" section. Multi-try models will make 2 more attempts to light the burner. If flame is re-established, normal operation resumes.

COMBUSTION AIR FLOW PROBLEMS

35-66 Models only:1. Combustion airflow is continually monitored during the ignitionsequence by the pressure switch (PSW terminal). If the pressureswitch contacts remain closed for 30 seconds at the start of the ignition sequence without an output signal to the combustion blower,an airflow fault is signaled and the control will remain in this faultmode with the combustion blower off. If the pressure switch contacts later open while there is still a call for heat, the controlbegins the pre-purge period followed by a normal TFI sequence.

2. If the pressure switch contacts remain open for more than 30seconds after the combustion blower output (F1 and F2 terminals) is energized, an airflow fault is signaled and the control will remainin this fault mode with the combustion blower on. If proper airflowis later detected from the pressure switch input (PSW terminal), the control begins the pre-purge period followed by a normal TFI sequence.

3. If the airflow signal is lost while the burner is firing, the control will immediately de-energize the gas valve and an airflow fault issignaled. The combustion blower will remain on for the post-purgeperiod and the control continues to monitor the PSW input waitingfor airflow to return. If proper airflow is detected during the post-purge period, a normal TFI sequence begins preceded by any pre-purge period. If not, the control will enter a lockout condition with the combustion blower off.


Page 2 Series 35-65, -66 HSI Control with 120/240 Field Selectable Line Voltage www.fenwalcontrols.com 1-800-FENWAL-1Courtesy of Steven Engineering, Inc.-230 Ryan Way, South San Francisco, CA 94080-6370-Main Office: (650) 588-9200-Outside Local Area: (800) 258-9200-www.stevenengineering.com

FAULT MODE

Internal Control Failure

Airflow Fault (35-66 models)

Erroneous Flame Signal

Lockout

MOUNTING AND WIRINGThe 35-65 and 35-66 models are not position sensitive and can bemounted vertically or horizontally. The control may be mounted onany surface and fastened with #6 sheet metal screws. Secure thecontrol in an area that will experience a minimum of vibration andremain below the maximum ambient temperature of 80°C (175ºF).

All connections should be made with UL approved, 105°C (221°F)rated 18 gauge, stranded wire with .054" minimum insulation.Refer to wiring diagram on Pages 5 or 6 when connecting the control to other components in the system.

SYMPTOM

1. Does not start

2. Thermostat on - no ignition

3. Valve on - no ignitor

4. Ignitor on - no valve

5. Flame okay during TFI -

no flame sense after TFI

LED INDICATION

Steady On

1 Flash

2 Flashes

3 Flashes

RECOMMENDED ACTIONS

A. Miswired

B. 24 VAC Transformer bad

C. Fuse/Circuit breaker bad

D. Bad control, check LED for steady

on or flashing codes

A. Miswired

B. Bad thermostat, no voltage

at thermostat terminal W

C. Failed ignitor

A. Defective ignitor

B. Miswired

C. Bad control, check voltage at ignitor

A. Valve coil open

B. Open valve wire

C. Bad control, check voltage at gas

valve terminal

A. Bad ignitor

B. Bad S1 wire

C. Poor ground at burner

D. Poor flame, check flame currentTERMINAL DESCRIPTION TERMINATION24 VAC supply to processor

(optional full time power)

Thermostat Input

120/240VAC Input (Hot)

Neutral

System Ground

Gas Valve

Remote Flame Sense

120 VAC Ignitor

Ignitor

240 VAC Ignitor

Flame Current Test Pins

35-66 Models Only

Blower Output

Blower Output

Pressure Switch Input

R

W

L1

L2

GND

GV

FS

S1 - 120

S2

S1 - 240

FC+ & FC-

F1

F2

PSW

¼ in. Quick Connect



(or 5-pin Mate-N-Loc)




3/16 in. Quick Connect














�! CAUTION: Label all wires prior to disconnection when servicing the control.Wiring errors can cause improper and dangerous operation.

�! CAUTION: Operation outside specifications could result in failure of the Fenwal product and other equipment with injury or death to peopleand damage to property. Service to this product should only be performed by a qualified technician.

Flame Fault (Full Time Power Models Only):During normal sequence if an erroneous flame signal occurs, due to the gas valve failing to close completely, the controller will energize the combustion blower. Should the gas valve later close completely and the flame signal be removed, the combustion blower will power off following an optional post-purge period.

FAULT CONDITIONS


Flame current is the current that passes through the flame from the sensor to ground. The minimum flame current necessary tokeep the system from lockout is 1 microamp. To measure flamecurrent, connect an analog DC microammeter to the FC terminalsper diagram below. Meter should read 1 microamp or higher. If meter reads below "0" on scale, meter leads are reversed.Disconnect power and reconnect meter leads for proper polarity

www.fenwalcontrols.com 1-800-FENWAL-1 Series 35-65, -66 HSI Control with 120/240 Field Selectable Line Voltage Page 3Courtesy of Steven Engineering, Inc.-230 Ryan Way, South San Francisco, CA 94080-6370-Main Office: (650) 588-9200-Outside Local Area: (800) 258-9200-www.stevenengineering.com

CONTROL WIRE HARNESS

Select the proper harness based on the 35-65 and 35-66 control's termination connection on back page. Once the terminal configuration isdetermined, complete the part number by replacing the last two digits ("XX") with the length in inches ("l" dimension). Standard wire lengthsare 12, 18, 24 30, 36 and 48 inches. Example 05-129845-018 = 18 inches. For other lengths, please contact Fenwal

Page 4 Series 35-65, -66 HSI Control with 120/240 Field Selectable Line Voltage www.fenwalcontrols.com 1-800-FENWAL-1


Part Number: 05-128981-XXX

Part Number: 22-100001-080

Part Number: 22-100001-110


Custom configurationsare available

Custom configurationsare available



LOCAL FLAME SENSING(SENSING THROUGH HOT SURFACE IGNITOR)

WIRING DIAGRAMS - SERIES 35-65

REMOTE FLAME SENSING(SENSING THROUGH INDEPENDENT FLAME ROD)

35-65

35-65


WIRING DIAGRAMS - SERIES 35-66


35-66

35-66

LOCAL FLAME SENSING(SENSING THROUGH HOT SURFACE IGNITOR)

REMOTE FLAME SENSING(SENSING THROUGH INDEPENDENT FLAME ROD)



DIMENSIONS - SERIES 35-65, 35-66

FRONT AND SIDE VIEWS




These instructions do not purport to cover all the details or variations in the equipmentdescribed, nor do they provide for every possible contingency to be met in connection withinstallation, operation and maintenance. All specifications are subject to change without notice.Should further information be desired or should particular problems arise which are not coveredsufficiently for the purchaser’s purposes, the matter should be referred to KIDDE-FENWAL,Inc., Ashland, Massachusetts.

P/N 35.65, 66.02 6/20/03

®



- X X XTrail For Ignition1 = 4 Seconds3 = 7 Seconds5 = 10 Seconds7 = 15 Seconds

Inter-Purge0 = None1 = 15 Seconds2 = 30 Seconds

Pre-Purge0 = None1 = 15 Seconds2 = 30 Seconds

Tries For Igntion0 = Single Try without Automatic Reset1 = Single Try with 1 Hour Automatic Reset5 = Three Tries without Automatic Reset6 = Three Tries with 1 Hour Automatic Reset

35-65 Only (No Blower Relay) Termination For Models0 = ALL Q.C. Terminals Without Full Time Power (W Only)1 = Mate-N-Loc (5 Pos.) with Q.C. Terminals without Full Time Power (W Only)2 = Mate-N-Loc (2 Pos.) with Q.C. Terminals without Full Time Power (W Only)5 = ALL Q.C. Terminals with Full Time Power (R Terminal)6 = Mate-N-Loc (5 Pos.) with Q.C. Terminals with Full Time Power (R Terminal)

35-66 Only (With Blower Relay) Termination and Post Purge for Models0 = No Post-Purge All Q.C. Terminals without Full Time POWER (W Only)1 = No Post-Purge All Q.C. Terminals with Full Time POWER (R Terminal)2 = 30 Second Post-Purge All Q.C. Terminals *3 = 60 Second Post-Purge All Q.C. Terminals *5 = No Post-Purge Mate-N-Loc (5 Pos.) with Q.C. Terminals without Full Time Power (W Only)6 = No Post-Purge Mate-N-Loc (5 Pos.) with Q.C. Terminals with Full Time Power (R Terminal)7 = 30 Second Post-Purge Mate-N-Loc (5 Pos.) with Q.C. Terminals *8 = 60 Second Post-Purge Mate-N-Loc (5 Pos.) with Q.C. Terminals *

* Post-Purge Requires Full Time Power (R)

Ignitor Options0 = 120/240 VAC Mini-Ignitor (6 Second Heat-Up)2 = 24 VAC Mini-Ignitor (4 Second Heat-Up) CE Approced5 = 120/240 VAC Ignitor (20 Second Heat-Up)6 = 120/240 VAC Ignitor (40 Second Heat-Up)7 = 24 VAC Mini-Ignitor (4 Second Heat-Up)

Custom Designs - Standard Part Number Configuration Does Not Apply3 = Customer Special Featrues CE Approved (Refer To Drawing)8 = Aftermarket Kit (Refer To Drawing)9 = Customer Special Features (Refer To Drawing)

Optional Features1 = Dual Speed Blower (35-66 Model Only)2 = 120/240 Field Selectable Line Voltage3 = Dual Speed BLOWER AND 120/240 Field Selectable Line Voltage (35-66 Model Only) 5 = None

Model5 = Without Combustion Blower Relay (Model 35-65)6 = With Combustion Blower Relay (Model 35-66)

35 - 6X X X X X Description


FEATURES� Proven pressure switch input� Combustion fan output� 24/120/240 VAC hot surface ignitor models available� ASME CSD-1 compatible models available (consult factory)� Pre-purge and lockout indicator outputs� Diagnostic LED� Multiple trials for ignition� Thermostat, pushbutton or remote reset� Remote diagnostic LED � Remote flame sensor option� Flame current test pins

APPLICATIONSCommercial and industrial appliances with combustion chambers in excess of 400K BTU. Applications requiring CSD-1 certification.

