F-35-1000
January 2016
Platform Ignition Module
Application Guide
TABLE OF CONTENTS
CHAPTER 1 PRODUCT OVERVIEW AND DESCRIPTION
1-1
Introduction ......................................................................................... 1-1
1-2
Applications ......................................................................................... 1-1
1-3
System Integration ............................................................................... 1-2
1-4
Features .............................................................................................. 1-3
1-5
Agency Approvals ................................................................................. 1-3
1-6
Reference Documents............................................................................ 1-4
1-7
Specifications ....................................................................................... 1-4
CHAPTER 2 PIM FEATURES
2-1
Control Power....................................................................................... 2-1
2-2
Wiring Connections ............................................................................... 2-1
2-3
Ignition Outputs ................................................................................... 2-1
2-4
Gas Valve Options................................................................................. 2-1
2-5
Combustion Blower ............................................................................... 2-1
2-6
High-Current Blower Option.................................................................... 2-1
2-7
Auxiliary Relay Outputs.......................................................................... 2-1
2-8
UL353 High Limit Sensor........................................................................ 2-2
2-9
Temperature Sensors ............................................................................ 2-2
2-10
Demand Inputs..................................................................................... 2-2
2-11
Safety Inputs ....................................................................................... 2-2
2-12
RATE INPUTS ....................................................................................... 2-2
2-13
Temperature Control ............................................................................. 2-2
2-14
Potentiometer (Setpoint) ....................................................................... 2-2
2-15
Configuration (DIP Switch Settings)......................................................... 2-2
2-16
ID Card ............................................................................................... 2-3
CHAPTER 3 HYDRONICS FUNCTIONS
3-1
Outdoor Reset ...................................................................................... 3-1
3-2
Domestic Hot Water Control ................................................................... 3-1
3-3
Pump Control ....................................................................................... 3-1
3-4
Freeze Protection .................................................................................. 3-1
CHAPTER 4 COMMUNICATIONS AND DIAGNOSTICS
4-1
RS485 Communications ......................................................................... 4-1
4-2
Energy Management System (Customer provided)..................................... 4-1
4-3
Indicators ............................................................................................ 4-1
4-4
Self-Check/Control Failure...................................................................... 4-1
4-5
System Safety Checks ........................................................................... 4-1
4-6
Flame Current Measurements ................................................................. 4-2
4-7
Non-Volatile Lockout/Manual Reset.......................................................... 4-2
CHAPTER 5 APPLICATION EXAMPLES
5-1
Application Examples............................................................................. 5-1
5-1.1
High Efficiency Modulating Boiler............................................................. 5-1
5-1.2
HVAC Space Heater............................................................................... 5-2
5-1.3
Commercial Cooking.............................................................................. 5-3
F-35-1000
i
January 2016
TABLE OF CONTENTS (CONT.)
APPENDIX A
A-1
A-2
A-3
A-4
APPLICATION WORKSHEET
Factory Low-Voltage Connections (30 VAC Max)........................................ A-1
Factory Line-Voltage Connections............................................................ A-1
Low-Voltage Field Wiring Connections (30 VAC Max).................................. A-2
Hardware Configuration ......................................................................... A-2
APPENDIX B
B-1
PIM PARAMETER DESCRIPTIONS
PIM Parameters .................................................................................... B-1
APPENDIX C
C-1
PART NUMBER BREAKDOWN
PIM Part Number .................................................................................. C-1
APPENDIX D
D-1
FENWAL DEVELOPMENT TOOL
Fenwal Development Tool ...................................................................... D-1
January 2016
ii
F-35-1000
Product Overview and Description
CHAPTER 1
PRODUCT OVERVIEW AND DESCRIPTION
1-1
INTRODUCTION
The Fenwal Controls® Platform Ignition Module (PIM™) integrates the functions of Automatic
Ignition Control with temperature regulating and appliance control functions. The PIM is
designed for a range of applications including both staged systems and modulating types. The
PIM can be configured as a direct spark ignition (DSI), intermittent pilot (IP) or Hot Surface
Ignition (HSI) to provide safe lighting and supervision of the burners in an appliance.
The PIM is capable of RS485 communications which can be tailored to interact with User
Interface/Displays, OEM controls, networks, PC analysis tools, or other devices. It also accepts
analog signals from other controllers or Energy Management Systems (EMS).
For hydronics applications, the PIM directly connects and communicates with the tekmar®
Boiler Temperature Control (BTC_II). When connected to a BTC_II, the PIM offers expanded
control functionality including Domestic Hot Water (DHW), outdoor reset, diagnostic messages,
and other system capabilities.
