F-35-1000January 2016

Platform Ignition Module

Application Guide

TABLE OF CONTENTS

CHAPTER 1 PRODUCT OVERVIEW AND DESCRIPTION

1-1 Introduction ......................................................................................... 1-11-2 Applications ......................................................................................... 1-11-3 System Integration ............................................................................... 1-21-4 Features .............................................................................................. 1-31-5 Agency Approvals ................................................................................. 1-31-6 Reference Documents............................................................................ 1-41-7 Specifications ....................................................................................... 1-4

CHAPTER 2 PIM FEATURES2-1 Control Power....................................................................................... 2-12-2 Wiring Connections ............................................................................... 2-12-3 Ignition Outputs ................................................................................... 2-12-4 Gas Valve Options................................................................................. 2-12-5 Combustion Blower ............................................................................... 2-12-6 High-Current Blower Option.................................................................... 2-12-7 Auxiliary Relay Outputs.......................................................................... 2-12-8 UL353 High Limit Sensor........................................................................ 2-22-9 Temperature Sensors ............................................................................ 2-22-10 Demand Inputs..................................................................................... 2-22-11 Safety Inputs ....................................................................................... 2-22-12 RATE INPUTS ....................................................................................... 2-22-13 Temperature Control ............................................................................. 2-22-14 Potentiometer (Setpoint) ....................................................................... 2-22-15 Configuration (DIP Switch Settings)......................................................... 2-22-16 ID Card ............................................................................................... 2-3

CHAPTER 3 HYDRONICS FUNCTIONS3-1 Outdoor Reset ...................................................................................... 3-13-2 Domestic Hot Water Control ................................................................... 3-13-3 Pump Control ....................................................................................... 3-13-4 Freeze Protection .................................................................................. 3-1

CHAPTER 4 COMMUNICATIONS AND DIAGNOSTICS4-1 RS485 Communications ......................................................................... 4-14-2 Energy Management System (Customer provided)..................................... 4-14-3 Indicators ............................................................................................ 4-14-4 Self-Check/Control Failure...................................................................... 4-14-5 System Safety Checks ........................................................................... 4-14-6 Flame Current Measurements ................................................................. 4-24-7 Non-Volatile Lockout/Manual Reset.......................................................... 4-2

CHAPTER 5 APPLICATION EXAMPLES5-1 Application Examples............................................................................. 5-15-1.1 High Efficiency Modulating Boiler............................................................. 5-15-1.2 HVAC Space Heater............................................................................... 5-25-1.3 Commercial Cooking.............................................................................. 5-3

F-35-1000 i January 2016

TABLE OF CONTENTS (CONT.)

APPENDIX A APPLICATION WORKSHEET

A-1 Factory Low-Voltage Connections (30 VAC Max)........................................ A-1A-2 Factory Line-Voltage Connections............................................................ A-1A-3 Low-Voltage Field Wiring Connections (30 VAC Max).................................. A-2A-4 Hardware Configuration ......................................................................... A-2

APPENDIX B PIM PARAMETER DESCRIPTIONSB-1 PIM Parameters .................................................................................... B-1

APPENDIX C PART NUMBER BREAKDOWNC-1 PIM Part Number .................................................................................. C-1

APPENDIX D FENWAL DEVELOPMENT TOOLD-1 Fenwal Development Tool ......................................................................D-1

January 2016 ii F-35-1000

Product Overview and Description

CHAPTER 1PRODUCT OVERVIEW AND DESCRIPTION

1-1 INTRODUCTION

The Fenwal Controls® Platform Ignition Module (PIM™) integrates the functions of AutomaticIgnition Control with temperature regulating and appliance control functions. The PIM isdesigned for a range of applications including both staged systems and modulating types. ThePIM can be configured as a direct spark ignition (DSI), intermittent pilot (IP) or Hot SurfaceIgnition (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 UserInterface/Displays, OEM controls, networks, PC analysis tools, or other devices. It also acceptsanalog 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 expandedcontrol 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-firedheating systems including:• 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

F-35-1000 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 singlecontrol. 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 andconstruction with a high-value solution.