DESCRIPTIONThe Series 35-67 is a hot surface ignition system in which the ignition source is proven to be capable of ignition prior to the gas valve being opened and is suitable for appliances over 400K BTU. Models compatible to the requirements of ASME standard CSD-1 are available.

The microprocessor circuit design provides precise, repeatable timing sequences for ignition times and purge times (pre-, inter-,and post-) as well as multiple tries for ignition. The control also continuously monitors the pressure switch, thermostat and mainburner flame to ensure safe system operation. On-board diagnosticswith LED output provide assistance with troubleshooting to ensuresafe and efficient burner operation.

Agency CertificationsDesign certified by CSA International to CAN C22.2 #199-M89 andANSI Z21.20 for Automatic Ignition Systems, including UL1998Software Review.

SERIES 35-6724 VAC Proven Hot Surface Ignition Control with Combustion Blower Relay Microprocessor Based

SPECIFICATIONS

www.fenwalcontrols.com 1-800-FENWAL-1 Series 35-67, 24 VAC Hot Surface Ignition Control Page 1

INPUT VOLTAGES

Control

Line

Thermostat

Pressure Switch

Hot Surface Element

Output Ratings

Inducer Fan

Hot Surface Element

Gas Valve Rating

Lockout & Pre-Purge Indicators

Operating Temperature

Flame Sensitivity


Types of Gas

Ignitor

Enclosure

Moisture Resistance

Size with enclosure

Weight

DESCRIPTION

18 to 30 VAC, 400mA max(not including gas valve)

24/120/240 VAC (L1 & L2 only, voltage depends on model)

18 to 30 VAC 30mA max (incl. Gas Valve)

18 to 30 VAC 25mA max

24/120/240 VAC 5A max

Relay: 15A max or 1/3HP @ 120 or 240 VAC

5.0A max @ 24, 120 or 240 VAC

5.0A max @ 24 VAC

1.0A max @ 24 VAC

-40ºF to +165ºF (-40ºC to +73ºC)

4.0mA minimum

0.8 seconds max


24 VAC, 120 VAC, or 240 VAC mini-ignitors and silicon carbide ignitorsdepending on model

Gray (Noryl N-190)

Conformal coated to operate non-condensing to 95% R.H. Care must be taken to protectmodule from direct exposure to water

See Figures 6 & 7

8oz including options and cover

®

35.67.02


1. POWER-UP.Power is applied to the full time 24 volt input. The micro-processor will start a self-check routine of about five seconds. After this delay, the LED will come on and the control is ready to start a new call for heat.For Manual Reset Button Models OnlyModels of the 35-67 with non-volatile lockout (manual resetbutton), the microprocessor will check memory to determine ifthe control should remain in lockout.

Lockout Present. The lockout indicator output will turn on, and the LED will repeatedly flash three times. To reset the control, the Reset Button must be pushed.Not in Lockout. The control is ready to start a new call for heat.

2. CALL FOR HEAT.The thermostat is turned on. The combustion fan relay will turn on.Proof of Pressure Switch. The control will look for a signal from the pressure switch, indicating that the fan has come on.Pre-Purge Delay. When the pressure switch signal is seen, the pre-purge delay will start. The pre-purge indicator output willturn on.

3. HEAT-UP. After the pre-purge delay, power will be applied to the hot surface ignition element. The pre-purge indicator will turn off.Current Proving. The 35-67 will monitor the current through the ignition element. When the current reaches a pre-determined level, the LED will flash once.Dwell Time. From the point when the current has been proven, there will be a delay called dwell time. Dwell time assures that the ignition element has sufficient time to reach ignition temperature.

4. IGNITION. When dwell time is completed, the gas valve will open. The ignition element will turn off 2 seconds before the end of the ignition period.No Flame.Single Trial for Ignition. The control will go to post-purge, and then lockout.Three Trials for Ignition. The control will make two additional purge/heatup/ignition cycles. If a flame is not proven, the control will go to post-purge, and then lockout.Flame is Proven.The gas valve will remain on beyond the normal ignition period. This continues as long as signals are present for the flame, thermostat and pressure switch.

5. LOSS OF FLAME SIGNAL. The gas valve will turn off. Depending on the model chosen:Single Trial for Ignition Models. A new trial for ignition cycle will start.Three Trial for Ignition Models. Three new ignition cycles will start.

Post-Purge. After all ignition cycles are complete, the control will enter post-purge. The combustion fan will remain on.Lockout. After post-purge is complete, the combustion fanwill turn off. The Lockout Indicator output will turn on. The LED will repeatedly flash three times

Proper location of the silicon carbide ignitor is important to achieveoptimum system performance for both ignition and flame sensing.See Figure 1.

NOTE: The temperature of the ceramic holder should not exceedthe manufacturer's specifications.

SEQUENCE OF OPERATION

www.fenwalcontrols.com 1-800-FENWAL-1

SILICON CARBIDE IGNITOR

Figure 1

TYPICAL HOT SURFACE IGNITOR

Figure 2

Figure 3

Flame current is the current that passes through the flame from the sensor to ground. The minimum flame current necessary tokeep the system from lockout is 4.0 microamps. To measure flamecurrent, connect an analog DC micro-ammeter to the FC terminalsper figure 5. Meter should read 4.0 mA or higher. If meter readsbelow "0" on scale, meter leads are reversed. Disconnect powerand reconnect meter leads for proper polarity.

Page 2 Series 35-67, 24 VAC Hot Surface Ignition Control

continued above >


MOUNTING AND WIRING

The 35-67 is not position sensitive and can be mounted verticallyor horizontally. The control may be mounted on any surface andfastened with #6 sheet metal screws. Secure the control in anarea that will experience a minimum of vibration and remain belowthe maximum ambient temperature of 80°C (175ºF). All conn-ections should be made with UL approved, 105°C (221°F) rated 18 gauge stranded wire with .054" minimum insulation. Refer to Figure 4A and Figure 5A on Page 5 when connecting the 35-67to other components in the system.

SYMPTOM

Control will not start up

Thermostat on and no igniton

Valve on - no ignitor

Ignitor on - no valve

Flame okay during TFI but no flame sense after TFI

LED INDICATION

Steady OFF

2 Flashes

3 Flashes

6 Flashes

FAULT MODE

Internal Control Failure

Erroneaus Flame Signal

Lockout

Valve Relay Problem

RECOMMENDED ACTIONS

A. Miswired

B. 24 VAC Transformer bad

C. Fuse/Circuit breaker badD. Bad control, check LED for

steady or flashing codes

A. MiswiredB. Bad thermostat, no voltage at

thermostat terminal

C. Failed ignitor

A. Defective ignitor

B. Miswired

C. Bad control, check voltage at ignitor

A. Valve coil open

B. Open valve wireC. Bad control, check voltage

at gas valve terminal

A. Bad ignitor

B. Bad wire

C. Poor ground at burner

D. Poor flame, check flame current

ON BOARD DIAGNOSTICS


TERMINAL DESIGNATIONS - P2 & P3 CONNECTOR

Table 2

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.

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. Service to this product shouldonly be preformed by a qualified technician

�!

Series 35-67, 24 VAC Hot Surface Ignition Control Page 3www.fenwalcontrols.com 1-800-FENWAL-1

PINLOCATION

12345677891011

WIRECOLORORANGE

REDVIOLETGRAY

BROWNBLUE

YELLOWGREENWHITE

BLACK

DESCRIPTION

Lockout IndicatorThermostatLockout Indicator (Ground Side)Pressure SwitchGas Valve24 VAC (Full Time)No Connection (Standard Version)Reset Button (Manual Reset Only)GroundPre-Purge Indicator

Remote Sense

MULTI-PIN CONNECTOR

AMP P/N 1-770849-1PINS AMP P/N 350980-1

TERMINAL DESCRIPTION MULTI-PIN CONNECTOR

QUICK CONNECTS

Ignitor

24, 120 or 240VAC

Input (Hot)

Neutral

Ignitor

Inducer Power

Supply

Inducer Blower

Remote LED

Connector

Flame Current

Test Pins

S1

L1

L2

S2

F1

F2

P3

FC+ & FC-

AMP 2-520183-2

PINS 350919-3

AMP 2-520183-2

PINS 350919-3

AMP 2-520183-2

PINS 350919-3

AMP 2-520183-2

PINS 350919-3

MOLEX 22-01-2021

PINS 08-500114

AMP 61260-1

¼ inch optional

¼ inch optional

¼ inch optional

¼ inch optional

¼ inch optional

¼ inch optional

TERMINAL DESIGNATIONS - P1 CONNECTOR

Table 1

�!


www.fenwalcontrols.com 1-800-FENWAL-1Page 4 Series 35-67, 24 VAC Hot Surface Ignition Control


CONTROL WIRE HARNESS


Part Number: 22-100001-080

Select the proper harness based on the 35-67 control's termination connection. Once the terminal configuration is determined, complete thepart number by replacing the last two digits ("XX") with the length in inches ("l" dimension). Standard wire lengths are 12, 18, 24 30, 36 and48 inches. Example 05-129845-018 = 18 inches. For other lengths, please contact Fenwal

Part Number: 22-100001-110

REMOTE FLAME SENSE ROD



WIRING

Figure 4A

STANDARD DESIGN - AUTOMATIC RESET

PIN LAYOUT

Figure 5A


www.fenwalcontrols.com 1-800-FENWAL-1Page 6 Series 35-67, 24 VAC Hot Surface Ignition Control

OPTIONAL DESIGN - MANUAL RESET

WIRING

Figure 4B

PIN LAYOUT

Figure 5B



DIMENSIONS

Figure 6

Figure 7




These instructions do not purport to cover all the details or variations in the equipmentdescribed, nor do they provide for every possible contingency to be met in connection withinstallation, operation and maintenance. All specifications are subject to change without notice.Should further information be desired or should particular problems arise which are not cov-ered sufficiently for the purchaser’s purposes, the matter should be referred to KIDDE-FENW-AL, Inc., Ashland, Massachusetts.

