PF2200-SB PRODUCT MANUAL

DOC-001043_rev 1.0
The PDF version is available here.


INTRODUCTION

SCOPE and PURPOSE

This document is intended to be a full description of the PF2200-SB product and the intended use in accordance with the product life cycle. This document outlines the following:

  • PF2200-SB Product Description: This section describes the intended use of the product; including I/O, operating sequence, general requirements, and approvals.
  • Installation and Commissioning: this section describes the actions needed to perform installation and commissioning of the PF2200-SB; including electrical/mechanical ratings, configuration parameters, mounting considerations, and warnings.
  • Operations and Maintenance: This section describes the actions needed for ongoing operation and maintenance of the PF2200-SB; including troubleshooting, maintenance, repair and replacement, decommissioning, and manufacturer notification.

TERMS and  ABBREVIATION

Alarm An indication of an abnormal condition in either the equipment or the process.
Continuous Pilot A pilot which, once placed in operation, is intended to remain ignited continuously until it is manually interrupted
Digital Input An input to the system that has two values (Energized or De-energized).
Electronic Disconnection Non-cycling interruption by an electronic device of a circuit for functional disconnection and which provides a disconnection other than by means of an air gap by satisfying certain electrical requirements in at least one pole
Flame Detector Device which provides the programming unit with a signal indicating the presence of absence of flame
Flame Detector Response Time Period of time between loss of the sensed flame and the signal indicating the absence of flame
Flame Detector Self-Checking Rate Frequency of self-checking function of the flame detector (in number of operations per unit of time)
Flame Failure Lock-out Time Period of time between the signal indicating absence of flame and lock-out
Full Rate Start Condition in which the main burner ignition and subsequent flame supervision occur at full fuel rate
Ignition Time Period of time during which the ignition device is energized
Incorporated Control Control intended for incorporation in, or on, an equipment, but which can be tested separately.
Intermittent Pilot A pilot which is automatically ignited when an appliance is called on to operate and which remains continuously ignited during each period of main burner operation.  The pilot is automatically extinguished when each main burner operating cycle is completed
Interrupted Ignition A type of ignition which is energized prior to the admission of fuel to the main burner and which is de-energized when the main flame is established
Interrupted Pilot A pilot which is automatically ignited prior to the admission of fuel to the main burner and which is automatically extinguished when the main flame is established
Lockout A state in which all powered outputs (Valves and Ignition) are de-energized and interaction from the user is required in order to exit the state.
Low Rate Start Condition in which main burner ignition occurs at low fuel rate.  Once ignition at low fuel rate occurs and the flame is proven, full main burner fuel rate may be admitted
Main Permissive An event which causes the BMS to de-energize the main solenoid outputs (SSV) and remain in that state until the event clears (or an alarm / wait condition forces the BMS out)
Maximum Flame-failure Re-ignition Time Period of time between the signal indicating absence of flame and the signal to energize the ignition device.  During this time period the fuel supply is not shut off.
Non-volatile Lockout Condition such that a restart can only be accomplished by a manual reset of the system and by no other cause
Permanent Operation System which is intended to remain in the running position for longer than 24 h without interruption
Pilot-flame Establishing Period Period of time between the signal to energize the pilot fuel flow means and the signal indicating presence of the pilot flame
Post-Ignition Time Period of ignition time between the signal indicating presence of flame and the signal to de-energize the ignition device
Post-Purge Time Purge time that takes place immediately following the shutting off of the fuel supply
Pre-Ignition Time Period of the ignition time between the signal to ignite and the signal to energize the fuel flow means
Pre-Purge Time Purge time that takes place immediately following the shutting off of the fuel supply
Recycle Time Period of time between the signal to de-energize the fuel flow means following the loss of flame and the signal to begin a new start-up procedure
Safety-interlock A term used to describe an input (either switch or Transmitter) that must be satisfied to run.  If the interlock is not satisfied (e.g. open switch or out of range transmitter) the system will proceed to lock-out.
Shutdown The process the system goes through when it receives an alarm event while running.  This is immediately followed by entering the state of Lockout.
Signal for Absence of Flame Maximum signal which indicates the loss of flame
Signal for Presence of Flame Minimum signal which indicates the presence of flame when there was previously no flame
Start-up Lock-out Time Period of time between the signal to energize the fuel flow means and lock-out
Type 2 Action Automatic action for which the manufacturing deviation and the drift of its operating value, operating time, or operating sequence have been declared and tested under the IEC 60730 standard.
Wait An event which causes the BMS to proceed to a state which will de-energize all safety outputs.  When all wait events clear, the BMS is free to automatically recycle.
Waiting Time Period between the start signal and the signal to energize the ignition device.  For burners without fans, natural ventilation of the combustion chamber and the flue passages normally takes place during this time.