Figure 1-1. PIM and Associated Components
1-2
APPLICATIONS
The PIM control system is suited to a wide variety of residential and commercial gas-fired
heating systems including:
F-35-1000
•
High-efficiency Modulating Condensing Boilers
•
Fan-assisted single and multi-staged Systems
•
Intermittent Pilot based appliances
•
Water Heaters
•
Pool and Spa Heaters
•
Commercial Cooking
•
HVAC and Air-Handling Systems
•
Industrial Process Systems
1-1
January 2016
Product Overview and Description
1-3
SYSTEM INTEGRATION
The PIM is able to intelligently integrate and replace multiple discrete components with a single
control. In a typical application it will replace all of the blue shaded items in the figure below.
This allows the OEM to increase burner and system performance while simplifying wiring and
construction with a high-value solution.
Temp
Sensor
Limit
Sensor
Flame Sense
Temperature
Control
High Limit
2nd Stage
Demand
PWM
Blower
Control
Blower
Relay
Burner
Gas
Valve
Ignition Control
TDR
2nd Stage
Valve
Combustion
Blower
Gas Flow
Diagnostics with
Fault Control
Blower
Contactor
Circulation
Blower
TDR
Temp
Sensor
AUX
Function
Control
Vent
Damper
Figure 1-2. System Integration
January 2016
1-2
F-35-1000
Product Overview and Description
1-4
FEATURES
The PIM provides the following features:
1-5
•
Integrated UL353 High Limit using Thermistor Sensor
•
Configuration parameters selected through a unique Identification Card
•
Communicates via RS485
•
Measures up to seven temperature sensors using NTC curve
J Thermistors, 10 KΩ (β3892) at 25°C (12 KΩ Thermistors optional).
•
Optional signals from DHW, System, and Outdoor Air sensors to a tekmar BTC_II for
Outdoor Reset and DHW functions.
•
Supports external input (0-10 VDC or 4-20 mA) from an Energy Management System
•
Controls up to three relays for auxiliary functions.
•
Controls the gas ignition sequence in response to heating demand
•
Rate sensor input for processing flow rates
•
Modulation of firing rate using combustion blower speed control, providing a PWM output
or a 4-20 mA signal.
•
Closed-loop control of blower speed (RPM) through tachometer signal monitoring
•
Optional support for two-stage blowers by re-assigning an auxiliary relay
•
Low-voltage detection and safe shutdown below 18.0VAC supply input
•
Hot Surface or Direct Spark Ignition (also allows for external HV transformer)
•
Intermittent Pilot Ignition (single stage only)
•
Fail-safe Control for one or two stages of gas valves
•
24 VAC or Isolated Contact Gas Valve operation
•
Five safety switch inputs for monitoring and diagnostics
•
Optional automatic reset after ignition lockout (one hour or as defined)
•
Safe-Start and full-time Flame sensing
•
Local (through the HSI or DSI element) or Remote Flame sensing
•
Configurable as needed to meet CSD-1 applications
•
System and Control Diagnostics through use of on-board or remote LED
•
Communication of Diagnostic status through RS485
•
Manual Reset for Ignition Lockout or Hi-Limit (on-board or remote)
•
Field Test capability
•
Dry contact relay output for Alarm and Alert conditions
•
Capability of dual PIM operation to support up to 4 gas valve stages using a
master/member configuration
AGENCY APPROVALS
CSA Design certified to ANSI Z21.20,
CAN/CSA C22.2 No. 199-M99
F-35-1000
1-3
January 2016
Product Overview and Description
1-6
REFERENCE DOCUMENTS
The PIM complies with the documents listed below and any applicable materials referenced in the
documents listed.
Table 1-1. Reference Documentation
Document Number
Name
ANSI Z21.20-2005
Thermostats and Automatic Gas Ignition Systems and Components
CAN C22.2 #199
Combustion Safety Controls and Solid State Igniters for Gas and Oil Burning Equipment
UL 372
Primary safety Controls for Gas and Oil Fire Appliances (Harmonized version)
UL 1998
Software in Programmable Components, 2nd edition
UL 353
Limit Controls
ASME CSD-1-2009
Requirements CF-200, CF-300 and CW-400
1-7
SPECIFICATIONS
Table 1-2. Specifications
Specification
Value
Input Power
Control: 18-30 VAC 50/60 Hz (Class 2 Transformer)
Input Current Drain
400 mA @ 24 VAC with gas and blower relays energized (Control only)
Gas Valve Relays
5.0A max (continuous)
Combustion Blower
5.0 A max for standard (J2) connection
15.0 A max for heavy-duty (K5 relay) terminals
Hot Surface Igniter
5.0 A max, 120/240 VAC
Auxiliary Relays
5.0 A max (continuous)
Alarm Relay
2.0 A, 30 VDC or 30 VAC max
Operating Temperature
-40°F to + 165°F (-40°C to +74°C)
Storage Temperature
-40°F to + 185°F (-40°C to +85°C)
Sensor Temperature Range
-22°F to + 260°F (-30°C to +126°C)
Flame Sensitivity
0.7 μA minimum
Flame Failure Response or Reignition Time
0.8 seconds minimum
Types of Gas
Natural, LP, or manufactured
Spark Rate
Remote sense (50/60 Hz)
Local sense (25/30 Hz)
Size (LxWxH)
8.50 x 6.50 x 2.50 inches
(21.59 x 16.51 x 6.35 cm)
Moisture Resistance
Conformal coated to operate non-condensing to 95% R.H.
