series 35-40 - Kidde Fenwal

SERIES 35-40 12/24 VDC Microprocessor-Based Direct Spark Ignition Control

F-35-40 October 2015

FEATURES • • • • • • • • •

Safe start with DETECT-A-FLAME® flame sensing technology Custom pre-purge and inter-purge timings* Single or three trials for ignition Green power LED System diagnostic LED Flame current test points Local or remote flame sensing Automatic reset** Non-volatile lockout with manual reset (optional) Digital alarm output

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UART communications (optional)

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RoHs compliant

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APPLICATIONS • • • • •

Commercial cooking Commercial laundry Gas furnaces Water heaters Other gas-fired appliances

DESCRIPTION The 35-40 is a 12/24 VDC direct spark ignition (DSI) control designed for use in all types of gas-fired appliances. The control uses a microprocessor circuit to provide precise, repeatable timing and operating sequences. High energy spark output and excellent flame sense characteristics provide reliable burner operation. On-board diagnostics with LED output makes troubleshooting easy and ensures safe and efficient operation.

Export Information (USA) Jurisdiction: EAR ECCN: EAR99

Agency Certifications Design Certified to ANSI Z21.20-2014 CAN/CSA C22.2 No. 60730-2-5-14 CE Approved to EN 298-2012 Code Compliant to: AS 4625 - 2008 AS 4622 - 2004

* Pre-purge time cannot exceed inter-purge time on CE Approved models. ** Automatic reset is not allowed for CE Approved models.

SPECIFICATIONS Input Power

Control: 10-14 VDC or 20-28 VDC

Input Current

300 mA with gas valve relay energized (control only)

Gas Valve

5.0A max (continuous)

Alarm (lockout)

Open collector: 30 VDC max. Pull to GND: 100 mA max.

Operating Temperature

-40°F to +176°F (-40°C to +80°C)

Storage Temperature

-40°F to +185°F (-40°C to +85°C)

Flame Sensitivity

0.7 µA minimum

Flame Failure Response or 0.8 seconds maximum Reignition Time Flame Detector Self-check Once per second minimum Rate Gas Types

Natural, LP, or manufactured

Spark Rate

16 per second

Size (LxWxH) with enclosure

5.32 x 3.29 x 2.00 inches (13.51 x 8.36 x 5.08 cm)

Moisture Resistance

Conformal coated to operate noncondensing to 95% R.H. Module should not be exposed to water

Ingress Protection

Not rated, protection provided by appliance in which it is installed

Tries for Ignition

One or three try versions available

Trial for Ignition Periods

4, 7, 10, 15 seconds available

Pre-purge and Inter-purge Timings

0, 15 or 30 seconds available

SEQUENCE OF OPERATION / FLAME RECOVERY / SAFETY LOCKOUT

Lockout Recovery Recovery from lockout requires a manual reset by either resetting the thermostat, or removing power for a period of 5 seconds. On models with automatic reset, if the thermostat is still calling for heat after one hour, then the control will automatically reset and attempt to ignite the burner.

Start Up - Heat Mode When a call for heat is received from the thermostat supplying 12 or 24 VDC to TH, the green power LED will illuminate, the control will reset, perform a self-check routine, flash the diagnostic LED and begin a pre-purge delay. Following the prepurge period, the gas valve is energized and sparking commences for the Trial For Ignition (TFI) period.

Some versions have an option for non-volatile lockout. In this case, only the external RESET input may be used to recover from an ignition lockout.

When flame is detected during the TFI, the sparking process is terminated and the gas valve remains energized. The thermostat and burner flame are constantly monitored to assure proper system operation. When the thermostat is satisfied and the demand for heat ends, the gas valve is immediately deenergized and the green LED turns off.

