SERIES 35-60J. 24 VAC Microprocessor Based Direct Spark Ignition Control Johnson Controls G76x Series Replacement FEATURES

Transcription

1 SERIES 35-60J 24 VAC Microprocessor Based Direct Spark Igitio Cotrol Johso Cotrols G76x Series Replacemet 35-60J FEATURES Drop-i replacemet for JCI G76x series Safe Start ad full-time flame sesig Custom prepurge ad iterpurge timigs Multiple trials for igitio Diagostic LED usig Fewal fault codes Three groud termials for ease of wirig Remote or local flame sese optios Automatic 5 mi or 1 hour reset after lockout optios APPLICATIONS Directly replaces Johso Cotrols G76x i: Commercial cookig equipmet Commercial gas furaces Uit heaters Water heaters Cosider the Fewal 35-60J for DSI applicatios where a smaller footprit is desirable SPECIFICATIONS DESCRIPTION The Fewal J Series provides all the features, performace ad reliability of our Series 24 VAC Direct Spark Igitio cotrol i a Johso Cotrols format. Desiged to directly replace the Johso G76x Series, the Fewal 35-60J matches the footprit, moutig hole patter, ad wirig coectios of the discotiued Johso series. ADVANTAGES Microprocessor cotrol for precise, repeatable timigs ad operatig sequeces Fewal Platform Desig for easy customizatio of igitio cycle ad timigs to appliace requiremets High Spark Eergy for fast, depedable burer igitio Superior 120V Flame Sese Sigal provides safe, reliable burer operatio (vs. 24V desig) O-board diagostics with LED display for efficiet operatio ad easy troubleshootig Agecy Certificatios Desig certified to ANSI Z21.20, CAN/CSA C22.2 No. 199-M99. NOTE: For the Itermittet Pilot versio comparable to the Johso G77x Series, see Fewal 35-63J. Iput Power Iput Curret Drai Mai Gas Valve Operatig Temperature Storage Temperature Flame Sesitivity Flame Failure Respose or Re-igitio Time Flame Detector Self-check Rate Types of Gas Spark Rate Size (LxWXH) Weight Moisture Resistace Tries for Igitio Trial for Igitio Periods Prepurge Timigs Iterpurge Timigs Cotrol: VAC 50/60 Hz (Class 2 Trasformer) 300 VAC with gas relay eergized (Cotrol oly) 2.0A max (cotiuous) -40ºF to +176ºF (-40ºC to +80ºC) -40ºF to +185ºF (-40ºC to +85ºC) 0.3 µa miimum 0.8 secods maximum Oce per secod miimum Natural, LP, or maufactured Remote sese (50/60 Hz) Local sese (25/30 Hz) 4.92 x 3.32 x 2.71 iches (with cover) x 8.43 x 6.88 cm (with cover) 8 ouces 224 grams (omial) Coformal coated to operate to 95% R.H. (o-codesig) Oe or three try versios available 4, 6, 8, 10, 15 secods available Noe, 15, or 30 secods available Noe, 15, or 30 secods available 24 VAC Direct Spark Igitio Cotrol - Johso Cotrols G76x Series Replacemet Page 1