Tries for Ignition
One or three try versions available
Trial for Ignition Period
1 to 30 seconds, up to 300 seconds (IP)
Pre-purge Timings
1 to 255 seconds
Inter-purge Timings
1 to 255 seconds
January 2016
1-4
F-35-1000
PIM Features
CHAPTER 2
PIM FEATURES
2-1
CONTROL POWER
The PIM requires 24 VAC to operate its microprocessor circuits, the safety switch connections,
and the field demand inputs. An onboard fuse protects the 24 VAC circuits and the 24 VAC relay
outputs to the gas valves.
2-2
WIRING CONNECTIONS
The PIM is designed for simplified wiring and acts as the central wiring point of a system. All
OEM factory connections are through unique multi-pin connectors to prevent mis-wiring.
Field connections for sensors, communications, EMS, and thermostats are provided by screwterminal blocks. These may be fixed or pluggable types.
A RJ-45 style connector is used for the BTC_II or system-level controller.
2-3
IGNITION OUTPUTS
The PIM is capable of DSI, IP, or HSI ignition depending on configuration. For spark ignition
(DSI or IP) the electrode is connected to the ignition coil. For HSI the igniter element connects
to P1 and is driven off the L1 supply voltage.
If configured, an external spark ignition transformer can be used by connecting it to P1. It is
powered by L1 and the spark output will be disabled.
2-4
GAS VALVE OPTIONS
The PIM is able to control one or two stage valves. It can also control a modulating valve using
PWM or 4-20mA output. If the optional isolated valve configuration is used, the valve power
and return must be separately supplied and the valve outputs are not protected by the fuse.
2-5
COMBUSTION BLOWER
The blower motor operates off the power supplied to L1, which can be 120VAC or 240VAC. If
a modulating blower is used, PWM or 4-20 mA signals are provided by the PIM for speed
control. The blower motor tachometer signal is required when configured for closed-loop fan
speed control.
2-6
HIGH-CURRENT BLOWER OPTION
With this option, the relay contacts of K5 must be used to connect the blower. The QC drycontact terminals on top of the relay are used for the blower output and supply voltage, which
may be 120VAC or 240VAC. The maximum current rating is 15.0A.
2-7
AUXILIARY RELAY OUTPUTS
Three additional relay outputs provide capability for integrating appliance functions into the
PIM. They may be operated off 120VAC or 240VAC. Two relays are sourced from L1, while the
third relay is powered by L1-S, providing isolated contacts if needed.
F-35-1000
2-1
January 2016
PIM Features
2-8
UL353 HIGH LIMIT SENSOR
The PIM requires two thermistor sensors for burner firing rate control and high-limit sensing
using the integrated UL353 high-limit function. These two thermistors may be independent but
co-located so they provide similar readings.
2-9
TEMPERATURE SENSORS
The PIM provides standard support for up to seven 10K ohm @ 77°F NTC curve J Thermistor
probes (β=3892). Special models may support other sensor types as required by the specific
application.
Four temperature sensors are directly processed by the PIM. For hydronics applications, the
optional System, Outdoor, and DHW tank sensors are also connected to the PIM but passed
through to the BTC_II which is required to provide those additional features.
2-10
DEMAND INPUTS
The PIM supports two demand inputs which can initiate heating cycles. These may be used for
two-stage thermostats or space heating and domestic hot water (DHW) calls in a hydronics
application. The 24VAC source for the demand inputs is supplied by the PIM.
2-11
SAFETY INPUTS
Four switch-closure safety inputs are provided sourced by the 24VAC control supply voltage.
One is dedicated for airflow proving and the others can be used for gas pressures, waterflow,
dampers, blocked drains, LWCO, interlocks, etc. One of the safety inputs is on the field
connections and the others on the factory wiring. Two of the inputs can accept either normally
open or normally closed switches for additional flexibility.
2-12
RATE INPUTS
The PIM can accept two rate-based signals. Usually one of these is RPM from the blower
tachometer. The other rate input can be waterflow, airflow, or as needed by the specific
application.