Failure to Light - Lockout SINGLE TRIAL MODEL Should the burner fail to light, or a flame is not detected during the TFI period, the gas valve will de-energize and the control will go into lockout. The diagnostic LED will indicate the fault code for ignition lockout. MULTI TRIAL MODEL Should the burner fail to light or the flame is not detected during the TFI period, the gas valve will de-energize. The control will then go through an inter-purge delay before an additional ignition attempt. The control attempts two additional ignition trials before de-energizing the gas valve and entering lockout. The diagnostic LED will indicate the fault code for ignition lockout. FLAME FAILURE - RE-IGNITION MODE If the established flame signal is lost while the burner is operating, the control will respond within 0.8 seconds by immediately energizing the H.V. spark for the TFI period in an attempt to relight the flame. If the burner does not light within the TFI, the gas valve will immediately de-energize and single try models will enter lockout. On multi-try models, a new TFI sequence will begin after an inter-purge delay. Multi-try models perform two additional attempts to light the burner before deenergizing the gas valve and entering lockout. If the burner relights, normal operation resumes. FLAME FAILURE-RECYCLE MODE With the “Recycle After Loss of Flame" option, upon loss of flame, the gas valve is de-energized and the control proceeds to inter-purge before attempting to relight the flame. Multi-try models permit three tries for ignition including inter-purges. If the burner relights, normal operation resumes. If the burner does not relight, the control will enter lockout.

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F-35-40 Effective: October 2015

MOUNTING AND WIRING

Wiring Diagrams - 35-40

The Series 35-40 control is not position sensitive and can be mounted vertically or horizontally. The case may be mounted on any surface with #6 sheet metal screws.

CAUTION

CAUTION

ALARM 1

All wiring must be performed in accordance with both local and national electrical codes.

POWER

2

RESET

3

TH 4 GND 5

Label all wires prior to disconnection when servicing controls. Wiring errors may cause improper and dangerous operation. A functional checkout of a replacement control should always be performed.

GAS VALVE

6

DIGITAL I/O

7 8

B_GND

9

24VDC

FS 10

Figure 1. 24 VDC with Remote Sense

This product uses voltages of shock hazard potential. Wiring and initial operation must be WARNING performed by a qualified service technician.

ALARM 1

POWER 2

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

RESET 3 TH

4

12V DC

GND 5 GAS VALVE 6

24V DC

Rx 7 Tx 8

Terminal Designations 10-pin (.156” Header) Name

Description

ALARM

Lockout

POWER

Power (24 VDC)

RESET

Manual Reset

Pin 3

TH

Thermostat

Pin 4

GND

Valve Return

Pin 51

VALVE

Main Gas Valve

Pin 6

RX

Digital Output

UART RX

Pin 7

TX

Unused

UART TX

Pin 8

B. GND

Burner Ground

Pin 9

S1

Flame Sensor

Pin 10

F-35-40 Effective: October 2015

B_GND 9

Alternate Use Connection Pin 1 (12 VDC)

Pin 2

Figure 2. 12 VDC Power, 24 VDC Valve with Local Sense

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TROUBLESHOOTING

Proper Electrode Location Proper location of electrode assembly is important for optimum system performance. The electrode assembly should be located so that the tips are inside the flame envelope and about 1/2-inch (1.2 cm) above the base of the flame as shown:

Troubleshooting Guide Symptom

Recommended Actions

1. Control does not start, green LED is off

A. Miswired B. 12/24 VDC supply fault C. Fuse/circuit breaker fault D. No Thermostat Signal

2. Thermostat on - no spark

A. Miswired B. Faulty thermostat, no voltage at thermostat terminal TH C. Faulty control, check red LED for fault codes

3. Valve on - no spark during TFI

4. Spark on - valve off

5. Flame okay during TFI no flame sense after TFI

Notes:

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A. Shorted electrode establish 1/8-inch gap B. Check high voltage cable C. Miswired

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A. Valve coil open B. Valve wire disconnected C. Faulty control, check voltage at gas valve terminal VALVE

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A. Check electrode position B. Check high voltage wire C. Poor ground at burner D. Poor flame, check flame current

Flame Current Measurement Flame current is the current that passes through the flame from sensor to ground. To measure flame current, connect a True RMS or analog DC micro-ammeter to the FC+ and FC- terminals. Readings should be 1.0 µA DC or higher. If the meter reads negative or below "0" on scale, meter leads are reversed. Reconnect leads with proper polarity.

