PF2200-SB INSTALLATION MANUAL
DOC-001041 ver 0.9
This guide includes information on the installation of the PF2200 burner management system. PROFIRE recommendations and requirements for installation.
This document covers:
- Product Overview.
- Safety and Warnings.
- Mounting Considerations.
- Wiring Guidelines.
- Post Installation Checklist
- Profire Recommendation and Requirements.
To help guide you through the entire install process. The PF2200 comes in two optional enclosures, polyester, and stainless steel. These distinctions are addressed where necessary in this installation guide. For configuring the PF2200, please refer to PF2200 Manual.
The PF2200-SB (Single Burner BMS) is certified to the following standards:
• IEC 61508, SIL II
• UL 60730-2-5/ANSI Z21.20-2014 & UL 121201
• CSA C22.2 No. 60730-2-5 & C22.2 No. 213
This appliance is a Class 1, Division 2, Group ABCD, T4 Type 4X, IP66.
Before installing the PF2200 system, please review the list of warnings below. Product use in a manner not specified by PROFIRE is not recommended. Failure to observe the following warnings may result in death, electrocution, property damage, product damage, government fines, or malfunction of the product itself.
- Installation and product use must conform to the directions in this manual.
- Solenoid powered outputs are rated to 5A max individually; however, the power input to the BMS card is fused at 10A. Care must be taken not to exceed the 10A max input when installing with high-powered solenoids.
- Do not jumper solenoid (-) terminals together under any circumstance; this compromises the safety-integrity of the system.
- Safety Functions must be end-to-end proven during commissioning (e.g., when using a high-pressure switch, ensure a high-pressure event triggers a lock-out).
- Electrical devices connected to the controller must meet local electrical codes, and be within voltage limits specified in this manual.
- Ensure the enclosure is securely closed each time after opening. Improper closure may result in moisture and or other environmental damage and may also compromise the integrity, and warranty of the product.
- The System must be connected appropriately to earth-ground to prevent electrocution.
- No more than one conductor is to be used per contact point.
- Properly fuse field wiring to local codes.
- Do not disassemble or modify the cards in any way. The cards are not field repairable and must be sent back to Profire for a replacement if damaged.
- Card installation shall be performed in accordance with local electrical code(s) by a capable electrician. Installation and modification shall NOT be performed while the system is energized.
- Failure to provide a low-impedance path from the burner assembly to the PF2200 may result in accidental electric shock, product damage, failure to ignite the pilot or failure to detect a flame.
- Do not connect wires or handle the electronics when powered.
- Do not modify the product once installed.
- Bypass of safety function(s) is required to update software.
- Do not disconnect power, open the enclosure, or otherwise service this product unless the area is known to be non-hazardous.
- Substitutions of components may impair suitability for specified zones.
- Replacement fuses must be ceramic and of a correct rating.
- Avoid unauthorized replacement of the fuse.
Installers which integrate the PF2200 and commission the system must meet the following criteria:
- Must understand local codes and how they apply to the installation (for both electrical and mechanical aspects of the installation).
- Must understand the electrical and mechanical limitations of the product and how that relates to the installation.
- Must verify all required safety functions prior to completing the commissioning of the appliance.
- Must be fluent in the English language (the only language this product supports).
- Must be familiar with navigating the product menus and modifying settings.
- Must understand the effect modifying a setting has on the safety and operation of the appliance.
There are two options for enclosure types for the PF2200-SB product:
- PF2200-SB-A: Stainless Steel Enclosure
- PF2200-SB-B: Polyester Enclosure
PF2200-SB-A Stainless Steel Enclosure
|Enclosure Construction||3/6" Stainless Steel|
|Ingress Protection||IP66/NEMA 4|
|Operating Temperature Rating||-40 to 55°C / -40 to 131°F|
|Dimensions with Optional Manual Switch||13.17(h) X 11.00(w) X 5.70(d)|
|Dimensions without Optional Manual Switch||13.17(h) X 9.64(w) X 5.70(d)|
PF2200-SB-A Polyester Enclosure
|Ingress Protection / NEMA||Type 4|
|Operating Temperature Rating||-40 to 55°C / -40 to 131°F|
|Dimensions with Optional Manual Switch||12.15(h) X 11.00(w) X 5.28(d)|
|Dimensions without Optional Manual Switch||12.15(h) X 9.64(w) X 5.28(d)|
The PF2200 has the approvals for installation in a Zone 2 or Class 1 Division 2 locations. The enclosure is typically mounted near the burner it is controlling or in another location that is both safe and easily accessible. The recommended mounting height is 1.5m (5ft) above the ground or a platform for the comfort of the operators. Ensure that the BMS is mounted in a safe area for operation. Look for tripping, high heat exposure, and other potential hazards.