2-13
TEMPERATURE CONTROL
The PIM calculates the required firing rate or stage demand using a PID-based algorithm. This
algorithm uses the sensor inputs and the target setpoint from the onboard potentiometer or
as communicated through RS485.
The PIM is also able to respond directly to firing rate commands from the BTC_II or other
system control and the EMS analog input.
2-14
POTENTIOMETER (SETPOINT)
The PIM’s integrated potentiometer allows assignment of a user setpoint. Examples are the
operating setpoint, economizer setpoint, or as required by a particular application.
2-15
CONFIGURATION (DIP SWITCH SETTINGS)
The PIM includes an 8-position DIP switch, located near the field wiring terminals. This DIP
switch allows the setting of field configurable items during installation or modification.
January 2016
2-2
F-35-1000
PIM Features
2-16
ID CARD
The PIM determines its operating parameters by reading the identification code of an external
plug-in ID card.
Note: This ID card must be present for the PIM and appliance to operate.
A total of up to 126 unique codes are supported. This card selects the proper settings in the
PIM's memory for various appliance models. These parameters include ignition timings and
operation, system configuration, and OEM configuration settings. Appendix B details the
parameters that are configurable for each unique ID code.
Fenwal supplies the PIM with its internal ID card settings blank. The first time a PIM is poweredup attached to an ID card, the PIM stores the ID card setting in non-volatile memory. Once
set, the PIM only operates with the correct ID card installed that matches the PIM’s internal ID
settings. The PIM verifies the ID card at power-up and on each heating cycle.
F-35-1000
2-3
January 2016
PIM Features
THIS PAGE INTENTIONALLY LEFT BLANK.
January 2016
2-4
F-35-1000
Hydronics Functions
CHAPTER 3
HYDRONICS FUNCTIONS
3-1
OUTDOOR RESET
If an optional outdoor sensor is connected to the PIM, the BTC_II control will optimize the
target setpoint for energy efficiency based on the outdoor reset curve settings.
3-2
DOMESTIC HOT WATER CONTROL
When the DHW call for heat is active, the PIM communicates this to the BTC_II. The BTC_II
calculates the optimal operation and sends the firing rate and pump output requests to the PIM
so it can activate the DHW pump and Boiler pump if needed.
If an optional DHW sensor is connected to J2-1 and J2-2 the PIM will pass this signal to the
BTC_II. This allows the BTC_II to optimize the DHW demand to maintain the DHW setpoint.
The DHW thermostat switch closure is not required when using the DHW sensor.
If a BTC_II is not present the PIM shall activate the DHW pump whenever the DHW call is
active. The Boiler pump may also be activated based on the DHW piping configuration setting.
3-3
PUMP CONTROL
The PIM supports direct control of the boiler, system and DHW pumps including optimization
when a BTC_II is connected. The boiler pump and the optional system pump will run whenever
there is a demand for space heating. The DHW pump will run whenever there is a DHW
demand. Depending on the system configuration and DHW piping, the boiler pump may be
required to turn off during DHW pump operation.
Pump Postpurge is controlled by the BTC_II or uses fixed timings in stand-alone mode.
Pump Exercising will cycle the pumps for 10 seconds every 72 hours, even with no heat
demand, to help extend the life of the pumps.
3-4
FREEZE PROTECTION
Freeze protection automatically provides the pump enable commands and/or boiler firing rate
to prevent freezing.
F-35-1000
•
If either the Outlet or Inlet temperature drops below 45°F, the Boiler and System pumps
shall be enabled. The pumps shall be turned off when both the Inlet and Outlet
temperatures rise above 50°F.
•
If either the Outlet or Inlet temperature drops below 38°F, the Burner shall start at the
minimum firing rate. The Burner cycle will terminate when both the Inlet and Outlet
temperatures rise above 42°F.
3-1
January 2016
Hydronics Functions
THIS PAGE INTENTIONALLY LEFT BLANK.
January 2016
3-2
F-35-1000
Communications and Diagnostics
CHAPTER 4
COMMUNICATIONS AND DIAGNOSTICS
4-1
RS485 COMMUNICATIONS
The PIM supports serial RS485 communications to a system-level control, network, PC
monitoring tool, or second PIM. The messaging software can be customized by Fenwal as
needed for the OEM's particular application.
For hydronics applications the PIM supports the Ft-bus protocol to communicate directly with
the tekmar BTC_II system control.
4-2
ENERGY MANAGEMENT SYSTEM (CUSTOMER PROVIDED)
An external EMS system can provide direct control of the PIM through the analog 0-10 VDC
input. This is enabled through the DIP switch. When active, the PIM internal commands for
firing rate will be ignored.