ACRONYMS

BMS Burner Management System
ESD Emergency Shut Down – a mechanism that shuts down the system in the event of a safety emergency
FMEDA Failure Mode, Effects and Diagnostic Analysis
HFT Hardware Fault Tolerance
HFV High Fire Valve
I/O Generic name for a terminal that can be an input, output, or a combination or both.
PFDAVG Average Probability of Failure on Demand
PF2200-SB Model number for the PF2200 Single Burner BMS product.  Consists of: BMS Card, User Interface Card, keypad, and enclosure.
PSC Product Safety Constraint provides safety relevant restrictions on the architectural design of the system.
PFN ProFire Network.  Method of communication between User Interface Card and BMS Card.
PWM Pulse Width Modulation
RTD Resistive Thermal Device
RMA Return Merchandise Authorization
RTD Resistive Thermal Device
RTL Real Time Loop. The software execution loop that runs in the processor of a logic solver.
SIL Safety Integrity Level. A discrete level (one out of a possible four) for specifying the safety integrity requirements of the safety functions to be allocated to the E/E/PE safety-related systems where Safety Integrity Level 4 has the highest level of safety integrity and Safety Integrity Level 1 has the lowest
SIF Safety Instrumented Function. A set of equipment intended to reduce the risk due to a specific hazard (a safety loop)
SIS Safety Instrumented System – Implementation of one or more Safety Instrumented Functions. A SIS is composed of any combination of sensor(s), logic solver(s) and final element(s)
SFF Safe Failure Fraction. The fraction of the overall failure rate of a device that results in either a safe fault or a diagnosed unsafe fault
SFR Safety Function Requirements define relevant safety functionality the system is to perform to maintain the safety integrity function.
SSC Symmetrical Safety Core.  It is a combination of two microprocessors which makes up the brain of the safety machine.
SSV Safety shutoff valve. A valve that shuts off for safety reasons.
TCV Temperature Control Valve

RELATED LITERATURE

PF2200 Single Burner BMS – Modbus Registers PF2200 Single Burner BMS – Software Release Notes

REFERENCE STANDARDS

  • IEC 61508:2000 Functional Safety of Electrical / Electronic / Programmable Electronic Safety-Related Systems CSA 22.2 No. 60730-2-5 / ANSI Z21.20:14
  • UL 60730-2-5
  • CSA 22.2 No. 213-17
  • UL 121201. ED9

PRODUCT OVERVIEW

The PF2200 Single Burner Controller (PF2200-SB) product is designed to provide safe and reliable control over industrial heating appliances. This product consists of five main pieces:

  • User Interface Card: The card which provides interaction to the user/operator. This card monitors user input and displays all relevant status / setting information to the user.
  • BMS Card: The “safety brain” of the product. This card stores all the relevant safety information, and performs the operating sequence in accordance with the timings in the safety settings.
  • Keypad: Allows the user/operator to interact with the product through a series of buttons.
  • Enclosure: Provides protection for the product against environmental conditions.
  • Ignition Switch: Allows the user/operator to Start and Stop the system via an external switch located on the side of the enclosure.

USER INTERFACE CARD

The User Interface Card allows interaction with the system through the use of the keypad and a display. This card interacts with the BMS card through a proprietary communication protocol, called PFN, which utilizes the RS-485 physical transport layer. PFN and power to the User Interface are factory wired to the BMS card through a wiring harness.

MODBUS

Remote access to status information, and non-safety critical settings, can be achieved via the Modbus port of the User Interface card. The Modbus port supports Modbus RTU over the RS-485 physical layer.

For a complete register list, see PF2200 Single Burner BMS – Modbus Registers. By design, safety-critical settings are not accessible via Modbus.

USB

The USB port located on the User Interface card has two main purposes, Firmware Update, and extracting the Event Log. Profire recommends using a 1GB or larger USB stick.

The Firmware Update is only supported by using authorized Firmware bundles supplied by Profire Energy. Contact PROFIRE CONTACT INFORMATION to get an authorized Firmware bundle. For more information of the Firmware Update process, go to the PF2200 FIRMWARE UPDATE GUIDE .

The Event Log can be extracted by navigating to the Event Log which is located on the System screen. Once in the Event Log screen you can choose to Export the log by pressing the OK button.

