Conversion Guide - Kidde Fenwal

1 Conversion Guide05-38 to 35-70 Series120 VAC Direct Spark Ignition ControlFenwal continues advancing direct spark gas ignition technology by employing its legendary design experience to develop a new line of microprocessor based ignition controls for the 120 VAC marketplace. The 35-70, 120 VAC DSI is the most recent advance in Fenwal 's broad product mix to serve this market. Providing safe gas ignition control and flame monitoring for 120 VAC gas burner systems, the 35-70's microprocessor based design offers a wide range of configurations in a cost effective 35-70 is the latest in a long line of 120 VAC controls and replaces the following Fenwal analog controls: the 05-13 (circa 1960), 05-14 (circa 1970) and 05-38 (circa 1985). This Conversion Guide providesinformation to quickly and safely convert an applicationfrom the 05-38 to the 35-70. The 35-70's microprocessor design offers significant advantages over its analog predecessors by providing:nExtremely precise ignition and purge timings +/- 5% accuracy versus +/- 20% for the previous controlsnLED diagnostics for accurate and fast troubleshootingnImproved flame sensitivity for difficult applications and prevention of nuisance lockoutsnPolarity insensitive wiringnReduced footprint for space limited applicationsnMultiple methods for lockout recoverynSoftware based customization for ignition and purge timingsThis Guide includes:nAgency approval comparisonsnTerminal designation and size comparisonnSingle Spark and Sense vs.

2 Local Sense electrode wiring nControl wiring comparisonnFootprint comparisonsnConversion list for most popular controlsAlong with the 35-70, Fenwal is proud to offer two additional controls (35-71, 35-72) as part of the 35-7X family of 120 VAC Direct Spark Ignition Controls. These products aredesigned to match the features and price needs of a wide variety of DSI Control- The "Base Model"is ideal for commodity products where simple ignition control is required and price is amajor determining DSI Control- Provides combustion blower relay control and monitors the pressure switch with LED diagnostics and flame sense test pins, ideal for those customers who prefer more integration to reduce component count and system wiring. 05-38 ApprovedApproved* *Certain ModelsAGENCY APPROVALUL 372, UL 1998 SoftwareCSA: ANSI , No. 199-M89FM: Ignition Device and Flame Safeguard35-70 ApprovedApproved*ApprovedAgency Comparison* The 35-70 Series has been FM approved by Factory Mutual as both an ignition device and flame safeguard.

3 FM certificationallows only single trial for ignition models with up to 15 secondTrial for Ignition time. Conversion Guide , 05-38 to 35-70 Page * * The 05-38 models that are FM approved have a single try forignition with a minimum of 5 seconds for pre-purge to prove thatno flame is present. The TFI time must be less than 10 CG to Designation and Size ComparisonLt. BlueBrownWhiteYellowBlackPurpleGrayN/A2 Pin Header AlarmValve Power120 VAC (Neutral)Valve Neutral120 VAC Input (Hot)Burner GroundRemote Flame SensorLocal SenseFlame Sense Test Pins NCV1L2V2L1B. GNDS1E2N/A1/4 3/16 3/16 3/16 1/4 3/16 1/4 SQ1/4 1/4 1/4 1/4 1/4 1/4 1/4 1/4 N/ADescriptionTERMINALDESIGNATIONQUICK CONNECT TERMINALMULTIPIN +,FC-111087621N/A05-3835-70 PINLOCATIONWIRE COLOR35-70 ONLYNew Grounding SchemeFor all models of the 35-70, the terminal is used to ground the burner and to complete the flame current signal circuit. This terminal must be connected to the burner (chassis) ground not only to ensure the best, longterm, stable flame signal, but also to ground the burner for proper sparking, especially in the case of single spark andsense.

4 See wiring diagrams for Conversion of 05-38 to 35-70 use of a burner ground terminal eliminates the problemof loss of flame sense signal due to a missing or loose neutral or ground (green) wire at the 120 VAC power 35-70 has been designed such that reversing the polarity of the 120 VAC line does not cause a loss of flame signal. Thus, the 35-70 provides a more reliable flame signal along with a reduction of nuisance lockouts, due to its designand the use of the requirements for Single Spark and Sense vs. Local Sense ApplicationsSince 05-38s with Local Sense are replaced by 35-70s withSingle Spark and Sense, the electrode must be re-wired orreplaced with a simpler electrode configuration. Typically, alocal sense electrode, see figure below, has two electrodeson the same bracket. This type of electrode assemblyrequires that a high voltage wire and flame sense wire beattached to each electrode and wired back to the control. A single spark and sense electrode has only one electrode onthe bracket and requires just the high voltage wire and a grounded burner.