Figure 1-2. System Integration

Temp Sensor

Temperature Control High Limit

Limit Sensor

Ignition Control Gas ValveBurner

Flame Sense

TDR2nd Stage

Demand

2nd Stage Valve

PWMBlower Control

BlowerRelay

Combustion Blower

TDR

BlowerContactor

Circulation Blower

Diagnostics with Fault Control

Temp Sensor

AUX Function Control

VentDamper

Gas Flow

January 2016 1-2 F-35-1000

Product Overview and Description

1-4 FEATURES

The PIM provides the following features:• 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

1-5 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 DOCUMENTSThe PIM complies with the documents listed below and any applicable materials referenced in the documents listed.

1-7 SPECIFICATIONS

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

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 2PIM 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 relayoutputs 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. AllOEM factory connections are through unique multi-pin connectors to prevent mis-wiring.

Field connections for sensors, communications, EMS, and thermostats are provided by screw-terminal 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 connectsto 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 ispowered 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 usingPWM or 4-20mA output. If the optional isolated valve configuration is used, the valve powerand 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. Ifa modulating blower is used, PWM or 4-20 mA signals are provided by the PIM for speedcontrol. The blower motor tachometer signal is required when configured for closed-loop fanspeed control.

2-6 HIGH-CURRENT BLOWER OPTION

With this option, the relay contacts of K5 must be used to connect the blower. The QC dry-contact terminals on top of the relay are used for the blower output and supply voltage, whichmay 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 thePIM. They may be operated off 120VAC or 240VAC. Two relays are sourced from L1, while thethird 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 sensingusing the integrated UL353 high-limit function. These two thermistors may be independent butco-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 Thermistorprobes (β=3892). Special models may support other sensor types as required by the specificapplication.

Four temperature sensors are directly processed by the PIM. For hydronics applications, theoptional System, Outdoor, and DHW tank sensors are also connected to the PIM but passedthrough 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 fortwo-stage thermostats or space heating and domestic hot water (DHW) calls in a hydronicsapplication. 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 fieldconnections and the others on the factory wiring. Two of the inputs can accept either normallyopen 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 blowertachometer. The other rate input can be waterflow, airflow, or as needed by the specificapplication.

2-13 TEMPERATURE CONTROL

The PIM calculates the required firing rate or stage demand using a PID-based algorithm. Thisalgorithm uses the sensor inputs and the target setpoint from the onboard potentiometer oras communicated through RS485.

The PIM is also able to respond directly to firing rate commands from the BTC_II or othersystem control and the EMS analog input.

2-14 POTENTIOMETER (SETPOINT)

The PIM’s integrated potentiometer allows assignment of a user setpoint. Examples are theoperating 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 DIPswitch 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 externalplug-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 thePIM's memory for various appliance models. These parameters include ignition timings andoperation, system configuration, and OEM configuration settings. Appendix B details theparameters 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 powered-up attached to an ID card, the PIM stores the ID card setting in non-volatile memory. Onceset, the PIM only operates with the correct ID card installed that matches the PIM’s internal IDsettings. The PIM verifies the ID card at power-up and on each heating cycle.

F-35-1000 2-3 January 2016

PIM Features

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January 2016 2-4 F-35-1000

Hydronics Functions

CHAPTER 3HYDRONICS FUNCTIONS

3-1 OUTDOOR RESET

If an optional outdoor sensor is connected to the PIM, the BTC_II control will optimize thetarget 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_IIcalculates the optimal operation and sends the firing rate and pump output requests to the PIMso 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 theBTC_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 isactive. 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 optimizationwhen a BTC_II is connected. The boiler pump and the optional system pump will run wheneverthere is a demand for space heating. The DHW pump will run whenever there is a DHWdemand. Depending on the system configuration and DHW piping, the boiler pump may berequired 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 heatdemand, to help extend the life of the pumps.

3-4 FREEZE PROTECTION

Freeze protection automatically provides the pump enable commands and/or boiler firing rateto prevent freezing.• 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 Outlettemperatures rise above 50°F.

• If either the Outlet or Inlet temperature drops below 38°F, the Burner shall start at theminimum firing rate. The Burner cycle will terminate when both the Inlet and Outlettemperatures rise above 42°F.

F-35-1000 3-1 January 2016

Hydronics Functions

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January 2016 3-2 F-35-1000

Communications and Diagnostics

CHAPTER 4COMMUNICATIONS AND DIAGNOSTICS

4-1 RS485 COMMUNICATIONS

The PIM supports serial RS485 communications to a system-level control, network, PCmonitoring tool, or second PIM. The messaging software can be customized by Fenwal asneeded for the OEM's particular application.