Note: Data Logging will be in a future feature release. Please contact Profire Energy to get more information on this features release date.

STATUS LED

The User Interface Card has a Status LED which is visible on the front panel of the product. Capable of producing Red, Green and Amber colors, the states of the Status LED are defined below:

LED Behavior State
Fast blinking red System is not running and is in the lockout state.
Blinking red System is not running and is in an alarm state.
Solid red System is not running and is in the ready state.
Solid green System is running - no warnings or waits present
Blinking green System is running - in wait state.
Blinking amber System is running and is in a waiting state with a warning present.
Solid amber System is running - with a warning present.

BMS CARD

The BMS card provides the necessary I/O, and functionality to reliably, and safely control a burner. Additionally, the BMS card also has tertiary features that are not safety rated but provide a functional benefit to the overall product.

OUTPUTS

PILOT VALVE OUTPUTS (Pilot 1 and Pilot 2)

Two powered outputs (terminals 15-16 and 17-18) are intended to be connected to solenoid valves, which control the fuel line for the pilot. When Pilot 2 is enabled, both outputs work in conjunction with one another meaning, that they energize, and de-energize in unison. If Pilot 2 is disabled, the Pilot 2 output will stay de-energized. The Pilot Outputs are capable of 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.

MAIN VALVE OUTPUTS (SSV)

Two powered outputs (terminals 19-20 and 21-22) are intended to be connected to solenoid valves which control the main fuel line for the burner. Both outputs work in conjunction with one another, meaning that they energize and de-energize in unison. The Main Valve Outputs are capable of 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.

IGNITION OUTPUTS (Coil +/-)

Two powered outputs (terminals 55-56 and 59-60) are intended to be connected to an ignition source (e.g. ignition transformer). When Pilot 2 is enabled, both outputs work in conjunction with one another meaning they energize and de-energize in unison. If Pilot 2 is disabled, the Pilot 2 Coil output will stay de-energized. Two ignition modes are supported by the system and configurable via the user interface: Coil Mode, and High Energy Ignition (HEI) mode. Coil mode sends a pulsed signal of fixed frequency and duty cycle and is intended to be used in conjunction with an ignition transformer. In HEI mode, the output is energized with a steady-state DC voltage that can be used to enable an external High Energy Ignition source.

FLAME DETECTION I/O (Ion +/-)

Two Ionization flame detection I/O (terminals 53-54 and 57-58) are supported by the PF2200-SB. These terminals are intended to be connected to a flame rod which makes physical contact with the flame.

Through the use of the rectification property of the flame, the PF2200-SB measures the presence of flame by applying an AC signal to the rod. If an open circuit event exists, the result will be a loss of flame.

Pilot 1 flame detection is always enabled, whereas Pilot 2 flame detection can be enabled or disabled via the user interface. If Pilot 2 flame detection is enabled, both Pilot 1 and Pilot 2 flames must be established and present in order for the system to continue to run.

HIGH FIRE VALVE (HFV) OUTPUT

One powered output (terminals 23 and 24), is intended to be connected to a safety shut off valve when a staged heating appliance is needed. In this application, the high fire valve output is intended to be the highest level of heat demand (Stage 2). If a lower level of heat demand is needed, the high fire valve will be de-energized while the Main Valve Outputs (SSV) will be energized (Stage 1).

INPUTS

START/STOP SWITCH

The external Start/Stop switch can be used to start, stop or clear a lockout on the system. The various positions / actions are outlined in the table below:

Switch State Behavior Behavior Switch State Mode
Stop Hold the system in lockout ESD or Shutdown
Run Transition to a ready state or maintain a running state. Ready
Ignite If held for 1 second or more, transition into the Confirm Start state. System Start
Run -> Stop -> Run Acknowledge and clear lockout condition N/A

Note: if the switch is held in the Ignite state for longer than 5 seconds, the system will alarm.

EMERGENCY SHUTDOWN (ESD) INPUT

The ESD input (terminals 33-34) is an energized-to-run digital input that is always enabled. If the contact is de-energized, the system will present an alarm and proceed to lockout (if running). If the contact is energized, the alarm will clear.

PRESSURE INPUT

The Pressure input (terminals 5-6) is meant to monitor an external pressure (e.g., fuel pressure), and provide the necessary feedback in the event of a high and/or low-pressure event. Configurable as disabled, Digital Input, or 4- 20mA signal through the user interface. The pressure input can be connected to either a switch or a transmitter.