P/N 35.67.02 2/15/03

Page 8 Series 35-67, 24 VAC Hot Surface Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1

®


- X X XTrial for Ignition0 = 2 Seconds1 = 4 Seconds3 = 7 Seconds5 = 10 Seconds7 = 15 Seconds

Proving Current (Amps)0 = 0.81 = 0.5 3 = 2.14 = 2.35 = 2.76 = 3.17 = 3.3

Purge Timing0 = 0 Prepurge, 0 Interpurge, 0 Postpurge1 = 15 Prepurge, 15 Interpurge, 0 Postpurge2 = 30 Prepurge, 30 Interpurge, 0 Postpurge3 = 0 Prepurge, 15 Interpurge, 0 Postpurge (3 Try Units Only)4 = 0 Prepurge, 30 Interpurge, 0 Postpurge (3 Try Units Only)5 = 15 Prepurge, 15 Interpurge, 30 Postpurge (Full Time Power) 6 = 30 Prepurge, 30 Interpurge, 30 Postpurge (Full Time Power)7 = 0 Prepurge, 15 Interpurge, 15 Postpurge (Full Time Power)8 = 0 Prepurge, 30 Interpurge, 30 Postpurge (Full Time Power)

Tries For Ignition0 = Single Try - Local Sense. Recycle On Flame Loss1 = Single Try - Remote Sense. Recycle On Flame Loss2 = Single Try - Local Sense. Lockout On Flame Loss3 = Single Try - Remote Sense. Lockout On Flame Loss5 = Three Tries - Local Sense. Recycle On Falme Loss6 = Three Tries - Remote Sense. Recycle On Falme Loss7 = Three Tries - Local Sense. Lockout On Flame Loss8 = Three Tries - Remote Sense. Lockout On Flame Loss

Dwell Time0 = 4 Seconds1 = 6 Seconds5 = 20 Seconds7 = 40 Seconds

Proven Pressure Switch, Full Time Power,Termination0 = No Full Time Power, Q.C. Terminals, No Local Reset Button1 = No Full Time Power, Mate-N-Lock, No Local Reset Button2 = Full Time Power, Q.C. TERMINALS, No Local Reset Button3 = Full Time Power, Mate-N-Lock, No Local Reset Button4 = No Full Time Power, Q.C. Terminals, Local Reset Button5 = No Full Time Power, Mate-N-Lock, Local Reset Button6 = Full Time Power, Q.C. Terminals, Local Reset Button7 = Full Time Power, Mate-N-Lock, Local Reset Button8 = Aftermarket Kits (Consult Factory for Special Number)9 = Special OEM Features (Consult Factory for SpecialNumber)

Other Features0 = No Indicators With No Inducer1 = No Indicators With Inducer2 = No Indicators With No Inducer3 =Indicators and Inducer9 = Manual Reset (Standard Includes Indicators and Inducers)

35 - 67 X X X X Description


THE TOTAL SOLUTION FOR GAS IGNITION CONTROLFenwal offers a complete range of ignition control including:

� Ignition Controls� Spark and Flame Sense Electrodes� Spark and Flame Sense Cables � Wiring harnesses

Designed, developed and manufactured by Fenwal, these componentsintegrate seamlessly providing maximum system performance.

Getting Started - SamplesTo 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 CenterSend 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 DevelopmentCenter has proven extremely beneficial for many customers focused onproduct quality and reducing time-to-market for their appliances.

FEATURES� 3 Enclosure Configurations

� Case and Cover - dust and foreign object protection� Open Board with Stand-Off's - saves space and cost � Potted - protection for washdown and extreme vibration

� 2 Wiring Options – ¼” quick connects and multi-pin connector� 2 Trial for Ignition Options – 1 and 3 try� 4 Trial for Ignition Times – 4, 7,10 and 15 seconds

(customized timings available)� 2 Flame Sense Options –

single spark and sense and remote sense� 2 Reset Options – thermostat/power off and automatic

(1 hour reset) � Diagnostic LED – 3 error codes for accurate troubleshooting� Flame Current Test Pins – instant access to circuit

for troubleshooting� Polarity Insensitive – reduces chance of miswiring

APPLICATIONS� Construction and Agriculture Heaters� Crop Dryers� Ceramic and Black Body Infrared Heaters� Commercial Cooking Equipment� 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 CertificationsRecognized under the Component Program of UnderwritersLaboratories 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 1www.fenwalcontrols.com 1-800-FENWAL-1

SERIES 35-70120 VAC Microprocessor BasedDirect Spark Ignition Control

®


Start up - Heat Mode120 VAC is supplied to the L1 terminal either from a thermostat or other control device. When this occurs, the control will power upand 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 functioningproperly. When the thermostat is satisfied and the demand forheat ends, the gas valve is de-energized immediately and the flameis extinguished.

System Response to Flame Failures Fenwal controls are configured with several options for managingloss of flame.

Failure during TFI PeriodSINGLE TRIAL MODELShould 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 MODELShould 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-IGNITIONIf 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 MODELIf 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.

RECYCLEIf the established flame signal is lost, the control responds by shutting off the gas valve within 0.8 seconds.

SINGLE TRIAL MODELThe 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 MODELThe 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 orflame is not established, the control automatically enters lockoutmode. The control will not open the gas valve unless there is inter-vention by the user or one hour has passed depending on themodel chosen. See Lockout Recovery.

Lockout Recovery - Two OptionsThere 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.


* 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-1Courtesy of Steven Engineering, Inc.-230 Ryan Way, South San Francisco, CA 94080-6370-Main Office: (650) 588-9200-Outside Local Area: (800) 258-9200-www.stevenengineering.com

1/4”3/16”3/16”3/16”1/4”

3/16”1/4”

AlarmValve Power

120 VAC (Neutral)Valve Neutral

120 VAC Input (Hot)Burner Ground

Remote Flame SensorFlame Sense Test Pins

NCV1L2V2L1

B. GNDS1*

FC+, FC-

111087621

Lt. BlueBrownWhiteYellowBlackPurpleGray

MOUNTING AND WIRINGThe 35-70 is not position sensitive and can be mounted vertically or horizontally. The control may be mounted on any surface and fastenedwith #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, 18gauge, stranded, .054” thick insulated wire. Refer to the appropriatewiring diagram when connecting the 35-70 to other components in the system. High voltage spark cables and control wiring harnesses aredetailed on Pages 5 and 6.

SYMPTOMControl will not start up

Gas Valve on and no sparkthrough TFI

Spark on and gas valve off

Flame during trial for ignition but no flame sense after trial for ignition

Input PowerInput Current DrainGas Valve RatingOperating TemperatureFlame Sense VoltageFlame Sense CurrentFlame Failure Response TimeTypes of GasSpark RateMoisture ResistanceSize (LxWxH)Weight

102 to 138 VAC, 50/60 Hz350mA @ 120 VAC, 60 Hz1.5A @ 120 VAC-40°F to +175°F, -40°C to +80°C120 VAC1.0 microamp minimum0.8 seconds maximumNatural, LP and manufacturedLine frequency (50/60 Hz)Conformal coated to operate to 95% R.H.See drawings on Page 8Integral stand-offs: 7.1 oz Potted:14.3 ozCase and Cover: 10.1oz

RECOMMENDED ACTIONSA. Check wiringB. No voltage @ L1, check thermostatC. Check fuse/circuit breakerD. Faulty transformer on controlE. Faulty control, consult FenwalA. Shorted electrode - re-establish 1/8” gapB. High voltage cable is disconnectedC. Check wiringA. Valve coil openB. Valve wire disconnectedC. Faulty control, check voltage @ V1A. Check electrode positionB. Check high voltage wire and connectionC. Poor ground @ burnerD. Check flame currentE. Check flame current on control

SINGLE SPARK AND SENSE

REMOTE SENSE

TERMINAL DESCRIPTION

MULTI-PINCONNECTOR

P/N: AMP 1-644615-1

QUICK CONNECT

TERMINALSIZE

SPECIFICATIONS



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 IndicationSteady on2 Flashes3 Flashes

Fault ModeInternal Control FailureFlame Fault**Ignition Lockout Fault

The LED will flash on for 0.2 seconds then off for 0.2 seconds to indicatean error condition. The pause time between error codes will be 2.5 to 3.0seconds. During power-up, the LED will light for one second and then turnoff 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.


** May indicate either that a flame was detected during pre- or post-purge,

or that there is a flame sensing error.