For hydronics applications the PIM supports the Ft-bus protocol to communicate directly withthe 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 VDCinput. This is enabled through the DIP switch. When active, the PIM internal commands forfiring rate will be ignored.

Once a valid call for heat is detected on the Analog EMS input, the PIM will operate to maintaina target temperature or accept a direct drive demand request as determined by the systemconfiguration.

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 acrossthe EMS terminals.

4-3 INDICATORS

The PIM has three LED indicators to display operational status and to help diagnose systemerror conditions.• 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.

4-4 SELF-CHECK/CONTROL FAILURE

The PIM confirms the integrity of the gas valve relay contacts to insure safety. It also monitorsthe 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 theLED displays a steady ON condition. If this condition persists after an attempt to restart thenthe control must be replaced.

4-5 SYSTEM SAFETY CHECKS

The PIM monitors the safety switches, temperature sensors, supply voltage, and blower speedand will go to soft lockout until the error condition is corrected. Individual LED diagnostic codesor messages on the RS485 communications help identify the problem for efficienttroubleshooting.

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, oralternately by using a standard digital voltmeter. The signal on P2 is calibrated to 1 micro-amp/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 lossin 24VAC power or the call for heat demand.

In certain applications or where required by standards (such a CSD-1), it can be configuredthrough the parameter settings for non-volatile lockout after ignition failure. In this case thelockout 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 lockoutrequiring a manual reset.

January 2016 4-2 F-35-1000

Application Examples

CHAPTER 5APPLICATION 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

Complete control of a modulating-condensing boiler including direct spark ignition, firing rate,outlet water temperature, high limit shutdown, domestic hot water priority, system safetyinputs, outdoor reset, and LWCO. Efficiency optimized through communications with anenergy management system, boiler temperature control, and thermostat network. The boilertemperature control monitors all system information to calculate burner firing rate. Integratedcontrol of boiler, system, and DHW pumps provides intelligent pump purging, residual heatcapture, and freeze protection.

Figure 5-1. High Efficiency Modulating Boiler

J4

J2 J1

SW2

Field Setting

DIP Switch

Limit

R91Operator

Set Point

SW1

J15

D80

D23

D90

Remote

LED

Diag

Alarm

PWR

Reset

F1

T2

FSP2

GND

J5

J6

J7

J8

J9

J10

J11

J12

J13

J14

FC

-F

C+

Remote Flame

Sense Rod

FT

-Bus

A

FT

-Bus

B

DH

WS

en

sor

Syste

mS

en

sor

Ou

tdoo

rS

en

sor

tN4

+E

MS

-0-1

0V

DC

Ala

rm

LW

CO

Rem

ote

Rese

t

Flo

wS

witch

DH

WT

H

Th

erm

osta

t

FT-Bus B

FT-Bus A

2nd

PIM

V+PIM

Identity CardV in

GND

High Limit

Sensor

Outlet Sensor

Air Flow

Safety #2

Safety #1

Inlet Sensor

Vent Sensor

4 to 20 MA

Fan Power (18 VDC)

Fan GND

Flow SEN GND

Flow SEN PW (12 VDC)

PWM-Out

Flo

wS

en

so

r

Ta

ch

om

ete

r

To

J10

Pin

3

To

J10

Pin

4

24 VAC

L1

L2

2 STG / MV

MV / PV

RTN

Hot

Dry

Contact

Blower

System

Pump

Boiler

Pump

DHW

Pump

L1 – S120 VAC

120 VAC

120 VAC

1 1091

1

2

1

2

3

1

2

3

4

1

2

3

4

5

6

1

2

3

4

1

2

3

5

6

7

48

1

2

3

5

6

7

48

12

1

25

4

36

1

2

3

4

T3

Spark

Electrode

J3

Boiler

Temperature

Control

F-35-1000 5-1 January 2016

Application Examples

5-1.2 HVAC Space Heater

Complete system operation including proven hot surface ignition, modulating blower,discharge air temperature control, high limit shutdown, economizer mode, selectable purgetimes, freeze protection, and ventilation. The PIM uses its internal PID algorithm to calculateoptimum firing rate. Integrated control of circulation fan, power exhaust, and vent damperallows intelligent response to any input condition and combines several existing controls intoa single intelligent solution.