Once a valid call for heat is detected on the Analog EMS input, the PIM will operate to maintain
a target temperature or accept a direct drive demand request as determined by the system
configuration.
The PIM normally expects the signal on the analog EMS input to be 0-10VDC. For flexibility,
the PIM can also accept a 4-20mA EMS input provided a 500Ω, 1/2W resistor is placed across
the EMS terminals.
4-3
INDICATORS
The PIM has three LED indicators to display operational status and to help diagnose system
error conditions.
4-4
•
Power: Green LED indicating the PIM module is receiving 24 VAC power.
•
Alarm/Test: Amber LED which indicates the PIM is in Commission Test Mode or that a
diagnostic alarm (fault) is present.
•
Diagnostic Code: Red LED that is normally off. During a control or system fault condition,
this LED flashes the error codes.
SELF-CHECK/CONTROL FAILURE
The PIM confirms the integrity of the gas valve relay contacts to insure safety. It also monitors
the processor memory and software execution for proper program flow.
If the control detects an error in its software or hardware, all outputs are turned off and the
LED displays a steady ON condition. If this condition persists after an attempt to restart then
the control must be replaced.
4-5
SYSTEM SAFETY CHECKS
The PIM monitors the safety switches, temperature sensors, supply voltage, and blower speed
and will go to soft lockout until the error condition is corrected. Individual LED diagnostic codes
or messages on the RS485 communications help identify the problem for efficient
troubleshooting.
F-35-1000
4-1
January 2016
Communications and Diagnostics
4-6
FLAME CURRENT MEASUREMENTS
The PIM supports direct measurement of flame signal strength using the flame current test pins
(FC+,FC-) on connector P2. Flame current may be measured by a micro-ammeter, or
alternately by using a standard digital voltmeter. The signal on P2 is calibrated to 1 microamp/volt, so flame current in micro-amps can be directly read on the volts scale.
If a user interface control is connected an approximation of flame current can be displayed,
with an upper limit of 5 micro-amps.
4-7
NON-VOLATILE LOCKOUT/MANUAL RESET
The PIM normally allows for volatile ignition lockout where a lockout condition is reset by a loss
in 24VAC power or the call for heat demand.
In certain applications or where required by standards (such a CSD-1), it can be configured
through the parameter settings for non-volatile lockout after ignition failure. In this case the
lockout may only be reset by the on-board manual reset button, or the remote reset input.
If the UL353 High Limit feature is used, any high limit fault will go to non-volatile lockout
requiring a manual reset.
January 2016
4-2
F-35-1000
Application Examples
CHAPTER 5
APPLICATION EXAMPLES
5-1
APPLICATION EXAMPLES
Figure 5-1, Figure 5-2, and Figure 5-3 illustrate standard configurations for the PIM.
5-1.1
High Efficiency Modulating Boiler
DHW TH
Thermostat
Flow Switch
LWCO
Alarm
FT-Bus A
FT-Bus B
tN4
+ EMS
- 0-10 VDC
Remote Reset
Outdoor Sensor
DHW Sensor
System Sensor
Complete control of a modulating-condensing boiler including direct spark ignition, firing rate,
outlet water temperature, high limit shutdown, domestic hot water priority, system safety
inputs, outdoor reset, and LWCO. Efficiency optimized through communications with an
energy management system, boiler temperature control, and thermostat network. The boiler
temperature control monitors all system information to calculate burner firing rate. Integrated
control of boiler, system, and DHW pumps provides intelligent pump purging, residual heat
capture, and freeze protection.
Boiler
Temperature
Control
1
J4
J3
2nd
PIM
FT-Bus B
FT-Bus A
1
V+
1
V in
GND
2
9
1
J2
10
J1
R91
J5
2
Operator
Set Point
PIM
Identity Card
SW2
J6
Limit
3
Field Setting
DIP Switch
High Limit
Sensor
SW1
1
2
J7
3
Reset
4
Outlet Sensor
Air Flow
Safety #2
4
1
5
2
6
3
J8
To J10 Pin 3
To J10 Pin 4
Flow Sensor
Tachometer
Safety #1
Inlet Sensor
3
1
4
2
Fan Power (18 VDC)
PWR
D23
Alarm
D80
Diag
J15
Remote
LED
F1
J9
Vent Sensor
4 to 20 MA
5
1
Fan GND
6
2
Flow SEN GND
7
3
Flow SEN PW (12 VDC)
8
4
T3
J10
Spark
Electrode
PWM-Out
L1
2
1
4
1
5
2
6
3
3
1
4
2
5
1
6
2
7
3
8
4
J11
24 VAC
120 VAC
RTN
2 STG / MV
Dry
Contact
Hot
MV / PV
T2
J12
120 VAC
Blower
L1 – S
DHW
Pump
System
Pump
J13
J14
FS
120 VAC
P2
GND
FCFC+
L2
D90
Boiler
Pump
Remote Flame
Sense Rod
Figure 5-1. High Efficiency Modulating Boiler
F-35-1000
5-1
January 2016
Application Examples
5-1.2
HVAC Space Heater
1
J4
J3
RS485
Communications
PC Based
Development
Tool
1
9
Ventilate
Remote Reset
Thermostat
1
J2
10
J1
R91
J5
2
Damper End Switch
Interlock
Alarm
+ EMS
- 0-10 VDC
Complete system operation including proven hot surface ignition, modulating blower,
discharge air temperature control, high limit shutdown, economizer mode, selectable purge
times, freeze protection, and ventilation. The PIM uses its internal PID algorithm to calculate
optimum firing rate. Integrated control of circulation fan, power exhaust, and vent damper
allows intelligent response to any input condition and combines several existing controls into
a single intelligent solution.