HIGH TEMPMATERIAL

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 theelectrode assembly be mounted temporarily using clamps or othersuitable means to check the system before permanently mountingthe assembly. The electrode assembly should be located so thatthe 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 assemblymust be replaced or adjusted (see troubleshooting)


4. Electrodes must be placed where they are not exposed to the appliance user in normal operation.

Flame SensingFlame 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 minimumflame current necessary to keep the system operating is 1.0 DC microamperes.


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 TerminalSpark, H.V. Ceramic Tube

Sense Electrode Ceramic Tube

Press Ring

Flame Sense Electrode

Ground Rod

Spark Electrode, High Voltage

STANDARD MATERIAL


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

46

75

8

9

TYPICAL SPARK ELECTRODE WITH INTEGRAL REMOTE FLAME SENSE

Figure 4

FLAME CURRENT CHECK: SINGLE SPARK & SENSE ANDREMOTE SENSETo measure flame current, disconnect the input voltage, and attachthe 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 read1.0 DC microamperes or higher. If meter reads below "0" on thescale, meter leads are reversed. Disconnect power and reconnectmeter leads for proper polarity.

+

-

Page 4 Series 35-70, 120 VAC Direct Spark Ignition Control www.fenwalcontrols.com 1-800-FENWAL-1Courtesy of Steven Engineering, Inc.-230 Ryan Way, South San Francisco, CA 94080-6370-Main Office: (650) 588-9200-Outside Local Area: (800) 258-9200-www.stevenengineering.com

Electrode AssembliesWith 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 todetail 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 5www.fenwalcontrols.com 1-800-FENWAL-1Courtesy of Steven Engineering, Inc.-230 Ryan Way, South San Francisco, CA 94080-6370-Main Office: (650) 588-9200-Outside Local Area: (800) 258-9200-www.stevenengineering.com

Electrode Assemblies continued

REMOTE SENSE

Part Number: 05-129864-6XXPart Number: 05-129864-5XX

Part Number: 22-100001-110

Part Number: 05-129864-0XX Part Number: 05-129864-1XX



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 HarnessSelect 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 MaterialAll Wires 600 V UL/CSA Listed 105°C (221°F) 18 gage stranded PVCGray 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


1. SILICONE RUBBER SUPRESSION TYPE: Resistive carbon coated fiberglas core prevents spark energy radiation from interfering withother 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 Material25K VDC SAE J2031 200°C (392°F) 7mm (.27”) Silicone Rubber

over Fiberglas BraidPart 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 PLUGWITH SILICONE RUBBER BOOT

2. SILICONE RUBBER COPPER CONDUCTOR TYPE: Low resistance copper conductor transmits maximum spark energy. Select thistype 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 Material25 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


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 shouldbe evaluated on the appliance to determine if there is sufficient spark energy to consistently light the burner under all conditions. Once thewire 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 INSULATEDBOTH ENDS

1/4” FEMALE Q.C. BOTH ENDSRIGHT 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 Material25 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 Material600 V UL/CSA Listed 200°C (392°F) 18 gage stranded PVC



3/16”FEMALE Q.C.FULLY INSULATED


1/4” FEMALE Q.C. FULLY INSULATEDBOTH ENDS


Case

�

�

�

�

Multi-Pin

Auto

MOST COMMON CONFIGURATIONSFenwal 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

Assemblies8 = Assemblies (may consist of control, high voltage ignition wire,

electrode and harness)

Non-Standard Configurations9 = 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 Options2 = 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)


Pre-Purge Time0 = None1 = 15 seconds2 = 30 seconds5 = 5 seconds

Inter-Purge Time0 = None1 = 15 seconds2 = 30 seconds

Number of Ignition Trials,Flame Sense Method and Lock Out Reset Method0 = 1 try, single spark and sense Thermostat / power off reset1 = 1 try, remote sense Thermostat / power off reset2 = 1 try, single spark and sense Automatic reset3 = 1 try, remote sense Automatic reset5 = 3 try, single spark and sense Thermostat / power off reset6 = 3 try, remote sense Thermostat / power off reset7 = 3 try, single spark and sense Automatic reset8 = 3 try, remote sense Automatic reset

X 0 X35 - 70 5 - X X X

400 MAIN STREET, ASHLAND, MA 01721TEL: (508) 881-2000FAX: (508) 881-6729www.fenwalcontrols.com


P/N 35-70-02 6/20/03

or

POTTED INTEGRAL STAND-OFF

Ignition ControlPart Number

Enclosure Type Wiring Number of Ignition Trials

Flame SenseMethod

Trial for Ignition Time (seconds)

Lockout ResetMethod

Pre-purge Time(seconds)

StandOff

Potted

�

�

Q.C.

�

�

�

�

�

�

1

�

�

�

�

3

�

�

Single

�

�

�

Remote

�

�

�

Thermostat/Power - off

�

�

�

�

�

�

0

�

�

15

�

�

�

30 5

�

4

�

�

7

�

10

�

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�

15

35-705700-001

35-705701-505

35-705500-001

35-705501-105

35-705505-113

35-705506-115

Figure 1 Figure 2CASE AND COVERFigure 3

or

0

�

�

�

�

15

�

�

30

Inter-purge Time (seconds)

Figure 4 Figure 5 Figure 6

© 2003 Kidde-Fenwal, Inc, Printed in U.S.A. TAG


®


SERIES 35-71120 VAC Microprocessor Based Direct Spark Ignition Control with Combustion Blower Relay

THE TOTAL SOLUTION FOR GAS IGNITION CONTROLFenwal offers a complete range of ignition control products including:


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 DevelopmentCenter has proven extremely beneficial for many customers focused on product quality and reducing time-to-market for their appliances.

35.71.02


®

FEATURES� 3 Enclosure Configurations

� Case and Cover - dust and foreign object protection� Open Board with Stand-offs - saves space and cost� Potted - protection for washdown and exteme vibration

� Full-time power option� Integral Blower Relay� 2 Wiring Options – 1/4” quick connects and multi-pin connector� 2 Trial For Ignition Options - 1 and 3 trial� 4 Trial For Ignition Times - 4, 7, 10 and 15 seconds

(customized timings available) � 2 Flame Sense Options – single spark and sense

and remote sense� Diagnostic LED - 3 error codes for accurate troubleshooting� Flame Current Test Pins - instant access to circuit

for troubleshooting� Polarity Insensitive – reduces chance of miswiring

APPLICATIONS� Construction and Agriculture Heaters� Crop Dryers� Ceramic and Black Body Infrared Heaters� Commercial Cooking Equipment� Any 120 VAC Gas Burner Application under 400K BTU

DESCRIPTIONThe 35-71 is a 120 VAC direct spark ignition control with blower relay for controlling a gas valve, controlling and monitoring combustion air-flow and igniting LP or natural gas for construction heaters, infrared heaters, crop dryers, commercial cooking 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-, inter- and post-) as well as multiple tries for ignition, 1 hour automatic reset and flame sensing during pre-, inter- and post-purge. The control continually monitors the pressure switch, thermostat and main burner flame to ensure safe system operation. The on-board diagnostics with LED output provideassistance with troubleshooting to ensure safe and efficient burner operation.

Agency CertificationsRecognized under the Component Program of UnderwritersLaboratories Inc., UL 372, UL 1998 Software

Design certified by CSA International, CAN C22.2 #199-M89 and ANSI Z21.20 Automatic Ignition Systems

LISTED


Start up - Heat Mode120 VAC is supplied to the L1 terminal, either from a thermostat or other controldevice. When this occurs the control will power up and perform a self-check routine and if selected, begin a pre-purge. Following the pre-purge, the gas valve is energized and sparks commence 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 and combustion blow-er remain energized. The thermostat, pressure switch and main 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 a post-purge is initiated (optional) and the flame is extinguished. When the post purge is complete, the combustion blower is de-energized.

System Response to Flame Failures Fenwal controls are configured with several options for managing loss of flame.

Failure during TFI PeriodSINGLE TRIAL MODELShould 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 MODELShould 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-IGNITIONIf 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 MODELIf 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 MODELIf the burner does not light after the first re-ignition attempt, the inter-purge sequence is completed between the next two attempts to re-lightthe burner. If the burner fails to light after the third attempt, the control will de-energize the gas valve and go into lockout mode.

RECYCLEIf the established flame signal is lost, the control responds by shutting off the gas valve within 0.8 seconds.

SINGLE TRIAL MODELThe 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 MODELThe 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.

Combustion Air Flow MonitoringIn normal operation, the control monitors the combustion air flow by reading the pressure switch (PSW) input to confirm that the blower is operating in the proper sequence. Initially, the control checks the PSW input to be sure that it is open. Once the blower is energized and the PSW closes the control proceeds to trial for ignition.

If during a call for heat 120 VAC power is present at the PSW input prior to the blower being energized, the control will wait 30 seconds, for the condition to change. Possible reasons for this condition includes a stuck or mis-wired pressure switch, or the blower is spinning down and keeping the switch closed. If the condition does not change, an airflow fault will be declared and the LED will flash the one flash pattern.

If the combustion blower is energized and the PSW does not close within 30 seconds, an airflow fault will be declared and the LED will flash the one- flash pattern. The blower will remain energized until the condition changes.

If the PSW signal is lost while the burner is firing, the control will immediately de-energize the gas valve and the combustion blower will remain on. If the call for heat remains and the PSW signal returns within 30 seconds, the control will restart with the pre-purge period. If the PSW input does not return within 30 seconds, the blower remains on and LED will flash the one-flash code indefinitely. If the PSW closes, the LED stops flashing and the control resumes oper-ation with the pre-purge function.