In digital input mode, the input can be configured as either an Alarm, Wait, Warning, or Main Permissive when the contact opens. This is intended to be connected to a low-pressure switch.

In 4-20mA mode, a high-pressure trip event will cause an Alarm, and a low-pressure trip event can be configured as an Alarm, Wait, Warning, or Main Permissive. The aforementioned high-pressure trip event will only Alarm the system if the high-pressure event persists after the mains have opened. This mode is intended for use with a pressure transmitter.

The following table outlines the behavior of the Pressure Input:

Input Configuration Event System Behavior
Disabled Any No Effect
Digital Input De-energized with low-pressure mode set to Wait Wait
De-energized with low-pressure mode set to Alarm Alarm
De-energized with low-pressure mode set to Main Permissive Main Permissive
Energized Run
4-20mA Out of range Alarm
Low trip with low-pressure mode set to Alarm Alarm
Low trip with low-pressure mode set to Wait Wait
Low trip with low-pressure mode set to Main Permissive Main Permissive
Active range Run
High trip with mains ON Alarm
High trip with mains OFF Run

LEVEL INPUT

The Level input (terminals 41-42) is meant to monitor an external level (e.g., tank level) and provide the necessary feedback in the event of a high and or low-level event. Configurable as Disabled, Digital Input, or 4-20mA signal through the user interface. The level input can be connected to either a switch or transmitter.

In digital mode, the level input can be used as a Wait, Warning or, an Alarm when the contact opens. This Input can be connected to a low or high-level trip switch, depending on the application.

In 4-20mA mode, the level input used in conjunction with the low-trip, and high-trip modes. These modes are independent of one another and can be configured as either a wait, warning, or an alarm. This input is intended to be connected to a level transmitter.

The following table outlines the behavior of the Level Input:

Input Configuration Event System Behavior
Disabled Any No Effect
Digital Input De-energized with digital mode set to wait Wait
De-energized with digital mode set to warning Warning
De-energized with digital mode set to alarm Alarm
Energized Run
4-20mA Out of range Alarm
Low trip with low trip mode set to wait Wait
Low trip with low trip mode set to warning Warning
Low trip with low trip mode set to alarm Alarm
Active range Run
High trip with high trip mode set to wait

Wait

High trip with high trip mode set to warning

Warning

High trip with high trip mode set to alarm Alarm

TEMPERATURE INPUTS

The PF2200-SB has three distinct temperature inputs: Bath, Outlet, and Stack; each of which is configurable to be either a Type-K thermocouple or PT-100 RTD input.

Each of the three distinct temperature inputs mentioned above has the following set points that can be configured via the user interface (note: dependent on the mode, the temperature input may or may not utilize all the set points below; see Temperature Mode for more details):

Setpoint Description
High-Temperature ESD Setpoint The temperature at which the system shuts down. If the temperature input exceeds this trip point, the system will generate an alarm and if running proceeds to lockout.
Pilot Off Setpoint The temperature at which the system de-energizes all valves, including the pilot, and enters a waiting state. When the temperature falls back down below this value minus the deadband, the system will reignite the pilot.
Main Off Setpoint The temperature at which the system de-energizes the main valves and enters the Pilot state. The main valves will be turned back on when the temperature drops below the Process Control Setpoint minus the deadband.
Process Control Setpoint The setpoint at which the process temperature will be controlled. In PID mode, the TCV will be actuated in relation to this setpoint. In Staged Heating mode, the HFV will be actuated by this setpoint.
Low-Temperature Warning Setpoint If the temperature drops below this trip point the system will display a warning on the user interface and will continue to run.

The three temperature inputs listed above also have a user-configurable mode. The various temperature modes are defined below:

Setpoint Description
Disabled The temperature input is ignored.
High Temp ESD The temperature input is monitored for High Temp ESD events only. Setpoints used in the mode are High Temperature ESD, and Lowe Temperature Warning.
Process Control Mode The temperature input is monitored for High Temp ESD events, as well as used for Process Control. Setpoints used in this mode are High-Temperature ESD, Pilot Off, Process Control, and Low-Temperature Warning.
Display Only The temperature inputs are read only and displayed on the User Interface of the PF2200. The system does NOT act on this information in any way. There are NO setpoints in this mode.