2 SEQUENCE OF OPERATION / FLAME RECOVERY / SAFETY LOCKOUT Start Up - Heat Mode Whe a call for heat is received from the thermostat supplyig 24 volts to THS, the cotrol will reset, perform a self check routie, flash the diagostic LED oce i the first two secods, ad a pre-purge delay begis. Followig the pre-purge period, the gas valve is eergized ad sparks commece for the trial for igitio period. Whe flame is detected durig the trial for igitio, the sparkig process is termiated ad the gas valve remais eergized. The thermostat ad burer flame are costatly moitored to assure the system cotiues to operate properly. Whe the thermostat is satisfied ad the demad for heat eds, the gas valve is de-eergized immediately. Failure to Light - Lockout SINGLE TRIAL MODEL Should the mai burer fail to light, or if the burer flame is ot detected durig the trial for igitio period, the cotrol will go ito lockout. The gas valve is de-eergized immediately. The LED will idicate the code for igitio lockout. MULTI TRIAL MODEL Should the mai burer fail to light, or if the burer flame is ot detected durig the first trial for igitio period, the mai gas valve is de-eergized. The cotrol the goes through a iterpurge delay before aother igitio attempt. The cotrol will attempt two additioal igitio trials before goig ito lockout ad the gas valve relay will be de-eergized immediately. Recovery from lockout requires a maual reset by either resettig the thermostat or removig 24 volts for a period of 5 secods. O models with automatic reset, if the thermostat is still callig for heat after 5 miutes the cotrol will automatically reset ad attempt to igite the burer. Flame Failure - Recycle Mode (stadard) With "recycle after loss of flame", upo loss of burer flame, the mai gas valve is de-eergized ad the cotrol proceeds to iterpurge before attemptig to relight the burer. Multi-try models will allow three tries for igitio icludig iterpurges. If the burer relights, ormal operatio resumes. If the burer does ot relight, the cotrol will go ito lockout as described i "Failure to Light". Flame Failure - Re-igitio Mode (optioal) If the established flame sigal is lost while the burer is operatig, the cotrol will respod withi 0.8 secods by eergizig the HV spark i a attempt to relight the burer for the programmed TFI period. If the burer does ot light withi the TFI, the gas valve is de-eergized immediately ad o multi-try models a ew TFI sequece begis. If the burer does ot relight, the cotrol will lockout as previously described i the "Failure to Light" sectio. Multi-try models will make two more attempts to light the burer. If flame is re-established, ormal operatio resumes. TABLE 1 - FAULT CONDITIONS LED INDICATION FAULT MODE 2 Flashes Flame without call for heat 3 Flashes Igitio Lockout Steady O Iteral Cotrol Failure The LED will flash o for 1/4 secod, the off for 1/4 secod durig a fault coditio. The pause betwee fault codes is 3 secods. Iteral Cotrol Failure: If the cotrol detects a error i its software or hardware, all outputs are tured off ad the LED displays a steady ON coditio. MOUNTING AND WIRING The Series 35-60J is ot positio sesitive ad ca be mouted vertically or horizotally. The case may be mouted o ay surface with #6 sheet metal screws. CAUTION: Label all wires prior to discoectio whe servicig cotrols. Wirig errors ca cause improper ad dagerous operatio. There are o field replaceable compoets iside the cotrol. It must be replaced i whole. TABLE 2 - WIRING TERMINALS TERMINAL THS MV _GND GND_ GND BLIND SENSE HV DESCRIPTION Thermostat Iput Mai Valve Power Valve Groud Valve Groud System Groud No Coectio Remote Flame Sesor High Voltage Output QUICK CONNECT 1/4 ich 1/4 ich 1/4 ich 1/4 ich 1/4 ich 1/4 ich 1/4 ich Rajah The cotrol must be located ad mouted i a maer that protects compoets from exposure to water (drippig, codesate, sprayig, rai). Ay cotrol that has bee exposed to water must be replaced. All wirig must be doe i accordace with both local ad atioal electrical code. Wirig must be at least #18 AWG rated for 105 C or higher. The Series 35-60J uses voltages of shock hazard potetial. Wirig ad iitial operatio must be doe by a qualified service techicia. Operatio outside specificatios could result i failure of the Fewal product ad other equipmet with ijury to people ad property. Page 2 24 VAC Direct Spark Igitio Cotrol - Johso Cotrols G76x Series Replacemet