Lockout Mode (On-Board Safety System)After single or multiple attempts to light the burner have failed or flame is not estab-lished, the control automatically enters lockout mode. The control will not open thegas valve unless there is intervention by the user or one hour has passed depending on the model chosen. See Lockout Recovery.

Lockout Recovery - Two OptionsThere are two options for recovering from lockout mode. When selecting the control, please specify one of the following methods for lockout recovery.

1. Thermostat/ Power Off Reset- requires the user to reset the thermostat 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.

Benefits of Full Time Power1. Separate 120 VAC input for ignition control operation and combustion blower

operation. Allows high current to feed the blower directly rather than have it pass through the thermostat.

2. Sense flame even with zero second pre-purge to provide safe operation. Control will monitor flame presence immediately upon a call for ignition.

3. Post purge blower operation to clear the combustion chamber and remove remaining heat when the call for heat has ended.

4. If a flame is detected during pre-, inter- or post-purge, the combustion blower will be energized. Should the main valve later close and the flame signal disappear, the combustion blower will be de-energized.

Page 2 Series 35-71, 120 VAC Direct Spark Ignition Control


www.fenwalcontrols.com 1-800-FENWAL-1Courtesy of Steven Engineering, Inc.-230 Ryan Way, South San Francisco, CA 94080-6370-Main Office: (650) 588-9200-Outside Local Area: (800) 258-9200-www.stevenengineering.com


LED IndicationSteady on1 Flash2 Flashes3 Flashes

Fault ModeInternal Control FailureAirflow FaultFlame Fault**Ignition Lockout Fault

MOUNTING AND WIRINGThe 35-71 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 35-71 to other components in the system. High voltage spark cables and control wiring harnesses are detailed on Pages 5 and 6.

Series 35-71, 120 VAC Direct Spark Ignition Control Page 3

1/4”3/16”1/4”

3/16”3/16”1/4”1/4”1/4”

3/16”1/4”

AlarmValve Power

Pressure Switch120 VAC Neutral

Valve Neutral120 VAC Input (Hot)

Inducer OutputThermostat InputBurner Ground

Remote Flame Sensor

Flame Sense Test Pins

NCV1

PSWL2V2L1

INDTH

B.GNDS1*

FC+, FC-

111098764321

BlueBrownOrangeWhiteYellowBlack

White/BlackRed

PurpleGray

TERMINAL DESCRIPTION

MULTI-PINCONNECTOR

P/N: AMP 1-644615-1

QUICK CONNECT

TERMINAL SIZE


PIN LOCATION

WIRE COLOR

2 Pin Header(AMP P/N: 640383-2, Molex P/N: 26-60-2020)

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 necessary to prevent porpertydamage and/or personal injury or death.

* 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.

Input PowerInput Current DrainGas Valve RatingCombustion Blower RatingOperating TemperatureFlame Sense VoltageFlame Sense CurrentFlame Failure Response TimeType of GasSpark RateMoisture ResistanceSize (LxWxH)Weight

102 to 138 VAC, 50/60 Hz350mA @ 120 VAC, 60 Hz1.5A @ 120 VAC3.0 FLA @ 120 VAC-40°F to +175°F, -40°C to +80°C120 VAC1.0 microamp minimum0.8 seconds maximumNatural, LP and manufacturedLine frequency (50/60 Hz)Conformal coated to operate to 95% R.H.See drawings on Page 8Integral stand-offs: 7.1 oz

Potted: 14.3 oz Case and Cover: 10.1oz

SPECIFICATIONS

The LED will flash on for 0.2 seconds then off for 0.2 seconds to indicate anerror 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 indicatenormal operation.

ON-BOARD DIAGNOSTICS

** May indicate either that a flame was detected during pre-, inter- or post-purge, or that there is a flame sensing error.

WARNING: Operation outside specifications could result in failure ofFenwal product and other equipment with injury to people and damage to property and even death.

PIN LAYOUT

FULL TIME POWER

NO FULL TIME POWER

SingleSpark

andSense

RemoteSense

On controls without full timepower the TH terminal is notused and L1 becomes the T’stat or control device input.


SYMPTOMControl will not start up

Gas Valve on and no spark during TFI


Flame during TFI but noflame sense after TFI

Call for ignition, but combustion blower doesn't start up

Pressure switch operating properly, but no TFI after purge period

RECOMMENDED ACTIONSA. Check for 120VAC at L1 and/ or THB. Check fuse/ circuit breakerC. Check thermostat on and set above ambientD. Red LED steady on. Reset power. Replace

control if LED remains on.A. Shorted electrode - re-establish 1/8" gapB. Check that bracket is making a solid

ground connectionC. Check connection at each end of high

voltage cableA. Check for 120VAC at V1B. Check wiring to V1 and V2C. Valve coil malfunctionA. Check that the spark electrode/ flame

sensor are in the flameB. Poor ground at the burnerC. Low flame current - check flame current

using test pins on the controlA. Check for 120VAC at L1 and THB. Check for 120VAC at IND, should be on if

pressure switch is operating properlyC. Check that the pressure switch has been

wired properlyD. Pressure switch failed off or on (1 LED Flash) E. Check blower fan assemblyA. Flame was detected during purge period

(2 LED Flashes)B. Check for 120VAC at L1 and THC. Check for 120VAC at IND, should be on

if pressure switch is operating properly


+

-

HIGH TEMPMATERIAL


Steel Cu Flashed

Nickel Plated Steel

Nickel Plated Steel

Alumina

Alumina

Spring Steel

Kanthal APM

Kanthal APM

Kanthal APM

ACCESSORIES


Proper location of the electrode assembly is important for optimum system performance. It is recommended that theelectrode assembly be mounted temporarily using clamps or othersuitable means to check the system before permanently mountingthe assembly. The electrode assembly should be located so thatthe tips are inside the flame envelope and about 1/2 inch (10 mm)above the base of the flame. See Figures 3a and 3b.


(3.12 ± 0.81 mm). If this spacing is not correct, the assemblymust be replaced or adjusted (see troubleshooting)



Flame SensingFlame sensing is achieved using the principal of flame rectification. Flame rectification relies on the current passing from ground through the flame to the sense rod. The minimumflame current necessary to keep the system operating is 1.0 microamperes.


Figure 3a

REMOTE FLAME SENSE

Figure 3b

ITEM#

1

2

3

4

5

6

7

8

9

DESCRIPTION

Mounting Bracket


3/16” Q.C. Flame Sense Terminal

Spark, H.V. Ceramic Tube


Press Ring


Ground Rod


STANDARD MATERIAL


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

46

75

8

9



Figure 4

FLAME CURRENT CHECK: SINGLE SPARK & SENSE ANDREMOTE SENSETo measure flame current, disconnect the input voltage, and attachthe leads from a DC current meter with a microampere range toFC+ and FC- terminals to the 35-70 flame sense test pins perFigure 4. Reconnect the input voltage and initiate a call for heat. After sparking is complete and the flame is established the meter should read 1.0 microamperes DC or higher. If meter reads below "0" on the scale, meter leads arereversed. Disconnect power and reconnect meter leads for proper polarity.

www.fenwalcontrols.com 1-800-FENWAL-1Courtesy of Steven Engineering, Inc.-230 Ryan Way, South San Francisco, CA 94080-6370-Main Office: (650) 588-9200-Outside Local Area: (800) 258-9200-www.stevenengineering.com

Electrode AssembliesWith 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 thehottest 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 todetail 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

SINGLE SPARK AND SENSE WITH INTEGRAL FLAME SENSE ELECTRODES



(FLAME SENSEELECTRODE)

(HIGH VOLTAGEELECTRODE)

(FLAME SENSEELECTRODE)



Control Wire HarnessSelect the proper harness (6 or 7 PIN) based on flame sense choice. Once the terminal configuration is determined, complete the part num-ber 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 60inches. Example: 05-129892-118 = 18 inches. For other lengths, please contact Fenwal.



REMOTE SENSE


Part Number: 22-100001-080

Part Number: 22-100001-110


SINGLE SPARK SENSE

REMOTE FLAME SENSE ELECTRODES







1.094 +.015



1. SILICONE RUBBER SUPRESSION TYPE: Resistive carbon coated fiberglas core prevents spark energy radiation from interfering withother 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 Material25 KVDC SAE J2031 200°C (392°F) 7mm (.27”) Silicone Rubber

over Fiberglas BraidPart Number: 05-129608-0XX Part Number: 05-129608-2XX Part Number: 05-129608-6XX






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. BOTH ENDS

RIGHT ANGLE SPARK PLUG WITHSILICONE RUBBER BOOT

1/4” FEMALE Q.C.










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


Inter-purge Time (seconds)

0

�

30

�

�

�

�

60

�

PostPurge



Non-Standard Configurations 9 = Non Standard Configuration A 9 in this location of the part number (i.e. 35-725 -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.

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)

Case

�

�

�

�

Multi-Pin

�

�

�

Auto

MOST COMMON CONFIGURATIONSFenwal 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. All controls listed below are Full Time Power Models.

HOW TO ORDER

901


Pre-Purge Time0 = None1 = 15 seconds2 = 30 seconds5 = 5 seconds


Number of Ignition Trials,Flame Sense Method and Lock Out Reset Method0 = 1 try, single spark and sense Thermostat / power off reset1 = 1 try, remote sense Thermostat / power off reset2 = 1 try, single spark and sense Automatic reset3 = 1 try, remote sense Automatic reset5 = 3 try, single spark and sense Thermostat / power off reset6 = 3 try, remote sense Thermostat / power off reset7 = 3 try, single spark and sense Automatic reset8 = 3 try, remote sense Automatic reset

X X X35 - 71 5 - X X X

or


Flame SenseMethod

StandOff

Potted

�

�

Q.C.