PF2200 enclosures shall be mounted upright in such a way that the screen is clearly visible, and the keypad is easy to access. Adequate space should be provided so that the enclosure door can fully open during maintenance and commissioning.
In some situations, it may be desirable to mount the system in a location not accessible to the general public to prevent accidental or intentional tampering.
Avoid placing the system in locations that are dangerous to the operator. Examine the area surrounding the potential installation site and look for such things as nearby open flames or close proximity to tanks that might overflow, and other potentially harmful situations.
Enclosures should be mounted to minimize the run-lengths to the burner assembly (ignition coil/rod and flame detect rod), as well as the valve train (solenoids) and temperature inputs elements.
To protect the system from being damaged, it should not be mounted:
- Where chemicals may splatter or bubble over from a tank onto the system. Chemicals on the keypad may interfere with an operator’s ability to control the product or view the display and LED indicators.
- Directly to a heated tank where excessive heat may damage the product. Refer to the maximum operating temperature listed in this document.
- Where anything may tip over due to wind or snow, some examples include poles that are not appropriately secured into the ground or tripods not secured with anchor bolts or guy wires.
- In locations that have a tendency of flooding.
IMPORTANT NOTE: It is recommended to avoid drilling into the top of the enclosure. If possible, side access is better.
It is essential to ensure the cable and conduits to meet local code requirements to ensure the best compliance, performance as well as a safe environment.
The PF2200 Single Burner BMS is designed, validated and verified under the following environmental conditions
- System Voltage Range:
- 12V mode: 10.2 – 16.2 V
- 24V mode: 20.4 – 32.4 V
- Ambient Temperature Range
- Operating: -40 to 55°C / -40°F to 131°F
- Storage: -40 to 55°C / -40°F to 131°F
The User Interface card is mounted on the back of the door panel of the enclosure.
|Terminals||Electrical Rating||Wire Gauge / Torque|
|4 & 7 (Power Input +/-)||
7 – 35 VDC
500 mA Max
-7V to 17V Common Mode Range
9600 and 19200 bps (configurable)
8 Data Bits, No Parity, 1 Stop Bit
200 mA Max
4.75k Source Impedance
BMS Card Specifications
The ambient temperature rating for the BMS Card is -40°C (-40°F) to +60°C (+140°F).
BMS Card Diagram
|I/O Type||Terminals||Electrical Rating||Wire Gauge / Torque|
15-16 (Pilot 1) 19-20 (SSV)
17-18 (Pilot 2) 21-22 (SSV)
12 / 24VDC, 5A Max
Expected Load: Inductive / Resistive
55-56 (Coil Pilot 1)
59-60 (Coil Pilot 2)
12 / 24VDC Pulsed Output [PWM]
Expected Load: Inductive
|Ionization I/O||53-54 (Ion Pilot 1)
57-58 (Ion Pilot 2)
|Intermittent 80-130 VRMS Output @ 5kHz (with 20kΩ source resistance)||
|Switch Internal (IGN, RUN, PWR)||
Power: 3.3V (1kΩ source resistance)
Ignite / Run: 3.3VDC Max (~10kΩ load)
7-8 (Press. High) 11-12 (PoC)
33-34 (ESD) 35-36 (Start)
Energized State: 10VDC, 1.25mA Min
De-energized State: 3VDC, 500uA Max
30 VDC Max
43-44 (Aux. Temp)
45-46 (Aux. In 1)
47-48 (Aux. In 2)
37-38 (Aux. Out 1)
39-40 (Aux. Out 2)
20 mA Max
Expected Load: Resistive (< 350Ω)
+/- 0.1mA accuracy
|Relay Output||25-27 (Status)||
120 VAC, 170V Peak Max
* The Bath Temperature Input is safety rated ONLY if the input is configured as a Dual. If configured as a Single element, the Bath temperature input is NOT safety rated.