Figure 5-2. HVAC Space Heater

J4

J2 J1

SW2

Field Setting

DIP Switch

Limit

R91Econ Set

Point

SW1

J15

D80

D23

D90

Remote

LED

Diag

Alarm

PWR

Reset

F1

T2

FSP2

GND

J5

J6

J7

J8

J9

J11

J12

J14

FC

-F

C+

S2

S1

Remote Flame

Sense Rod

Hot

Surface

Ignitor

+E

MS

-0-1

0V

DC

Ala

rm Inte

rlo

ck R

em

ote

Rese

t

Ve

ntila

te

Th

erm

osta

t

PC Based

Development

Tool

V+PIM

Identity CardV in

GND

High Limit

Sensor

Discharge Sensor

Inlet Sensor

(OAT)

24 VAC

L1

L2

Gas Valve

RTN

Hot

Dry

Contact

L1 – S120 VAC

120 VAC

1 1091

1

2

1

2

3

1

2

3

4

1

2

3

4

5

6

1

2

3

4

1

2

3

5

6

7

48

12

1

25

4

36

J3

24 VAC

24 VAC RETURN

L2

L1

High Current Blower

Comb.

Blower

GND

Air Flow

Da

mp

er

En

dS

witch

Power

Exhaust

Vent

Damper

Circ.

Blower

Change Filter

RS485

Communications

J10

Fan Power (18 VDC)

Fan GND

RPM

1

2

3

5

6

7

48

PWM-Out

January 2016 5-2 F-35-1000

Application Examples

5-1.3 Commercial Cooking

Intelligent operation of advanced fryer including intermittent pilot ignition, two speed PWMblower, 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 meltcycles. Optional communication to a cooking computer or user interface. Three available relayoutputs for integrating auxiliary functions.

Figure 5-3. Commercial Cooking

J4

J2 J1

SW2

Field Setting

DIP Switch

Limit

R91Operator

Set Point

SW1

J15

D80

D23

D90

Remote

LED

Diag

Alarm

PWR

Reset

F1

T2

FSP2

GND

J5

J6

J7

J8

J9

J11

J12

J13

J14

FC

-F

C+

Ala

rm

Inte

rlock 2nd

Sta

ge

The

rmo

sta

t

Network

V+PIM

Identity CardV in

GND

High Limit

Sensor

Temp Sensor

Air Flow

Safety #2

Safety #1

24 VAC

L1

L2

MV

PV

Dry

Contact

Blower

Relay

#2

Relay

#3

Relay

#1

L1 – S120 VAC

120 VAC

1 1091

1

2

1

2

3

1

2

3

4

1

2

3

4

5

6

1

2

3

4

1

2

3

5

6

7

48

12

1

25

4

36

1

2

3

4

T3

Spark

Electrode

J3

Local

Sense

Cooking

Computer

RS485

Communications

J10

Fan Power (18 VDC)

Fan GND

RPM

1

2

3

5

6

7

48

PWM-Out

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Application Examples

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January 2016 5-4 F-35-1000

APPENDIX AAPPLICATION WORKSHEET

A-1 FACTORY LOW-VOLTAGE CONNECTIONS (30 VAC MAX)

A-2 FACTORY LINE-VOLTAGE CONNECTIONS

Connector Input/Output Assigned FunctionJ5 RS485 Communications (PIM to PIM)

J6 ID Card

J7 Hi-Limit SensorJ7 Outlet Temp Sensor

J8 Airflow switchJ8 Safety #1 switchJ8 Safety #2 switch

J9 Temp Sensor #1J9 Temp Sensor #2

J10 4-20 mA Out (modulation %)J10 PWM Out (modulation %)J10 Rate Sensor SignalJ10 Tachometer Signal (RPM)

J11 24VAC Power (R)

Connector Input/Output Assigned FunctionJ12 Gas Valve (MV/PV)J12 2nd stage Valve

J13 Blower Output J13 L1 supply input

J14 AUX Relay #1J14 AUX Relay #2J14 AUX Relay #3 (Isolated)J14 L1s – Relay #3 Supply PowerJ14 L1 Supply Power

F-35-1000 A-1 January 2016

A-3 LOW-VOLTAGE FIELD WIRING CONNECTIONS (30 VAC MAX)

A-4 HARDWARE CONFIGURATION

Connector Input/Output Assigned FunctionJ4 FT-bus Connection to tekmar

J3 RS-485 Communications

J2 Temp Sensor #3J2 Temp Sensor #4J2 Temp Sensor #5J2 tN4 CommunicationsJ2 0-10Vdc Analog EMS Input

J1 Alarm Relay (Dry Contacts)J1 Interlock (LWCO)J1 Remote ResetJ1 Safety #3 SwitchJ1 DHW or 2nd Stage Call J1 Heat Call (TH)

PIM Configuration Selected OptionIgnition 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 A-2 F-35-1000

APPENDIX BPIM 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 - Off60 - 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

Tachometer Type Tach signal (pulses/revolution)

0 indicates Tach not present.