Econ Set
Point
PIM
Identity Card
V+
1
V in
GND
2
SW2
J6
Limit
3
Field Setting
DIP Switch
High Limit
Sensor
SW1
1
2
J7
3
Reset
4
Discharge Sensor
Air Flow
Change Filter
Inlet Sensor
(OAT)
4
1
5
2
6
3
3
1
4
2
Fan Power (18 VDC)
5
1
Fan GND
6
2
7
3
8
4
RPM
J8
D90
PWR
D23
Alarm
D80
Diag
J15
Remote
LED
F1
J9
J10
PWM-Out
L1
L2
2
1
4
1
5
2
6
3
5
1
6
2
7
3
8
4
J11
24 VAC
120 VAC
RTN
Dry
Contact
Gas Valve
T2
J12
High Current Blower
Hot
L1
Comb.
Blower
GND
L1 – S
Power
Exhaust
Circ.
Blower
J14
FS
120 VAC
P2
GND
S1
24 VAC RETURN
S2
24 VAC
FCFC+
L2
Vent
Damper
Hot
Surface
Ignitor
Remote Flame
Sense Rod
Figure 5-2. HVAC Space Heater
January 2016
5-2
F-35-1000
Application Examples
5-1.3
Commercial Cooking
Cooking
Computer
1
J4
J3
RS485
Communications
Network
1
9
2nd Stage
1
J2
10
J1
R91
J5
2
Thermostat
Interlock
Alarm
Intelligent operation of advanced fryer including intermittent pilot ignition, two speed PWM
blower, and high limit shutdown. Fixed firing rate control using the two heating demand inputs.
Smart ramping of blower speed to smoothly control burner after light-off and allow fat melt
cycles. Optional communication to a cooking computer or user interface. Three available relay
outputs for integrating auxiliary functions.
Operator
Set Point
PIM
Identity Card
V+
1
V in
GND
2
SW2
J6
Limit
3
Field Setting
DIP Switch
High Limit
Sensor
SW1
1
2
J7
3
Reset
4
Temp Sensor
Air Flow
Safety #2
4
1
5
2
6
3
J8
Safety #1
3
1
4
2
Fan Power (18 VDC)
5
1
Fan GND
6
2
7
3
8
4
RPM
J10
MV
PV
Blower
Relay
#1
Relay
#2
Diag
J15
Remote
LED
2
1
4
1
5
2
6
3
3
1
4
2
5
1
6
2
7
3
8
4
J11
Local
Sense
T2
J12
J13
J14
FS
120 VAC
P2
GND
FCFC+
L1 – S
Alarm
D80
Spark
Electrode
L2
Dry
Contact
D23
T3
24 VAC
120 VAC
PWR
F1
J9
PWM-Out
L1
D90
Relay
#3
Figure 5-3. Commercial Cooking
F-35-1000
5-3
January 2016
Application Examples
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January 2016
5-4
F-35-1000
APPENDIX A
APPLICATION WORKSHEET
A-1
FACTORY LOW-VOLTAGE CONNECTIONS (30 VAC MAX)
Connector
J5
Input/Output
RS485 Communications (PIM to PIM)
J6
ID Card
J7
J7
Hi-Limit Sensor
Outlet Temp Sensor
J8
J8
J8
Airflow switch
Safety #1 switch
Safety #2 switch
J9
J9
Temp Sensor #1
Temp Sensor #2
J10
J10
J10
J10
4-20 mA Out (modulation %)
PWM Out (modulation %)
Rate Sensor Signal
Tachometer Signal (RPM)
J11
24VAC Power (R)
A-2
F-35-1000
Assigned Function
FACTORY LINE-VOLTAGE CONNECTIONS
Connector
J12
J12
Input/Output
Gas Valve (MV/PV)
2nd stage Valve
J13
J13
Blower Output
L1 supply input
J14
J14
J14
J14
J14
AUX Relay #1
AUX Relay #2
AUX Relay #3 (Isolated)
L1s – Relay #3 Supply Power
L1 Supply Power