The wiring in this section is required for all PF2200 installations. Skipping or performing any steps in this section incorrectly will result in the PF2200 functioning improperly. Conduct pull tests on terminating wires in the BMS to ensure proper installation. Install tags identifying that electrical seals have not been poured on electrical connectors entering the PROFIRE BMS.
The PF2200 can be powered from 12V or 24V. The maximum current that the PF2200 can safely handle without blowing the main fuse is 10A. The system on its own draws about 100mA. The rest of the current is used by additional hardware such as valves. Make sure that you select a power supply that is rated appropriately for the total amount of current that is consumed by the system, and all devices attached to it.
For more information on the wiring guidelines see WIRING in the Product Manual.
Two powered outputs (terminals 15-16 and 17-18) are intended to be connected to solenoid valves which control the fuel line for the pilots. When Pilot 2 is enabled, both outputs work in conjunction with one another. Meaning that they open and close in unison. If Pilot 2 is disabled, the Pilot 2 output stays de-energized. The Pilot Outputs are capable of peak and hold PWM output mode at a fixed 3 kHz frequency. Supported duty cycles for PWM mode are 10-100% and are configurable via the user interface. Depending on the selected input type, the Pilot valve has a maximum of 5 amps and 12 / 24 volts.
Two powered outputs (terminals 19 and 20) are intended to be connected to solenoid valves which control the fuel line for the main burner. Both outputs work in conjunction with one another. Meaning that they open and close in unison. The Main Valve Outputs are capable of peak and hold PWM output mode at a fixed 3 kHz frequency. Supported duty cycles for PWM mode are 10-100% and are configurable via the user interface.
The Bath input is mandatory and must be connected to a Dual Element temperature inputs. The Outlet Stack and Auxiliary temperature inputs are only needed when a second process temperature (such as the outlet temperature on a line heater) must be monitored. Otherwise, the Auxiliary temperature inputs terminals can be left unconnected. Please note that Type-K temperature inputs wire and connectors should be used exclusively.
Ensure the Type K temperature input wire is used. (Yellow = positive and red = negative). Point to point wiring is a must with temperature inputs wires (no cold junctions). A cold junction can cause inaccurate temperature readings and therefore, poor temperature performance. Do not hook up shield wires; this should be done in the field if necessary. It is common to terminate the shield wires to earth ground or ground grid of each vessel skid; however, this can only be done upon field installation. The temperature inputs are shipped loose and installed in the vessel on location. This is when the wiring is installed as well.
The PF2200 system must be connected to a PROFIRE ignition coil.
SINGLE ROD CONFIGURATION
|Distance Between 2200 and Pilot *||Wire Size|
|0 - 10 feet||14 - 16 gauge|
|10 - 25 feet||7mm Ignition Wire|
|25 - 60 feet||7mm Ignition Wire|
*For single rod installations, the distance is defined as the length from the positive ion terminal, to the ignition coil, plus the distance from the ignition coil, to the ignition/flame rod as shown in the Single Rod Wiring Diagram. Note that the ignition wire should be no longer than 3m (10 ft).
Figure 1: Burner with Ferrofix nozzle – side view.
Figure 2: Burner with Ferrofix nozzle – top view.
Figure 3: Burner with bell nozzle - isometric.
Figure 4: Burner with bell nozzle – top view.
Figure 5: Burner with Ferrofix nozzle and Inline Igniter – Side View.
Figure 6: Burner with Ferrofix nozzle and inline Igniter – Top View.
Figure 7: Burner with Bell nozzle and Inline Igniter – Side View.
Figure 8: Burner with Bell nozzle and Inline Igniter – Top View.
PRE / POST-ASSEMBLY CHECKLIST
The following checklist will help ensure proper installation techniques for the PF2200 Burner Management System, fuel train components, and burner components. This checklist should be consulted before and after installation, to ensure requirements are met for the installation of the system.