The following table shows Input Temperature Modes:

Input Terminals Type Modes Supported
Bath 61-66 Dual Element with cross comparison
Single Element
High Temp ESD
Process Control
Outlet 67-69 Single Element Disabled
High Temp ESD
Process Control
Display Only
Stack 70-72 Single Element Disabled
High Temp ESD
Display Only
Aux Temp 43-44 4-20mA Input Disabled
Process Control
High Temp ESD
Display Only

PROOF OF CLOSURE (PoC) INPUT

The Proof of Closure input (terminals 11-12) is a digital input meant to be connected to a Proof of Closure switch, indicating the closure of the main valve(s). An energized Proof of Closure input indicates that the main valve is closed. The PF2200-SB monitors the Proof of Closure input and takes action, as outlined in the table below.

Input Configuration Event System Behavior

Disabled

Any

No Effect

Digital Input

De-energized with main off

Alarm

De-energized with main on

Run

Energized

Run


REMOTE START INPUT

Input Configuration Event System Behavior
Disabled Any No Effect
Digital Input De-energized and system is in a running state Wait
De-energized and system is not running No Wait
Transition from de-energize to energize Acknowledge lockout if present, start if no alarm present
Energized Run

HIGH PRESSURE INPUT

The High-Pressure input (terminals 7-8) is a digital input intended to be connected to a high-pressure switch. This contact is energized to run, meaning that a non-energized contact indicates a high-pressure event. The high-pressure functionality is outlined in the table below.

Input Configuration Event System Behavior
Disabled Any No Effect
Enabled De-energized Alarm
Energized Run

PROOF OF MAIN LIGHT-OFF (POL) INPUT

The Proof of Main Light Off input (terminals 9-10) is intended to be used in conjunction with either, a TCV capable of position feedback, or a High-Fire valve with light-off position indication. This input is capable of both 4-20mA and Digital modes. The Proof of Main Light Off input gives the system the ability to prove a light-off position before opening the main gas valves.

In Digital mode, this input connects to a proof of closure switch on the HFV or, with a proof of position switch on a TCV.

In 4-20mA mode, this input connects to a TCV that has positional feedback. When in 4-20mA mode, the system will monitor the position input and cross-check with the user-defined setpoint and tolerance fields.

In either mode Digital or 4-20mA, the input is monitored only during the transition from pilot, to main in the request light off sequence. If the contact is not proven within 60 seconds, the system will lock-out.

Mechanically, the light off position requires a proof of closure valve for the HFV if the system is utilizing staged heating control, or in PID control mode a position switch / 4-20mA position feedback signal from the TCV.

The following table outlines the functionality of the input.

Input Configuration Event System Behavior
Disabled Any No Effect
Digital Input De-energized during pilot to main transition (60s elapsed) Alarm
Energized during pilot to main transition System transitions to main
De-energized or Energized in all other states No Effect
4-20mA Input Out of range Alarm
Low trip or High Trip during pilot to main transition (60s elapsed) Alarm
Low trip, Active Range, or High Trip during all other states No Effect
Active range during pilot to main transition System transitions to main

AUXILIARY TEMPERATURE INPUT

The Auxiliary Temperature Input (terminals 43-44) is intended to be connected to a temperature sensor with a 4- 20mA interface. This 4-20mA input can be mapped to a temperature using the span settings (Max and Min), and can be configured as Disabled, High Temp ESD, Process Control, or Display Only. For details on the individual modes, and setpoints, see the Temperature Inputs section of this document.

AUXILIARY INPUTS

The Auxiliary Inputs 1 and 2 (terminals 45-46 and terminals 47-48 respectively) are intended to be connected to a generic I/O device that does not fit into any of the above categories of inputs. Configurable as either a Digital or 4- 20mA input, this input is intended to be connected to either a switch/PLC output (digital) or transmitter (4-20mA).

The following table outlines the modes/behavior of the Auxiliary Input:

Input Configuration Event System Behavior
Disabled Any No Effect
Digital Input De-energized (input mode set to Alarm) Alarm
De-energized (input mode set to Wait) Wait
De-energized (input mode set to Warning) Warning
De-energized (input mode set to Main Permissive) Main Permissive
Energized Run
4-20mA Out of range Alarm
Low/High Trip (input mode set to Alarm) Alarm
Low/High Trip (input mode set to Wait) Wait
Low/High Trip (input mode set to Warning) Warning
Low/High Trip (input mode set to Main Permissive) Main Permissive
Active range Run

APPLIANCE FIRING RATE

In addition to the features mentioned above, Auxiliary Input 1 has the ability to map to the appliance firing rate. This input maps directly to the TCV output position (e.g. 4mA = 0%, 20mA = 100%). This is, however, gated by the TCV minimum opening position. The TCV output position can only be set by the appliance firing rate during the process control state. In any other state, it abides by the rules outlined in the TCV section of this document.