Assigned Function
A-1
January 2016
A-3
LOW-VOLTAGE FIELD WIRING CONNECTIONS (30 VAC MAX)
Connector
J4
Input/Output
FT-bus Connection to tekmar
J3
RS-485 Communications
J2
J2
J2
J2
J2
Temp Sensor #3
Temp Sensor #4
Temp Sensor #5
tN4 Communications
0-10Vdc Analog EMS Input
J1
J1
J1
J1
J1
J1
Alarm Relay (Dry Contacts)
Interlock (LWCO)
Remote Reset
Safety #3 Switch
DHW or 2nd Stage Call
Heat Call (TH)
A-4
Assigned Function
HARDWARE CONFIGURATION
PIM Configuration
Ignition Type (DSI, HSI, IP, or PHSI)
Valve Type (1 stage, 2 stage, or Modulating)
Isolated Valve Contacts (Yes or No)
Blower Type (1 stage, 2 stage, or Modulating)
High-Current Blower Relay (Yes or No)
Flame Sense Method (Local, Remote, or Both)
Field Terminals (Fixed or Pluggable)
January 2016
Selected Option
A-2
F-35-1000
APPENDIX B
PIM PARAMETER DESCRIPTIONS
B-1
PIM PARAMETERS
The following tables list the parameters available for the PIM™.
Name
Description
Allowed Range
Ignition Settings
Type
Ignition Type
DSI, HSI, Proven HSI, IP
Ext_Spark
External spark transformer
Yes or No
TFI
Trial for Ignition (seconds)
1 to 300 (limit 25 if not IP)
Trials
Number of ignition tries
1 to 3
Heatup
HSI Heat-up period (seconds)
0 to 255
HSI Current
Ignitor Proving Current (amps)
0.5 to 4.0
Prepurge
Ignition Prepurge (seconds)
0 to 255
Interpurge
Ignition Interpurge (seconds)
0 to 255
Postpurge
Blower Postpurge (seconds)
0 to 255
Sense
Flame Sense Method
Local or Remote
Recycle/Re-ignition
Flame Loss Retry Method (re-ignition N/A with HSI)
Recycle or Re-ignition
Lockout on Loss of Flame
Locks-out on loss of flame or airflow in TFI and burn (CSD-1)
Yes or No
Reset Method
Lockout Reset Method
Volatile or Manual
Automatic Reset
Automatic Reset Delay after Lockout (seconds)
0 - Off
60 - 3600 (enabled)
Gas Stages
Number of Gas Valve Stages
One Stage, Two stage, Three
Stage, or Four Stage
Blower Type
Blower Configuration
One Stage, Two-stage, Modulating,
None
Flame Period Ignition
Flame Integration Period during Ignition and first 5 seconds
after
10 to 30 (25mS periods)
Flame Period Burn
Flame Integration Period during Burner On Cycle
4 to 30 (25mS periods)
System Settings
Type
Selects order of 's for Multi stage boilers
Master or Member
Hi-Limit
Hi-Limit setpoint
100-240 (°F)
Operator Safeguard
Maximum allowed Operating setpoint below Hi-Limit Setting
0 to 30 (°F)
Manual Differential
Operator setpoint differential when Manual Differential DIP
switch enabled
5 to 30 (°F)
F-35-1000
B-1
January 2016
Name
Tachometer Type
Description
Allowed Range
Tach signal (pulses/revolution)
0,1,2 or 3
0 indicates Tach not present.