�

�

�

1

�

�

3

�

�

�

�

Single

�

�

�

Remote

�

�

�

Thermostat/Power - off

�

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�

�

�

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0 15

�

�

�

�

30 5

�

�

4 7

�

�

�

�

�

10

�

15

35-715510-505

35-715325-113

35-715526-113

35-715331-503

35-715725-113

35-715226-113

Figure 1 Figure 2


400 MAIN STREET, ASHLAND, MA 01721TEL: (508) 881-2000FAX: (508) 881-6729www.fenwalcontrols.com


P/N 35-71-02 6/20/03

CASE AND COVER

Figure 3

or

0

�

�

15

�

�

�

�

30

Figure 4 Figure 5 Figure 6

© 2003 Kidde-Fenwal, Inc. Printed in U.S.A. TAG

Combustion Blower Control,Post-purge time and Power Options0 = 0 second post-purge and no full-time power1 = 0 second post purge with full-time power2 = 30 second post purge with full-time power3 = 60 second post purge with full-time power


Lockout ResetMethod

Number of Ignition Trials

WiringEnclosure TypeIgnition Control

Part Number

Trial for Ignition Time (seconds)


requires individual 120VAC inputs for blower and the thermostat which allows higher current tofeed the combustion blower without having the high current pass through the thermostat

requires single 120 VAC input for both blower and thermostat/ control device

®


FEATURES� Two Mounting Configurations

� Open Board With Stand-Off's - saves space and cost

� Potted - protection for washdown and extreme vibration

� Multi Pin Connector - fast assembly� 2 Trial for Ignition Options – 1 and 3 try� 4 Trial for Ignition Times – 4, 7,10 and 15 seconds

(customized timings available)� 2 Flame Sense Options – single spark and sense

and remote sense� Thermostat/Power Off Reset� Line Polarity Insensitive – reduces chances of miswiring

APPLICATIONS� Construction Heaters� Ceramic Infrared Heaters� Black Body Infrared Heaters� Commercial Cooking Equipment� Any 120 VAC Gas Burner Application under 400K BTU

DESCRIPTIONThe 35-72 is a 120 VAC direct spark ignition control for controlling a gas valve and igniting LP or natural gas on heating equipment that provides a 120 VAC operating voltage.

The microprocessor circuit design provides precise, repeatable timing sequences for ignition times, purge times (pre- and inter-)along with multiple tries for ignition and flame sensing during pre-purge.

Agency CertificationsDesign certified by CSA International to CAN C22.2 #199-M89 and ANSI Z21.20 for Automatic Ignition Systems

SERIES 35-72120 VAC Microprocessor BasedDirect Spark Ignition Control

THE TOTAL SOLUTION FOR GAS IGNITION CONTROLFenwal offers a complete range of ignition control products including:


Designed, developed and manufactured by Fenwal, these componentsintegrate seamlessly providing maximum system performance.

Getting Started - SamplesTo 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 CenterSend 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 DevelopmentCenter has proven extremely beneficial for many customers focused onproduct quality and reducing time-to-market for their appliances.

www.fenwalcontrols.com 1-800-FENWAL-1 Series 35-72, 120 VAC Direct Spark Ignition Control Page 1

35.72.02

®


Start up - Heat ModeWhen the thermostat is set above the ambient temperature, 120 VAC are supplied to the L1 terminal. When this occurs the con-trol will power up and perform a self-check routine and begin a pre-purge*, if selected. Following the pre-purge, the gas valve is ener-gized and sparks commence until flame is detected or the Trial For Ignition (TFI) period expires.

When flame is detected, the spark is shut off and the gas valveremains energized. The thermostat and burner flame are constantly monitored to ensure that the system is functioning prop-erly. When the thermostat is satisfied and the demand for heatends, the gas valve is de-energized immediately and the flame isextinguished.

System Response to Flame Failures The robust design of our gas ignition controls is demonstrated by their ability to respond to flame failures in a safe manner and provide re-ignition options for the equipment designer.

Flame Failure During Trial-for-Ignition Period

SINGLE TRIAL MODELShould the burner fail to light or flame is not detected at the end of the trial-for-ignition period, the gas valve is de-energized immediately and the control will go into lockout mode.

MULTI TRIAL MODELShould the 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 starts the inter-purge sequence before another ignition attempt. After inter-purge, the control will attempt two additional ignition trials. If these attempts are unsuccessful the control will go into lockout mode.

Flame Failure of Established Flame

RE-IGNITIONIf the established flame signal is lost while the burner is operating, the control responds and begins sparking within 0.8 seconds. The spark will be energized for the duration of the trial-for-ignition period in an attempt to re-light the burner. If flame is re-established, normal operation resumes.

SINGLE TRIAL MODELIf the burner does not light after the first attempt, the control will de-energize the gas valve and go into lockout mode. See Lockout Recovery

MULTI TRIAL MODELIf the burner does not light after the first attempt, the inter-purge sequence is completed between attempts to re-light the burner. If the burner fails to light after the third try, the control will de-energize the gas valve and go into lockout mode. See Lockout Recovery

Lockout Mode (On-Board Safety System)After single or multiple attempts to light the burner have failed orflame is not established, the control automatically enters lockoutmode. The control will not open the gas valve unless there is intervention by the user. See Lockout Recovery.

Lockout RecoveryFor lockout recovery, reset the thermostat below ambient tempera-ture or remove the 120 VAC power supply for 5 seconds.



* The pre-purge is simply a delay to allow gas to dissipate from the combustion chamber. This control is not equipped with a combustion blow-er relay and therefore does not initiate a fan powered pre-purge.



�!

MOUNTING AND WIRINGThe 35-72 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 (175ºF).

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 35-72 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 sparkthrough TFI


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


Type of Gases

Spark Rate

Moisture Resistance

Size (LxWxH)

Weight

102 to 138 VAC, 50/60 Hz

50mA @ 120 VAC, 60 Hz

1.5A @ 120 VAC

-40°F to +175°F, -40°C to +80°C

45% of line voltage

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.Potted to operate up to 100% R.H.

See drawing on back page for details

Integral stand-offs: 2.3 ozPotted: 6.1 oz

RECOMMENDED ACTIONS

A. Check wiringB. No voltage @ pin 4, check thermostatC. Check fuse/circuit breakerD. Faulty control, consult Fenwal

A. Shorted electrode - re-establish 1/8” gapB. High voltage cable is disconnectedC. Check wiring

A. Valve coil openB. Valve wire disconnectedC. Faulty control, check voltage @ pin 2

A. Check electrode positionB. Check high voltage wire and connectionC. Poor ground @ pin 1D. Check flame currentE. Check remote sensor wire on pin 7


REMOTE SENSE

TERMINAL DESCRIPTION MPIN LOCATION WIRE COLOR

Single Spark and Sense

Burner Ground

Valve Power

Line Neutral

120 Vac Input (Hot)

Valve Neutral

B. Gnd

V1

L2

L1

Not Used

V2

1

2

3

4

5

6

Purple

Brown

White

Black

Yellow

6-Pin Connector

Remote Flame Sense 7-Pin Connector (same as above plus pin 7)

S1 Remote Flame Sensor 7 Gray

SPECIFICATIONS



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.

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.

�!


SIX PIN HEADER AMP PART NUMBER 644615-6ON CIRCUIT BOARD. SEE PAGE 6 FOR MATCHINGCONNECTORS AND WIRING HARNESSES.

SIX PIN HEADER AMP PART NUMBER 64415-7ON CIRCUIT BOARD. SEE PAGE 6 FOR MATCHINGCONNECTORS AND WIRING HARNESSES.


HIGH TEMPMATERIAL


Steel Cu Flashed

Nickel Plated Steel

Nickel Plated Steel

Alumina

Alumina

Spring Steel

Kanthal APM

Kanthal APM

Kanthal APM

ACCESSORIES


Proper location of the electrode assembly is important for optimum system performance. It is recommended that theelectrode assembly be mounted temporarily using clamps or othersuitable means to check the system before permanently mountingthe assembly. The electrode assembly should be located so thatthe tips are inside the flame envelope and about 1/2 inch (10 mm)above the base of the flame. See Figures 3a and 3b.


(3.12 ± 0.81 mm). If this spacing is not correct, the assemblymust be replaced.



Flame SensingFlame sensing is achieved using the principal of flame rectific-ation.Flame rectification relies on current passing from ground throughthe flame to the sense rod. The minimum flame current necessaryto keep the system from lockout is 1.0 µA.


Figure 3a

REMOTE FLAME SENSE

Figure 3b

FLAME CURRENT CHECK: SINGLE SPARK & SENSETo measure flame current, disconnect input voltage, then insert a 0-50 µA DC meter and capacitor in series with the spark electrodeper Figure 4a. Reconnect input voltage and initiate call for heat.After sparking is complete and flame is established meter shouldread 1.0 µA or higher while flame is established. If meter readsbelow "0" on the scale, meter leads are reversed. Disconnectpower and reconnect meter leads for proper polarity.

FLAME CURRENT CHECK: REMOTE SENSETo measure flame current, disconnect input voltage, then insert a 0-50 µA DC meter inline with flame sense wire per Figure 4b.Reconnect input voltage and initiate call for heat. After sparking iscomplete and flame is established meter should read 1.0 µA orhigher while flame is established. If meter reads below "0" on thescale, meter leads are reversed. Disconnect power and reconnectmeter leads for proper polarity.