- Ensure that the BMS is mounted in a safe area for operation. Look for tripping, high heat exposure, and other potential hazards.
- Conduct pull tests on terminating wires in the BMS to ensure proper installation.
- Install tags identifying that electrical seals have not been poured on electrical connectors entering the PROFIRE BMS.
- Ensure the Type K temperature inputs wire is used. (Yellow = positive and red = negative).
- Point to point wiring is a must with temperature inputs wires (no cold junctions). A cold junction can cause inaccurate temperature readings and therefore, poor temperature performance.
- Do not hook up shield wires; this should be done in the field if necessary. It is common to terminate the shield wires to earth ground or ground grid of each vessel skid; however, this can only be done upon field installation. The temperature inputs are shipped loose and installed on location in the vessel. The wiring is completed at that time.
- For flame detection to work correctly, the flame must be in physical contact with both the flame detection rod and the grounded pilot nozzle. This allows a current path from the flame detection rod through the flame to ground. When nozzle velocity is high, the flame may not make contact with the nozzle. This situation is referred to as "poor flame anchoring." To resolve poor flame anchoring, add a second grounded Kanthal rod can be placed further in front of the nozzle so that it catches the flame.
|Starting, and stopping the burner can be done by selecting the Start, or Stop button on the PF2200. The system prompts for an acknowledgment of this action. Press the OK button to continue with the safe start-up or shutdown of the burner. When shutting down the burner, press the Stop button. The system prompts the user to confirm the shutdown, press OK. When the shutdown process is complete, the system will prompt for an acknowledgment that the shutdown is complete. Press OK to acknowledge the shutdown.|
|With the optional manual Start/Stop switch, startups and shutdowns of the burner are achieved. This switch has three functional positions, as shown. When in the Stop position the burner is shut down and de-energizes the system. Moving the switch from the run position to the Ignite position, and holding the switch in the Ignite position for more than 2 seconds, starts the ignition sequence, and return to the Run position. By moving the switch from Stop to Run positions, you can clear a lock state.|
The optional Manual Switch (part# PFA-004260 ) mentioned above can be ordered by contacting Profire Energy.
|Note: Holding the switch in the Ignite position for more than 4.5 seconds results in a system shutdown on an External Stuck Switch event.|
|Cycle through the PF2200 Status, Settings, and Systems screens using the Carousel button.|
|Arrow keys are used to navigate screen menu items. The OK Key is also used in combination with the Arrow Keys to navigate drop-down menus.|
|Using the + and – keys, allow the user to change view modes on the status screen, increases or decreases settings, or drop-down menus enumeration in the settings screen.|
|Once the desired changes are input, click the OK button to save the changes. The OK key is also used to acknowledge any prompt screens.|
|To escape the current dialog, return to the previous screen, or escape from drop-down menus and spin boxes, use the Back key.|
|Enter Commissioning Mode by pressing the Commissioning button, and acknowledging the on-screen prompt. This mode indicated with the commissioning icon in the top right corner of the screen.|
Below is a mapping of the PF2200-SB in Commissioner mode.
For more information on system navigation visit the User Guide section on NAVIGATION.
The PF2200 Single Burner BMS is designed to be configured from the user interface through a password protection mechanism. End users are not given the ability to program any of the safety-related system settings without the appropriate password.
Every setting in the PF2200 Single Burner BMS has a settings-level which is pre-programmed at the factory. The setting's level can be one of three levels:
- Level 0 (no level): settings that DO NOT impact the safety-integrity of the system AND DO NOT impact the process operation
- Level 1: settings that DO NOT impact the safety-integrity of the system BUT can impact the process operation
- Level 2: settings that DO impact the safety-integrity of the system
In order to modify a setting that has Level 1 or Level 2 access, the user is required to enter the appropriate password via a prompt. Furthermore, modification of any safety-critical settings must be validated prior to starting the appliance.
Password protection and authentication of safety critical settings are done locally on the PF2200-SB BMS card, making it more resilient to unauthorized modification.
For Level 1 and Level 2 passwords, please contact Profire Energy. Passwords shall only be distributed to individuals that are capable of assessing the safety impact of the changes they intend to make.