0 uses open loop control
Temp Sensor #1
Temp Sensor #1 Present
Yes or No
Temp Sensor #2
Temp Sensor #2 Present
Yes or No
Rate Sensor
Rate Sensor Present
Yes or No
Airflow Switch
Airflow Switch Monitoring
Normal,
Ignore Open switch test, or Ignore
All
Safety #1 Input
Safety Switch Input Monitoring
Normally Open,
Normally Closed, or Ignore
Safety #2 Input
Additional Safety Input Monitoring
Normally Open,
Normally Closed, or Ignore
Safety #3 Input
Additional Safety Switch Monitoring
Normal,
Ignore Open switch test, or Ignore
All
Pump Prepurge
Pump Prepurge Period (seconds)
0 to 255
Pump Postpurge
Pump Postpurge Period (seconds)
0 to 255
(stand-alone mode only)
DHW Pump Piping
Activate Boiler pump when DHW Pump is active (stand-alone
only)
Yes or No
Boiler Configuration Settings
Boiler Mass
Boiler Construction (thermal mass)
Low, Medium, High or Proportional
Application Type
Designates application settings for BTC_II to follow
Boiler, Water Heater or Pool Heater
Hi-Delta T Threshold
Difference between outlet and inlet temperatures for Delta T
limiting
20 to 200 (°F)
Vent Temperature Limit
Threshold setting for High Vent temperature shutdown
100 to 300 (°F)
Turndown
Minimum Modulation Rate (% of full fire)
5% -50%
Closed Loop Modulating Blower Settings (tach required)
Maximum Blower Speed
Blower RPM at Maximum Modulation Rate (100% full-fire)
0 - 16000
Purge Blower Speed
Blower RPM during Prepurge and Interpurge periods
0 - 16000
Light off Blower Speed
Blower RPM during Ignition period
0 - 16000
Minimum Blower Speed
Blower RPM at Minimum Modulation Rate (Turndown)
0 - 16000
Postpurge Blower Speed
Blower RPM during Postpurge
0 - 16000
Open Loop Modulating Blower Settings
Maximum PWM Rate
Blower Modulation Rate (PWM output % at 100% full-fire)
0 - 100%
Purge Blower Rate
Modulation of Blower during Purge periods (% of full fire)
20% - 100%
Light off Blower Rate
Modulation of Blower during Ignition period (% of full fire)
10% - 100%
Postpurge Blower Speed
Modulation of Blower during Postpurge (% of full fire)
20% - 100%
January 2016
B-2
F-35-1000
APPENDIX C
PART NUMBER BREAKDOWN
C-1
PIM PART NUMBER
The following image explains the meaning of the various digits in the part number. Use this
information to order the correct board.
35 – 9 X X X X X – X X X
Description
FLAME SENSE METHOD
0 = Local Sense
1 = Remote Sense
3 = Dual (Local and Remote)
BLOWER RELAY
0 = Standard (5A)
1 = High-Current (15A)
TERMINAL CONFIGURATION
0 = Standard
1 = Pluggable Field Terminal Blocks
RESERVED
0 = Standard Model
0-9 = Special Feature Assignment
RESERVED
0 = Standard Model
0-9 = Special Feature Assignment
MODEL CONFIGURATION
0 = Standard Model
2 = CE (EN298) Standard Model
3 = CE (EN298) OEM Special Feature Model (Consult Factory for Number)
9 = OEM Special Feature Model (Consult Factory for Number)
VALVE/FAN CONFIGURATION
0 = Modulating (1-stage)
1 = One Stage
2 = Two Stage
3 = Intermittent Pilot (PV/MV)*
4 = One Stage with Auxiliary
5 = Isolated Modulating (1-stage)
6 = Isolated One Stage
7 = Isolated Two Stage
* Not included under scope
of current CSA certification
IGNITION TYPE
1 = Direct Spark
2 = Direct Spark with External Relay
6 = Hot Surface Ignition
7 = Proven Hot Surface Ignition
Figure C-1. Part Number Breakdown
F-35-1000
C-1
January 2016
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January 2016
C-2
F-35-1000
APPENDIX D
FENWAL DEVELOPMENT TOOL
D-1
FENWAL DEVELOPMENT TOOL
To assist in developing and testing PIM applications Fenwal provides free development tool
support using a customized software package and PC-to-PIM converter box. This allows the
parameters to be modified as needed and provides visual and graphic feedback on all aspects
of PIM operation and system performance.
Once parameters are finalized they can be programmed into the production control and
accessed by the corresponding ID card. For production versions, the parameters cannot be
modified but the Development Tool can still be used to monitor and record system operation.
Figure D-1. Fenwal Development Tool
F-35-1000
D-1
January 2016
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January 2016
D-2
F-35-1000
Fenwal Controls is a registered trademark of Kidde-Fenwal Inc.
PIM is a trademark of Kidde-Fenwal Inc.
All trademarks are property of their respective owners.
Kidde-Fenwal Inc.
400 Main Street
Ashland, MA 01721 USA
Customer Service: (508) 881-2000
Website: www.fenwal.com
These instructions do not purport to cover all the details or variations in the equipment
described, nor do they provide for every possible contingency to be met in connection with
installation, operation and maintenance. All specifications subject to change without notice. Should further information be desired or should particular problems arise which are
not covered sufficiently for the purchaser’s purposes, the matter should be referred to
Kidde-Fenwal, Inc., Ashland, Massachusetts.
F-35-1000 Rev. AA ©2016 Kidde-Fenwal All Rights Reserved.