ITEM#

1

2

3

4

5

6

7

8

9

DESCRIPTION

Mounting Bracket


3/16” Q.C. Flame Sense TerminalSpark, H.V. Ceramic Tube


Press Ring


Ground Rod


STANDARD MATERIAL


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

46

75

8

9


Figure 4a

Figure 4b



Electrode AssembliesProviding over 1,000 configurations of spark electrodes and flame sense rods, Fenwal has a design for almost any application. The lateststate-of-the-art wire forming and assembly equipment is used to accurately and efficiently produce high quality electrodes that deliver thehottest 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 todetail or send us a print and we will provide you with a quote and samples.

Part Number: 22-100001-117

Part Number: 22-100001-052



Part Number: 22-100000-593

Part Number: 22-100001-076

(FLAME SENSE ELECTRODE)

(HIGH VOLTAGE ELECTRODE)

(1/8” SPARK GAP TO BE MADEBY CUSTOMER)

(FLAME SENSE ELECTRODE)






REMOTE SENSE


Part Number: 22-100001-080

Part Number: 22-100001-110



To make your own harness select AMP connector housing P/N: 770849-6 and AMP housing terminal P/N: 770552-1

Control Wire HarnessSelect the proper harness (6 or 7 PIN) based on flame sense choice. Once the terminal configuration is 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: 05-129892-118 = 18 inches. For other lengths, please contact Fenwal.



To make your own harness select AMP connector housing P/N: 770849-7 and AMP housing terminal P/N: 770552-1




1. SILICONE RUBBER SUPRESSION TYPE: Resistive carbon coated fiberglass core prevents spark energy radiation from interfering withother electronic systems. Select this wire type for applications where wire lengths are less than 36” and noise is a major concern.


over Fiberglass BraidPart Number: 05-129608-0XX Part Number: 05-129608-2XX Part Number: 05-129608-6XX






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 shouldbe evaluated on the appliance to determine if there is sufficient spark energy to consistently light the burner under all conditions. Once thewire 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. For other lengths, please contact Fenwal.



RIGHT ANGLE SPARKPLUG WITH SILICONERUBBER BOOT

1/4” FEMALE Q.C.








MOST COMMON CONFIGURATIONSFenwal offers any option variation listed in the above part number scheme along with customized configurations to meet your exact applica-tion 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



Non-Standard Configurations9 = Non Standard Configuration

A 9 in this location of the part number (i.e. 35-725 -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 Options2 = Potted Multi-Pin Connector (Figure 1)4 = Integral Stand-off’s Multi-Pin Connector (Figure 2)

or

Trial for Ignition Time (TFI)1 = 4 seconds3 = 7 seconds5 = 10 seconds7 = 15 secondsPre-Purge

Time0 = None1 = 15 seconds2 = 25 seconds5 = 5 seconds


Number of Ignition Trials,Flame Sense Method and Lock Out Reset Method0 = 1 try, single spark and sense Thermostat / power off reset1 = 1 try, remote sense Thermostat / power off reset5 = 3 try, single spark and sense Thermostat / power off reset6 = 3 try, remote sense Thermostat / power off reset

X 0 X35 - 72 5 - X X X




P/N 35.72.02 6/20/03

or


Part Number: 35-72520X-XXX Part Number: 35-72540X-XXX

Ignition ControlPart Number

Enclosure Type Wiring Number ofIgnition Trials

Flame SenseMethod

Trial for Ignition Time(seconds)

Lockout ResetMethod


Stand-Off Potted Multi-Pin 1 3 Single Remote Thermostat/Power - off 0 15 30 5 4 7 10 15

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35-725200-501

35-725205-115

35-725400-501

35-725405-115

Inter-purge Time(seconds)

0 15 30

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35-725201-501

35-725206-115

35-725401-501

35-725406-115

�

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Single Spark and Sense Models

Remote Sense Models

Figure 1 Figure 2


®


FEATURESSafe Start - verifies no flame is present and proper controlfunction before heat sequence beginsUse with variety of 120 VAC hot surface ignitors up to 5 AmpsTwo Mounting Configurations

Open Board with Stand-Off's - saves space and costPotted - protection for washdown and vibration

Multi Pin Connector - fast assembly2 Trial for Ignition Options - 1 and 3 try4 Trial for Ignition Times - 4, 7, 10 and 15 seconds(customized timings available)2 Flame Sense Options - local or remote senseAutomatic One Hour Reset OptionFlame current test pins - facilitates field service

APPLICATIONSTube heatersConstruction heatersCommercial cookersAny 120 VAC gas burner application under 400K BTU

The Series 35-75 controls are designed to perform many gas-fired120 VAC appliance functions in a single control resulting in lowersystem cost. The Series 35-75 monitors the demand for heat,ignites and monitors the flame during heating.

The microprocessor circuit design provides precise, repeatabletiming sequences for ignition times and purge times as well asmultiple tries for ignition. The control will accommodate a varietyof ignitor models up to 5 Amps.


Design certified by CSA International to CAN C22.2 #199-M89 andANSI Z21.20 for Automatic Ignition Systems, including UL1998 soft-ware review.

SERIES 35-75120 VAC Microprocessor BasedHot Surface Ignition Control

SPECIFICATIONS

www.fenwalcontrols.com 1-800-FENWAL-1 Series 35-75, 120 VAC Hot Surface Ignition Control Page 1

35.75.02

®

Input Power Voltage

Current

Control: 102 to 138 VAC 50/60 Hz(Class 2 Transformer)

Line: 120 VAC

Current: 100 mA max. @ 120 VAC at 25ºC (Control only)

Output (Contact Ratings) Gas Valve: 1.5A max. @ 120 VAC

Hot Surface Element: 5.0 microamp max. @ 120 VAC

Operating Temperatures -40ºF to +176ºF (-40ºC to +80ºC)Flame Sense Voltage 50% of line voltage minimum

Flame Sensitivity 1.0 microamp minimum

Types of Gas Natural, LP, or manufacturedIgnitor 120 VAC hot surface ignitors

up to 5 Amps

Moisture Resistance Open Board: Conformal coated to

operate non-condensing to 95% R.H. Care must be taken to protect module from direct exposure to water

Potted: To operate up to 100% R.H

Size (LxWxH) See Figures 2a or 2b

WeightOpen 2.3 ozBoard:

Potted: 6.1 oz


Power-UpUpon applying power (120 volts), the control will reset, perform aself-check routine, monitor the flame sense input to verify no flameis present and enter the thermostat scan state.

Call for HeatWhen a call for heat is received from the thermostat supplying 120 volts to the TH terminal, the control will perform a self-checkroutine, the safety timing sequence and flame check. After anoptional "pre-purge" period, the hot surface ignitor is energized fora heat-up period, followed by the gas valve for the "trial for ignition"

(TFI) period. If flame is detected during purge, the gas valve willremain de-energized.

IgnitionWhen a valid flame is detected during the TFI period, the ignitor isde-activated and the gas valve remains energized. The thermostatand main burner flame are constantly monitored to assure that thesystem operates properly. The control will continuously monitor theflame during the heating period. (If flame is lost, the gas valve willbe shut off within 0.8 seconds.) When the thermostat is satisfiedand the demand for heat ends, the gas valve is de-energized imme-diately.

System Failure During Trial-for-Ignition PeriodThe robust design of our gas ignition controls is demonstrated by their ability to respond to flame failures in a safe manner andprovide re-ignition options for the appliance designer.

Flame Failure During Trial-for-Ignition Period

SINGLE TRIAL MODELShould the main burner fail to light or the flame is not detected during the TFI, the control will lockout. The gas valve will be turned off immediately. With the 1 hour reset option, if the thermostat is still calling for heat, the control will auto-matically reset and attempt a new TFI after one hour.MULTI TRIAL MODELShould the main burner fail to light or the flame is notdetected during the first TFI, the gas valve is de-energized

and the control performs an optional "inter-purge" delay before attempting another TFI. The control will attempt 2 additional TFI's before locking out. In lockout, the gas valve will be turned off immediately. With the 1 hour reset option,if the thermostat is still calling for heat, the control will

automatically reset and attempt a new TFI after one hour.

Flame Failure of Established FlameRE-IGNITIONIf the established flame signal is lost while the burner is operating, the control will respond within 0.8 seconds and de-energize the gas valve. The control performs an optional "inter-purge" delay before attempting a new TFI. If the burner does not re-light, the control will lockout as previously described in the "Failure to Light - Lockout" section. Multi-try models will make 2 more attempts to light the burner. If flame is re-established, normal operation resumes.

Lockout Mode (On-Board Safety System)After single or multiple attempts to light the burner have failed orflame is not established, the control automatically enters lockoutmode. The control will not open the gas valve unless there is intervention by the user. See Lockout Recovery.Lockout RecoveryRecovery from lockout requires a manual reset by either resetting the thermostat or by removing the 120 volts for a period of 5 seconds.



Symptom Recommended Actions

1. Does not start A. Check wiringB. No voltage at PIN 3, check thermostatC. Fuse/circuit breaker badD. Bad control, consult factory

2. Thermostat on - no ignition

A. Check wiringB. Bad thermostat, no voltage

at thermostat terminal THC. Failed ignitor

3. Valve on - no ignitor A. Check wiringB. Defective ignitorC. Bad control, check voltage at ignitor

4. Ignitor on - no valve A. Valve coil openB. Open valve wireC. Bad control, check voltage

at gas valve terminal

5. Flame okay during TFI - no flame sense after TFI

A. Bad ignitorB. Bad S1 wireC. Poor ground at burnerD. Poor flame, check flame current


! WARNING: Operation outside specifications could result in failure of the Fenwal product and other equipment with injuryor death to people and damage to property. Service to thisproduct should only be performed by a qualified technician.