The PF2200 Single Burner BMS is a logic solver designed to interface with various sensors and final elements. These configurations can be broken down into the following categories:
- Switch Contact Inputs: digital switch connection to the PF2200
- 4-20mA Loop-Powered Inputs: 4-20mA input powered by the PF2200
- 4-20mA Self Powered Inputs: 4-20mA input powered from an independent supply
- Powered Outputs: switched output intended to power a solenoid
- Contact Output: switched output intended to provide status feedback
- Mixed I/O
- Ionization / Ignition: switched output to control primary winding of an ignition transformer (Coil +/-) combined with ionization flame detection on the secondary of the ignition transformer
Commissioning Mode is a mode that elevates the user to access all settings within the system. This is usually entered to make specific settings during installation or making major changes to the system. Below is an example of the different views from User Mode and Commissioner Mode.
From the Status screen you can navigate to the Settings screen by using the Carousel key.
Below is an example of the navigational sequence to enter the Bath Sensor type setting.
To navigate to any element of the Settings screen is identical. Once in the Settings screen, use the Arrow keys to highlight any element and press the OK button to enter the specific settings related to the element for a Drop-down Option menu item, or the Plus / Minus key for a Numerical Digital Setting.
Note: When an attempt to make a setting change is conducted, the system will challenge the user for a Password. Use the Arrow keys in the correct sequence followed by pressing the OK key to Authenticate and continue to adjust settings. This security challenge resets after five minutes regardless of activity. It is also important to note the system is capable of being set up for remote access that will allow for setting changes from a remote location. This remote access is restricted to Non-Safety critical settings.
To make changes to a Drop-down menu option there are two methods as follows.
- Highlight the Drop-down option menu you wish to set and press the Plus or Minus key.
- Enter the password sequence in the Password prompt followed by pressing the OK key.
- Use the Plus and/or the Minus keys to scroll through the different options of the Drop-down menu.
- With the Drop-down menu highlighted press the OK button.
- Enter the password sequence in the Password prompt followed by pressing the OK key.
- Press OK again to expand the Drop-down menu.
- Use the Up and Down Arrow keys to highlight your selection.
- Press the OK key to set the selection.
Numerical Setting Changes
You can make changes to a numerical digital setting as follows:
- Use the Arrow keys to highlight the digital numerical setting and press the Plus or Minus key.
- Enter the password sequence in the Password prompt followed by pressing the OK key.
- Press the Plus or Minus key to adjust the setting to the desired level.
Note: A single press of the Plus or Minus key while making changes to a numerical digital setting will increase or decrease the value by one tenth. While a long press of the Plus or Minus key will accelerate the level change to help make large changes easier.
A full layout of all menus can be referenced in the Product Manual under Menu Maps
The PF2200 Systems screen holds the more global settings and information on the PF2200. Here you will find troubleshooting information, settings, backup, restore settings as well as Firmware Updates.
|In the PF2200 series, you have the option to select what events you record. To set up the filters for the event log, navigate to the System screen, highlight “Event Log” and press the OK button. You will be presented with the Event Log that, by default, records all events on the PF2200 system.
While in the Event Log screen, press the OK key to open the filters screen. Use the Arrow Up and Down keys to underline the desired filter. Press the OK key to make the selection. When complete, use the Down Arrow key to go to navigate to highlight the “Accept” button. Press the OK key to accept the selections.
You will then be returned to the Event Log screen where your filters will take effect and only show your selected events.
When a USB storage device is installed in the supplied USB port on the back of the enclosure door, the system will automatically log events to the storage device. The USB storage device can be removed and records extracted to be sent to Profire Service for analysis.
|Opening the Data Log in the Systems menu presents a Data Log Configuration screen. Here you can use the Up and Down Arrow keys to underline the desired data to log. Pressing the OK key makes the selection.
You can choose up to 8 items to capture to the USB. The sample interval rate for data collection is 15 seconds. The Data logger creates folder for each individual data logging set, and creates a .CSV file that can be opened and inspected. when the USB storage device becomes full the logging will begin to delete the oldest logs to make room for the newest logs recorded.