When this mode is enabled, the process setpoint is ignored by the system, and instead, the TCV is actuated based on the 4-20mA input.

If this input goes invalid or out of range the appliance firing rate will be set to 0% and an alarm will be set to shut the system down.

PROCESS SETPOINT ADJUSTMENT INPUT

In addition to the features mentioned above, Auxiliary Input 2 also supports a Process Setpoint Adjustment mode. The Process Setpoint Adjust mode is intended to be connected to a 4-20mA signal sourced by a PLC which allows the application to provide advanced temperature control (e.g. cascaded PID). By utilizing the span setting (max and min) for the setpoint, this system allows the process setpoint to be adjusted based on the input signal. Note: the system still adheres to the safety constraints of the system regarding setpoints (i.e., setpoint cannot exceed the high temp ESD setpoint).

The following table outlines the behavior of the system concerning the Process Setpoint Adjustment input:

Input Configuration Event System Behavior
Disabled Any No Effect
4-20mA Out of range Alarm
Active range, system not in process control No Effect
Active range, system in process control Run with process setpoint set by Process Setpoint Adjustment Input

TEMPERATURE CONTROL VALVE (TCV) OUTPUT

The Temperature Control Valve output (terminals 13-14) is a 4-20mA output that is intended to connect to a proportional fuel gas valve on the main fuel train. The TCV output behavior corresponds to the current state of the system, as outlined by the table below:

System State TCV Position Behavior
Ready, Waiting, Alarm, Lockout, Power On Purge Position Holding
Startup Pilot Position Holding
Main Light off TCV Minimum Position Holding
Transition from Main Light Off to Process Control TCV Minimum Position -> Requested Process Control Position Ramping according to ramp time setting
Process Control (PID) Requested Process Control Position Actively controlled by PID
Process Control (Staged Heating, ON/OFF) 100% Output railed to maximum value.

Where:

  • Purge Position: User configurable setting from 0-100% corresponding to valve opening percentage (0% = 4mA, 100% = 20mA) – position held while the system is not running.
  • Pilot Position: User configurable setting from 0-100% corresponding to valve opening percentage (0% = 4mA, 100% = 20mA) – position held during the Ignition state.
  • TCV Minimum Position: User configurable setting from 0-100% corresponding to valve opening percentage (0% = 4mA, 100% = 20mA) – the minimum position the valve can be told to go by the Process Control state.
  • Process Control Position: position of the TCV during process control. Either controlled by PID (if enabled), or set to 100% in Staged Heating or On/Off control.

The TCV output also supports a manual override mode, where the output percentage is modifiable via the user interface. When in manual override mode, the TCV output percentage is mapped to the manual output position regardless of the system state.

AUXILIARY OUTPUTS

The Auxiliary Outputs 1 and 2 (terminals 37-38 and 39-40 respectively) are a 4-20mA output signal which be set to various modes of operation. The following is a list of modes along with detailed description of behavior:

Mode Behavior
Disabled N/A
Proc Temp Echo The output will follow a selected temperature input of the system. The output range will be between 4-20mA spanned from 0 °C to 1350 °C.   If the temperature is not valid (loss of temperature input or a temperature fault) the output will send out a 0mA signal.
Level Echo The output will follow the level input measurement of the system.  The output range will be between 4-20 mA spanned from the level span Min to the level span Max value.  If the level input is not valid or it is not enabled (loss of input signal or an input fault) the output will send out a 0mA signal.
Aux 1 Input Echo The output will follow the Aux 1 Input. The output range will be between 4-20 mA spanned from the Aux 1 span Min to the Aux 1 span Max value.  If the aux input is not valid or it is not enabled (loss of input signal or an input fault) the output will send out a 0mA signal.
Aux 2 Input Echo The output will follow the Aux 2 Input. The output range will be between 4-20 mA spanned from the Aux 2 span Min to the Aux 2 span Max value. If the aux input is not valid or it is not enabled (loss of input signal or an input fault) the output will send out a 0mA signal.
Modbus Echo The output will follow the Modbus register “Aux Out x” value from 0 to 100%. If the Modbus is not configured, the output will send out a 0 mA signal.