3 PROPER ELECTRODE LOCATION Proper locatio of the electrode assembly is importat for optimal system performace. The electrode assembly should be located so that the tips are iside the flame evelope ad about 1/2 ich (1.2 cm) above the base of the flame. TROUBLESHOOTING GUIDE SYMPTOM 1. Cotrol does ot start RECOMMENDED ACTIONS A. Miswired B. 24 VAC trasformer bad C. Fuse/Circuit breaker bad D. Bad cotrol. Check LED for steady o or flashig code (see Table 1) CAUTIONS: 1. Ceramic isulators should ot be i or close to the flame. 2. Electrode assemblies should ot be adjusted or disassembled. Electrodes should have a gap spacig of 0.125± ich (3.12± 0.81 mm), uless otherwise specified by the appliace maufacturer. If this spacig is ot correct, the assembly must be replaced. Electrodes are NOT field-adjustable. 3. Exceedig the temperature limits ca cause uisace lockouts ad premature electrode failure. 4. Electrodes must be placed where they are ot exposed to the appliace user i ormal operatio. 2. Thermostat o, o spark 3. Valve o, o spark durig TFI 4. Spark o, valve off 5. Flame okay durig TFI, o flame sese after TFI A. Miswired B. Bad thermostat, o voltage at thermostat termial THS. C. Bad cotrol. Check LED for steady O or flashig codes A. Shorted electrode - establish 1/8th ich gap B. Check high voltage cable C. Mis-wired A. Valve coil ope B. Valve wire discoected C. Bad cotrol, check voltage at gas valve termials MV ad GND A. Check electrode positio B. Check high voltage wire C. Poor groud at burer D. Poor flame, check flame curret WIRING DIAGRAMS LOCAL SENSE REMOTE SENSE 24 VAC Direct Spark Igitio Cotrol - Johso Cotrols G76x Series Replacemet Page 3

4 DIMENSIONS With Cover Without Cover Page J 24 VAC Direct Spark Igitio Cotrol - Johso Cotrols G76x Series Replacemet

5 PART NUMBER CONFIGURATION SERIES J X X X -X X X Optios 1 = Recycle After Loss of Flame (stadard) 3 = 1 Hour Auto Reset (i place of 5 miutes) 5 = Re-igitio After Flame Loss 9 = Special OEM Cofiguratio* *No-Stadard Cofiguratios A 9 i this locatio of the part umber (i.e J ) idetifies this cofiguratio as a o-stadard desig. The part umber does ot follow the part umberig system. The 9XX is a sequetial part umber assiged by Fewal. Cosult factory for operatig characteristics of this cotrol. Trial for Igitio 1 = 4 Secods 3 = 6 Secods 4 = 8 Secods 5 = 10 Secods 7 = 15 Secods Iter-Purge 0 = Noe (Sigle Try Oly) 1 = 15 Secods 2 = 30 Secods Pre-Purge 0 = Noe 1 = 15 Secods 2 = 30 Secods Tries for Igitio, Flame Sese ad Lockout Reset Methods 0 = Sigle Try, Local Sese Thermostat / power off reset 1 = Sigle Try, Remote Sese Thermostat / power off reset 2 = Sigle Try, Local Sese 5 miute automatic reset 3 = Sigle Try, Remote Sese 5 miute automatic reset 5 = Three Tries, Local Sese Thermostat / power off reset 6 = Three Tries, Remote Sese Thermostat / power off reset 7 = Three Tries, Local Sese 5 miute automatic reset 8 = Three Tries, Remote Sese 5 miute automatic reset Eclosure 0 = Noryl Gray Eclosure 1 = Itegral Stadoffs 2 = Board Oly NOTES: Maximum Flame Failure Lockout Time = # of Tries x (Iter-Purge + TFI Time) Maximum Valve Sequece Period = # of Tries x TFI Time FENWAL CONTROLS 400 MAIN STREET, ASHLAND, MA TEL: (508) FAX: (508) These istructios do ot purport to cover all the details or variatios i the equipmet described, or do they provide for every possible cotigecy to be met i coectio with istallatio, operatio ad maiteace. All specificatios subject to chage without otice. Should further iformatio be desired or should particular problems arise which are ot covered sufficietly for the purchaser s purposes, the matter should be referred to KIDDE-FENWAL, Ic., Ashlad, Massachusetts Fewal 35.60J 10/14/ VAC Direct Spark Igitio Cotrol - Johso Cotrols G76x Series Replacemet Page 5