Advanced system diagnostics are available for display. The diagnostics screen continually updates its values so they’re always live. The type of information shown, along with many others include:
The Flame Diagnostics screen shows a real-time evaluation of the Pilot status. This includes the High and Low (DC) voltage in millivolts (mV). Also, the (AC) voltage in mV.
Flame Diagnostics will record the number of Flame Fails as well as Relights. On the right side of the screen, you will get a graphical representation of the flame health ranging from Bad to Excellent. The graph is in the form of a vertical bar.
The Status Priority screen allows you to change the focus of the Status Screen from Bath to Firing Rate. This makes the selected priority the most prominent on the status screen to make the information more relevant for the application of the unit.
To change the Priority use the + and – keys to alternate the priority from Bath to Firing Rate or back again.
The right side of the screen shows the various layouts of the status screen.
The right portion of this screen shows the different layouts in accordance to the selected priority.
|The About screen shows all the information about the Hardware and Software for the PF2200. This includes, but not limited to such information as Hardware Model, Serial Number, Manufacturing Date, Testing Date, Firmware Version, as well as information on the User Interface software.|
|Reset Settings allows the user to reset all the Burner Management Systems settings back to the factory defaults. When this action is taken, the user will be prompted to confirm the intention to reset all settings to defaults.|
BMS settings may be saved to a USB backup. This will create a human-readable .csv file that may be restored on the same unit later or used to configure other units to the same settings.
Settings can only be restored to another single burner BMS unit, the settings are not compatible between Profire product lineups.
Settings can be restored between different firmware version, however there is no guarantee of compatibility.
Not all settings may be restored due to mismatches in settings between different firmware versions.
In these cases, the settings that have failed to restore are listed on the UI screen. The commissioning complete setting is always reset to default during the restore. The operator must validate all setting on the BMS unit and acknowledge the completion of commissioning.
This very basic fire-up sequence assumes that all wiring is correct, and solid earth ground is installed.
- Apply power to the unit. The system runs a self-diagnostic test.
- The unit should display a “Ready” status, indicating that it is ready to fire.
- Ensure all ball valves are closed.
- Verify temperatures against an analog temperature gauges.
- Open the pilot ball valve, and start unit.
- Confirm flame signal is adequate.
- Visually confirm that the pilot flame safely lights the main burner.
- Slowly open the main ball valve. Once the stack temperature has increased, the main ball valve can be fully opened.
- Cycle the unit off and on with all the valves open and check all shutdowns that are wired into the PF2200.
For information on the operation of the PF2200-SB, refer to the Operations section of the User Guide found here.
|System has visible flame but cannot detect|
|Card is unresponsive or BMS card will not communicate with User Interface card|
|Ignition transformer “clicks” but no visible spark|
|Solenoids are not turning on, or turning on then over time turn off|
|Digital input will not energize|
In order to ensure that the PF2200 system works correctly and efficiently, the following maintenance and inspection diagnostic queries should be followed:
- Ensure that all wires are connected correctly.
- Routinely check for corrosion.
- Wires must not be frayed or worn, and all insulation must be intact and undamaged.
- Ensure that no moisture or condensation is apparent on the board within the enclosure.
- Check that the board does not show any sign of mechanical damage (e.g. – damage from impact from a dropped item such as a screwdriver).
- Check that the board does not show any sign of electrical damage. This means that no components should be burnt or damaged in any way.
- Confirm that the temperature of the board is within ambient temperature operating limits.
- Check that the device is not subject to excessive vibration.
- Routine inspections should be performed on all equipment. If any abnormality is found, corrective actions should be taken. If the abnormality cannot be corrected, contact PROFIRE as soon as possible.
- A qualified technician should perform any tests necessary to confirm that the equipment is still in a safe condition.
Note: care should be taken to ensure that testing does NOT damage the equipment in any way.
If the card becomes dirty it can be cleaned with compressed air. Do NOT use solvents, cleaners, or liquids to clean the board. Caution must be exercised when cleaning the board in order to prevent damage from ESD (electrostatic discharge).
Please contact PROFIRE should any replacement be required.
If you have any concerns or questions about this product, please contact PROFIRE as follows:
321 South, 1250 West Suite 1
Box 3313, Bay 12, 55 Alberta Ave
Spruce Grove, AB
T7X 3A6, Canada