Fault Conditions - Red diagnostic LED LED Indication

Fault Mode

Steady On

Internal Control Failure

2 Flashes

Flame without call for heat

3 Flashes

Ignition Lockout

Ceramic insulators must not be in or close to the flame. Electrode assemblies must not be adjusted or disassembled. Electrodes are NOT field adjustable. Electrodes should have a gap spacing of 0.125± 0.031 in (3.12± 0.81 mm), unless otherwise specified by the appliance manufacturer. If spacing is not correct, the assembly must be replaced. Exceeding temperature limits can cause nuisance lockouts and premature electrode failure. Electrodes must be located where they are not exposed during normal operation.

Alternately, a Digital Voltmeter may be used to measure DC voltage between FC+ and FC- terminals. Each micro-amp of flame current produces 1.0 VDC. For example, 2.6 VDC equates to 2.6 µA. A good burner ground that matches the control ground is critical for reliable flame sensing.

Note:

During a fault condition, the LED will flash on for 1/4 second and off for 1/4 second as needed to indicate the fault code. The code will repeat every 3 seconds. Removing power from the control will clear the fault code. Digital Output: The diagnostic LED codes are also available as a 0 to 5 VDC signal on Pin 7. This output is current limited to 2 mA.

Internal Control Failure If the control detects a software or hardware error, all outputs are turned off and the red LED displays a Steady On condition. If this condition persists after an attempt to restart, then the control must be replaced.

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F-35-40 Effective: October 2015

DIMENSIONS

5.11

.21

4.25 RED LED (FAULT)

1.615 2.63

GREEN LED

.178 DIA 4 MOUNTING HOLES

PIN 1

1.80

Figure 3. Standard Enclosure Note: All dimensions are in inches F-35-40 Effective: October 2015

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3.29

PART NUMBER CONFIGURATION

SERIES 35 - 40 X X X X - X X X Trial for Ignition Time 1 = 4 Seconds 3 = 7 Seconds 5 = 10 Seconds 7 = 15 Seconds

Voltage & Configuration 0 = 12 VDC Model 1 = 12 VDC with 24 VAC/VDC Thermostat/GV 2 = 12 VDC with Isolated GV Contacts 5 = 24 VDC Model 6 = 24 VDC with 12 VAC/VDC Thermostat/GV 7 = 24 VDC with Isolated GV Contacts

Inter-Purge Time 0 = None 1 = 15 Seconds 2 = 30 Seconds

Product Designation 2 = Standard CE Approved Model* 3 = Special CE Approved Model* 5 = Multi-Pin Standard 9 = Special OEM Configuration

Pre-Purge Time 0 = None 1 = 15 Seconds 2 = 30 Seconds

A 3 or 9 in this location (i.e. 35-40 0 901 -113) indicates a special configuration. 9XX is a sequentially assigned part number and does not follow the standard part numbering configuration.

Enclosure Configurations 0 = Noryl Gray Enclosure 1 = Integral Standoffs

Tries for Ignition & Method of Flame Sense 0 = Single Try, Local Sense 1 = Single Try, Remote Sense 2 = Single Try, Local Sense with 1 Hour Automatic Reset 3 = Single Try, Remote Sense with 1 Hour Automatic Reset 5 = Three Tries, Local Sense 6 = Three Tries, Remote Sense 7 = Three Tries, Local Sense with 1 Hour Automatic Reset 8 = Three Tries, Remote Sense with 1 Hour Automatic Reset

Consult Fenwal for operating characteristics of this control.

* On CE Approved models, pre-purge time cannot exceed inter-purge time and automatic reset is not permitted.

FENWAL® and DETECT-A-FLAME®are registered trademarks of Kidde-Fenwal, Inc. All other trademarks are the property of their respective owners. Fenwal Controls, Kidde-Fenwal, Inc. 400 Main Street Ashland, MA 01721 Tel: 800-FENWAL-1 Fax: 508-881-7619 www.fenwal.com

This literature is provided for informational purposes only. KIDDEFENWAL, INC. assumes no responsibility for the product’s suitability for a particular application. The product must be properly applied to work correctly. If you need more information on this product, or if you have a particular problem or question, contact KIDDE-FENWAL, INC., Ashland, MA 01721. © 2015

Kidde-Fenwal, Inc.

P/N F-35-40

Rev AA