Table 1


!

MOUNTING AND WIRINGThe 35-75 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 (176ºF). All connections should be made with UL approved, 105°C (221°F) rated 18 gaugestranded wire with .054" minimum insulation. Refer to Figures1a & 1b Wiring Diagram when connecting the control to othercomponents in the system.

LOCAL SENSE

Figure 1a

REMOTE SENSE

Figure 1b


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. Service to this product should only be performed by a qualified technician.

CAUTION: Label all wires prior to disconnection when servicing the control. Wiring errors can cause improper and dangerousoperation. A functional checkout of a replacement is required.

!


TERMINAL PIN LOCATION

DESCRIPTION WIRE COLOR

S1 1 Remote Sense ORANGE

HS1 2 Ignitor Power GRAY

L1 3 120VAC Input (Hot) (Full Time Power)

RED

TH 4 Thermostat BLACK

L2 5 Neutral WHITE

V1 6 Valve Power BROWN

V2 7 Valve Neutral YELLOW

HS2 8Ignitor Return (or NC Contact)

BLUE

B.GND 9 Burner Ground GREENFC+ & FC Flame Current Test Pins -

Table 2

Wiring Diagrams


DIMENSIONS

OPEN BOARD WITH STANDOFFS

Figure 2a


Flame current is the current that passes through the flame from the sensor to ground. The minimum flame current necessary to keep the system from lockout is 1.0 microamps. To measure flame current, connect an analog DC micro-ammeter to the FC terminals per Figure 5. Meter should read 1.0 mAor higher. If meter reads below "0" on scale,meter leads are reversed. Disconnect power and reconnectmeter leads for proper polarity.

HOT SURFACE IGNITOR

Proper location of the hot surface ignitor is important to achieve optimum system performance for both ignition and flame sensing. See Figures 3 and 4.

NOTE: The temperature of the ceramic holder should not exceed the manufacturer's specifications.

Figure 3

WARNING:Operation outside specifications could result in failure of the Fenwal product and other equipment with injury or death to peo-ple and damage to property. Service to this product should onlybe performed by a qualified technician.

POTTED

Figure 2b


Figure 5

!

TYPICAL HOT SURFACE IGNITOR

Figure 4


SPECIFICATIONS: Voltage Rating Temperature Rating Diameter Jacket Material Agency Listings600 V 105ºC (221ºF) 18 AWG stranded PVC UL/CSA

CONTROL WIRE HARNESSSelect the proper harness based on the 35-75 control's termination connection. Once the terminal configuration is 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 and 48 inches. Example 05-129921-024 = 24 inches. For other lengths, please contact Fenwal.

Figure 8:

9 POSITION REMOTE OR LOCAL SENSE HARNESS



Figure 6:

Part Number: 22-100001-080

Figure 7:

Part Number: 22-100001-110

REMOTE FLAME SENSE

To make a harness select Amp connector housing Part Number 770849-9 and Amp housing terminal Part Number 770552-1 XX = Wire length in inches



35 - 7 5 5 X X X - X X X DESCRIPTIONTRIAL FOR IGNITION1 = 4 Seconds3 = 7 Seconds5 = 10 Seconds7 = 15 Seconds

INTER-PURGE0 = None1 = 15 Seconds2 = 30 Seconds

PRE-PURGE0 = None1 = 15 Seconds2 = 30 Seconds5 = 5 Seconds

TRIES FOR IGNITION0 = Single Try - Local Sense without Automatic Reset1 = Single Try - Remote Sense without Automatic Reset2 = Single Try - Local Sense with Automatic Reset3 = Single Try - Remote Sense with Automatic Reset5 = Three Tries - Local Sense without Automatic Reset6 = Three Tries - Remote Sense without Automatic Reset7 = Three Tries - Local Sense with Automatic Reset8 = Three Tries - Remote Sense with Automatic Reset

HEAT-UP TIME AND IGNITOR OPTIONS1 = 6 Seconds, Norton 6012 = 30 Seconds, Norton 1013 = 15 Seconds, Norton 6075 = 20 Seconds, Norton 2716 = 40 Seconds, Norton 201, 501

PACKAGING2 = Potted4 = Integral Stand-Off9 = OEM Special



These instructions do not purport to cover all the details or variations in the equipmentdescribed, nor do they provide for every possible contingency to be met in connection withinstallation, operation and maintenance. All specifications subject to change without notice.Should further information be desired or should particular problems arise which are not coveredsufficiently for the purchaser’s purposes, the matter should be referred to KIDDE-FENWAL, Inc.,Ashland, Massachusetts.

P/N 35.75.01 3/21/05


®



Fenwal Controls

400 Main Street

Ashland, MA 01721

508. 881.2000

www.fenwalcontrols.com

The 35-80 is a 24 VAC direct spark ignition control with integratedfurnace blower control features. In addition to controlling the gas valve, the 35-80 controls combustion and indoor blower motors, monitors the thermal limit,flame rollout, combustion blower airflow switch and provides service diagnostics. Four field selectable blower delays allow the furnace cooldown time to properly match every field application.

Features– Benefits:

Microprocessor based – precise, repeatable

timing sequences2 sensing options:– single spark and sense

or remote flame senseMultiple functions on one control– combustion blower control– indoor air fan control – adjustable fan-off delay– heat/cool relay– thermostat inputs

New fromFenwal

35-80 series, 24 VACFunctional integration – eliminates discrete components

and lowers costCentral wiring point – easy installationOn-board diagnostics withLED output and flame current test pins– quick troubeleshootingCSA Approved

Multi-Function Gas Ignition & Integrated Gas/Temperture

Ignition Control Features:

Input voltage - 24 VAC 120/240 V igniterLED diagnostics2 sensing optionsEnhanced flame sensitivityRemote & local flame senseConfigurable for all hot surface igniters.

Temperature ControlFeatures:

Thermistor sensor with +/- 1ºF accuracyShort/open sensor detection & diagnosticsShort cycle protectionLinearized setpoint dial

Advantages:Combines two discrete controlsLowers installed costSimplified wiringCompact SizeOEM custom design

Direct Spark Ignition withMulti-functions

Hot Surface Ignition with Precision Temperature Control

The 35-85 is a 24 VAC integrated hot surface ignition and temperature control. It utilizes a microprocessor to accurately monitor temperature and initiate the ignition sequence as needed for precise and safe control of thegas burner. Optional dual-voltagecapability allows use of a standard120 VAC HSI element with either120 or 240 VAC line voltages.Additional features such as a combustion blower control relay,LED diagnostic output, multipleignition tries, and the availability of custom ignition timings and temperature algorithms highlight the control’s versatility.

35-85 series, 24 VAC

®


Kidde-Fenwal Inc., 400 Main Street, Ashalnd, MA 01721 1-800-FENWAL-1 www.fenwalcontrols.com Page 1

®

Electrode AssembliesWith over 1,000 configurations of spark electrodes and flame sense rods, Fenwal has a design for almost anyapplication. The latest state-of-the-art wire forming and assembly equipment is used to accurately and efficientlyproduce high quality electrodes that deliver the hottest spark. The "Universal" electrodes depicted below are just a sampling of the many 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


LC Electrodes.01


Electrode Assemblies For Direct Spark and Hot SurfaceIgnition Systems

Part Number: 22-100001-117


Part Number: 22-100001-110


Part Number: 22-100001-080

Part Number: 22-100001-117

Part Number: 22-100001-025

SINGLE SPARK AND SENSE ELECTRODES continued

Page 2 www.fenwalcontrols.com 1-800-FENWAL-1 Kidde-Fenwal Inc., 400 Main Street, Ashland, MA 01721 Courtesy of Steven Engineering, Inc.-230 Ryan Way, South San Francisco, CA 94080-6370-Main Office: (650) 588-9200-Outside Local Area: (800) 258-9200-www.stevenengineering.com

Kidde Fenwal Inc., 400 Main Street, Ashland, MA 01721 1-800-FENWAL-1 www.fenwalcontrols.com Page 1

®

High Voltage Ignition WireDelivering 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 ignitionwires 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.

LC Wires.01

Wire Harnesses For Delivering 15K to 25K Volts of Spark Energy









RIGHT ANGLE SPARK PLUG WITHSILICONE RUBBER BOOT

1/4” FEMALE Q.C.

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.




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.


over Fiberglas Braid


Control Wire HarnessBelow is an overview of our most popular designs. Standard wire lengths are 12, 18, 24, 30, 36, 48, and 60 inches.


Page 2 www.fenwalcontrols.com 1-800-FENWAL-1 Kidde-Fenwal Inc., 400 Main Street, Ashland, MA 01721

FLAME SENSE WIRES:

SPECIFICATIONS: Voltage Rating Agency Rating Temperature Rating Diameter Jacket Material600 V UL/CSA Listed 200°C (392°F) 18 gage stranded PVC





FOR SERIES 35-53

FOR SERIES 35-65, -66Part Number: 05-128844-0XX




Kidde-Fenwal Inc., 400 Main Street, Ashland, MA 01721 1-800-FENWAL-1 www.fenwalcontrols.com Page 3

FOR SERIES 35-67

FOR SERIES 35-70


REMOTE SENSE








“L” “L”

“L” “L”



FOR SERIES 35-71

FOR SERIES 35-72

Remote SensePart Number: 05-129864-4XX Part Number: 05-129864-3XX










“L” “L”




“L” “L”

Page 4 www.fenwalcontrols.com 1-800-FENWAL-1 Kidde-Fenwal Inc., 400 Main Street, Ashland, MA 01721



ignition control

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