STATUS RELAY OUTPUT

The Status Relay Output (terminals 25-27) is a normally open contact designed as an isolated output that has a configurable mode of operation. The modes of operation are outlined below:

Configuration Behavior
Run Status
  • De-energized when in Power On, Lockout, Ready, or Alarm states
  • Energized when in Waiting, Startup, Pilot, Main Light Off or Process Control
Heating Status
  • De-energized when in Power On, Lockout, Ready, Alarm, or Waiting states
  • Energized when in Startup, Pilot, Main Light Off or Process Control
Low temp Warning Status
  • De-energized when in Power On, Lockout, Ready, Alarm states OR Process temperature is below low temp warning setpoint
  • Energized when in Startup, Pilot, Main Light Off, Process Control states AND Process temperature is above low temp warning setpoint

KEYPAD

The keypad is the primary method for the operator to interface with the PF2200 system. It allows for screen navigation, start/stop control, and the adjustment of settings.

The following buttons are offered:

Button Behavior
When pressed, the user interface will prompt for a confirmation of system shutdown. A second user action is required to shut the system down by confirming the stop with the press of the OK button.
When pressed, the user interface will prompt to confirm the start request. A second user action is required to start the system by confirming the start with the press of the OK button.  Once a start sequence is sent, the system will start only if safe to do so (e.g., no Alarms or Waits present).
Context-sensitive return button which will:
- Escape the current dialog
- Go back to the previous screen
- Escape from setting combo boxes
- Escape from setting spin boxes
User interface navigation
Alternates between the three screens: Status, Settings, and System.
This button toggles display modes from Operator to Commissioner.  Where Commissioner mode is intended as a mode to access settings for commissioning, and Operator mode is intended as a mode to access settings while the appliance is in operation.
Toggles view modes on the status screen. In the settings screen, these buttons increment or decrement settings, as well as combo box enumeration.

Safety Note: The keypad is intended to aid in commissioning, and observe the system status. As such, the keypad is not considered part of nor should be incorporated into ANY safety function. If the user shut-down is a required safety function, then the user input must be hard-wired into the ESD input of the BMS card.

ENCLOSURE SPECIFICATIONS

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

 

Item Description
Enclosure Construction 304 Stainless Steel
Ingress Protection IP66/NEMA 4x
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-B Polyester Enclosure Specifications

 

Item Description
Enclosure Construction Polyester
Ingress Protection / NEMA Type 4X
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)

OPERATING SEQUENCE

Where:

  • IGNITION: consists of first energizing the ignition coils, then followed by turning on the pilot solenoid(s).
  • Automatic Recycle is only permitted once the system has proven the main burner flame. Upon flame loss, the system can attempt to relight the flame. If the maximum number of relight attempts (default set to 3) is exceeded the system will shut down on Flame Fail.
  • Flame Loss event results in detecting an absence of flame that exceeds the Flame Failure Lock-out Time.

OPERATIONAL STATES

POWER ON

Power On, is the default state of the system when power is applied. In this state, the system will check if a previous lockout condition was set, and if so, will force the system into a lock-out state.

If the system previously shut-down due to a power loss, and the Low Voltage Restart setting is enabled, the system will purge, and then proceed to system start-up.

If there are no lockouts or alarms, and the system is not automatically restarting, then the system will transition into the Ready state.

In the Power On state, the status of each powered outputs is as follows:

Powered Output Status
Pilot 1 / 2 De-energized
Coil 1 / 2 De-energized
SSV De-energized
HFV De-energized

LOCKOUT

The system transitions to Lockout state when an alarm event occurs while running. If the alarm event clears while in the Lockout state, the system will stay in a Lockout state until the lockout has been acknowledged. There are four ways to acknowledge a lockout:

  • User Interface: Using the keypad on the PF2200 to acknowledge the lockout state.
  • Toggling of the Start input: .???
  • Toggling of the Start/Stop Switch: Turning the Optional Manual switch to the Stop position, then back to the run position.
  • Modbus Interface: With a terminal input register sequence of 1234.

In the Lockout state, the status of each powered outputs is as follows:

Powered Output Status
Pilot 1 / 2 De-energized
Coil 1 / 2 De-energized
SSV De-energized
HFV De-energized

READY

Ready is the system state where the system is not running, and no alarms are present. If there are any alarms present while in this state, the system will move to the Alarm state. In the Ready state, the system may proceed to start by one of the following methods:

  • User Interface: Pressing the Start button on the PF2200 unit and acknowledging the prompt to confirm startup.
  • Toggling of the Start input.
  • Holding the Start/Stop switch in the ignite position for more than 2 seconds.
  • Modbus Interface start.