0,1,2 or 3

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)

(stand-alone mode only)

0 to 255

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%

Name Description Allowed Range

January 2016 B-2 F-35-1000

APPENDIX CPART NUMBER BREAKDOWN

C-1 PIM PART NUMBER

The following image explains the meaning of the various digits in the part number. Use thisinformation to order the correct board.

Figure C-1. Part Number Breakdown

35 – 9 X X X X X X X X–

IGNITION TYPE

1 = Direct Spark

2 = Direct Spark with External Relay

6 = Hot Surface Ignition

7 = Proven Hot Surface Ignition

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

RESERVED

0 = Standard Model

0-9 = Special Feature Assignment

TERMINAL CONFIGURATION

0 = Standard

1 = Pluggable Field Terminal Blocks

BLOWER RELAY

0 = Standard (5A)

1 = High-Current (15A)

FLAME SENSE METHOD

0 = Local Sense

1 = Remote Sense

3 = Dual (Local and Remote)

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)

Description

* Not included under scope

of current CSA certification

F-35-1000 C-1 January 2016

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January 2016 C-2 F-35-1000

APPENDIX DFENWAL DEVELOPMENT TOOL

D-1 FENWAL DEVELOPMENT TOOL

To assist in developing and testing PIM applications Fenwal provides free development toolsupport using a customized software package and PC-to-PIM converter box. This allows theparameters to be modified as needed and provides visual and graphic feedback on all aspectsof PIM operation and system performance.

Once parameters are finalized they can be programmed into the production control andaccessed by the corresponding ID card. For production versions, the parameters cannot bemodified 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

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 no-tice. Should further information be desired or should particular problems arise which arenot covered sufficiently for the purchaser’s purposes, the matter should be referred toKidde-Fenwal, Inc., Ashland, Massachusetts.

Kidde-Fenwal Inc.400 Main StreetAshland, MA 01721 USACustomer Service: (508) 881-2000Website: www.fenwal.com

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.

F-35-1000 Rev. AA ©2016 Kidde-Fenwal All Rights Reserved.

http://www.fenwal.com

Table of ContentsChapter 1Product Overview and Description1-1 Introduction1-2 Applications1-3 System Integration1-4 Features1-5 Agency Approvals1-6 Reference Documents1-7 Specifications

Chapter 2PIM Features2-1 Control Power2-2 Wiring Connections2-3 Ignition Outputs2-4 Gas Valve Options2-5 Combustion Blower2-6 High-Current Blower Option2-7 Auxiliary Relay Outputs2-8 UL353 High Limit Sensor2-9 Temperature Sensors2-10 Demand Inputs2-11 Safety Inputs2-12 RATE INPUTS2-13 Temperature Control2-14 Potentiometer (Setpoint)2-15 Configuration (DIP Switch Settings)2-16 ID Card

Chapter 3Hydronics Functions3-1 Outdoor Reset3-2 Domestic Hot Water Control3-3 Pump Control3-4 Freeze Protection

Chapter 4Communications and Diagnostics4-1 RS485 Communications4-2 Energy Management System (Customer provided)4-3 Indicators4-4 Self-Check/Control Failure4-5 System Safety Checks4-6 Flame Current Measurements4-7 Non-Volatile Lockout/Manual Reset

Chapter 5Application Examples5-1 Application Examples5-1.1 High Efficiency Modulating Boiler5-1.2 HVAC Space Heater5-1.3 Commercial Cooking

A-1 Factory Low-Voltage Connections (30 VAC Max)A-2 Factory Line-Voltage ConnectionsA-3 Low-Voltage Field Wiring Connections (30 VAC Max)A-4 Hardware ConfigurationB-1 PIM ParametersC-1 PIM Part NumberD-1 Fenwal Development Tool