5 See Figure 1 Guide 05-38 to 35-70 Page SPARK AND SENSE VS. LOCAL SENSE WIRINGF igure 1:Terminology - Single Spark and Sense vs. Local SenseOne important note on wiring the 35-70 has to do with terminology and wiring for flame sense. In all of the new 120 VAC control literature, especially that for the 35-70, we have made a point to use the term "Single Spark and Sense" rather than the more colloquial "Local Sense" when referring to sensing flame on the spark electrode. Local Sense versions of the 05-38s have the flame sense signaltravel to the board along a separate wire (not the wire) to aterminal on the control typically identified as E2. This is a very important distinction. Single Spark and Sense is easier to wire as it eliminates the need for an additional sense wire, because the high voltage wire serves the dual role of supplying spark energy to the electrode and passing the flame sense current to the control. Conversion Guide 05-38 to 35-70 Page to 35-70 Wiring ComparisonREMOTE SENSELOCAL SENSESINGLE SPARK AND SENSE05-3835-7035-7005-3835-7005-3835-70 35-70 Conversion Guide 05-38 to 35-70 Page to 35-70 Footprint Comparison05-38 POTTED35-70 POTTED05-38 CASE AND COVER35-70 CASE AND COVER05-38 STAND-OFF35-70 STAND-OFFNOTES05-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 1 05-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2.

6 Figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense, see page 2, figure 1; potted, see page 6, note 105-38 local flame sense is replaced by 35-70 with single spark and sense, see page 2, figure 1; potted, see page 6, note 105-38 local flame sense is replaced by 35-70 with single spark and sense, see page 2, figure 1; potted, see page 6, note 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 1; 3 try, see page 6, note 205-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2 , figure 1; 3 try, see page 6, note 2 05-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2, figure 1.

7 Potted, see page 6, note 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2 , figure 105-38 local flame sense is replaced by 35-70 with single spark and sense flame sense, see page 2 , figure 1 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2; potted, see page 6, note 1 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2.

8 Potted, see page 6, note 1 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2;3 try, see page 6, note 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2.

9 3 try, see page 6, note 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller, see chart on top of page 2 Electrically interchangeable though some terminal sizes on the 35-70 are smaller.

10 See chart on top of page 2 Conversion Guide 05-38 to 35-70 Page to 35-70 Conversion Chart35-70 CROSS REFERENCE35-705600-10135-705600-00135-70 5600-00135-705600-00535-705500-10535-705 500-10535-705500-50135-705500-00135-7055 00-00135-705500-00335-705500-00535-70570 0-10335-705605-11535-705505-11135-705505 -11335-705505-11535-705505-22535-705505- 51135-705505-51535-705705-11535-705601-1 0335-705601-20135-705601-00135-705601-00 535-705601-10135-705501-10535-705501-201 35-705501-50135-705501-50535-705501-0013 5-705501-00135-705501-00335-705501-00535 -705501-00535-705701-10135-705701-00135- 705606-11135-705606-11335-705606-22535-7 05606-51135-705506-11135-705506-11135-70 5506-11535-705506-22135-705506-22535-705 506-51535-705600-00535-705500-10135-7055 00-10535-705500-20335-705500-50535-70550 0-00135-705500-00135-705500-00335-705500 -00535-705500-00535-705505-11335-705505- 11535-705505-115 EXISTING PART NUMBER05-384200-15005-384200-75005-38420 0-75105-384200-75505-384201-15505-384201 -15605-384201-55105-384201-75005-384201- 75105-384201-75305-384201-75505-384202-1 5305-384240-15505-384241-15005-384241-15 305-384241-15505-384241-25505-384241-551 05-384241-55505-384242-15505-384400-1530 5-384400-25105-384400-75105-384400-75505 -384400-15105-384401-15505-384401-25105- 384401-55105-384401-55505-384401-75005-3 84401-75105-384401-75305-384401-75505-38 4401-75605-384402-15105-384402-75105-384 440-15105-384440-15305-384440-25505-3844 40-55105-384441-15005-384441-15105-38444 1-15505-384441-25105-384441-25505-384441 -55505-384600-75505-384601-15005-384601- 15505-384601-25305-384601-55505-384601-7 5005-384601-75105-384601-75305-384601-75 505-384601-75605-384641-15305-384641-155 05-384641-156 Conversion Guide 05-38 to 35-70 Page MAIN STREET, ASHLAND, MA 01721 TEL: (508) 881-2000 FAX.