In the Ready state, the status of each powered outputs is as follows:

Powered Output Status
Pilot 1 / 2 De-energized
Coil 1 / 2 De-energized
SSV De-energized
HFV De-energized

ALARM

An Alarm is the state of the system where there is an active and persistent alarm present. Typically, this is indicative of a static problem (e.g., transmitter not connected, system voltage too low, etc.) and the system can only exit this state when all alarms have cleared.

In the Alarm state, the status of each powered outputs is as follows:

Powered Output Status
Pilot 1 / 2 De-energized
Coil 1 / 2 De-energized
SSV De-energized
HFV De-energized

WAITING

Waiting is considered a “running” state of the system, with all powered outputs de-energized. The system will hold this state until all wait conditions have been cleared, or shut down if an alarm is present. Once all waits have been cleared, the system will automatically trigger a startup sequence without any user interaction – provided no alarms are present.

Note: purging after a flame loss is considered a waiting state.

In the Waiting state, the status of each powered outputs is as follows:

Powered Output Status
Pilot 1 / 2 De-energized
Coil 1 / 2 De-energized
SSV De-energized
HFV De-energized

IGNITION

Ignition is the process of safely establishing a pilot flame, and the system achieves this by energizing the coil and pilot outputs while monitoring flame presence on the ionization inputs. Actuating and monitoring of Pilot 2 can be enabled/disabled via the user interface and should only be enabled if a multiple-pilot configuration is desired.

The sequence begins by energizing the coil output(s) and waits the Pre-Ignition Time. After the Pre-Ignition Time, the system then energizes the pilot output(s) and monitors flame presence. This stage is referred to as Ignition on the user interface. If a flame is not detected within the Pilot-Flame Establishing Period window, the system will purge and enter the waiting state, while decrementing the Relights Remaining counter. If the system tries to light three times and fails to establish a flame, it will proceed to Lockout (Flame-Fail). Note that a successful establishment of flame effectively resets the Relights Remaining counter. If a flame is detected within the Pilot-Flame Establishing Period window, the system will proceed to hold a pilot flame for a startup delay time. This startup delay helps warm up the appliance and establish the draft in the appliance. Once the flame has been established and the startup delay time has elapsed, the system will move into the Pilot state.

If the Pilot 2 is enabled, the system requires both flames to be satisfied within the Pilot-Flame Establishing Period in order to proceed.

If the Pilot 2 is disabled, the system only requires Pilot 1 flame to be satisfied within the Pilot-Flame Establishing Period in order to proceed.

Any alarms or waits that occur during this still will force the system to go to the respective state (e.g. alarm or wait, respectively).

In this system state, the status of each powered outputs is as follows:

Powered Output Status
Pilot 1 De-energized during Pre-Ignition
Energized after Pre-Ignition
Pilot 2 De-energized if disabled
Same as Pilot 1 if enabled
Coil 1 Energized during and after pre-ignition
De-energized during startup delay
Coil 2 De-energized if disabled
Same as Coil 1 if enabled
SSV De-energized
HFV De-energized

PILOT

The Pilot state is a system state which represents a minimum amount of heating required to light off the main burner. It is typically tied to the Pilot valve in the fuel gas train – meaning that the pilot valve(s) are on in this state, but the main valves are off. This state is executed in one of the following situations:

  • Once a flame is established during the Ignition state,
  • If one of the configured temperatures exceeds the Main Off setpoint, or If a main permissive is configured and not satisfied

Once in the Pilot state, the system must verify all configured process temperatures are below their respective process setpoints, and main permissive(s) (if configured) have been cleared in order to enter the Main Light Off state.

Any alarms or waits that occur during this still will force the system to go to the respective state (e.g., Lockout or Waiting, respectively).

In the Pilot state, the status of each powered outputs is as follows:

 

Powered Output Status
Pilot 1 Energized

Pilot 2

De-energized if disabled

Energized if enabled

Coil 1 /2

SSV

HFV

De-Energized

MAIN LIGHT-OFF

Once the system has a proven flame, and all conditions are satisfied, the system enters the Main Light Off state. If the system entered the Main Light Off state from the Ignition state, the Main Light Off state is held for a configurable amount of time (Main Startup Delay Time). This parameter is configurable during commissioning and is intended to give the appliance time to establish a draft and heat up before the mains are turned on. If the system entered the Main Light Off state from a Process Control state, the Main Startup Delay Time will is set to a fixed 5 seconds – since a draft has already been established, and the appliance is already warm.

In addition to the minimum time requirements, the Main Light Off state also has the option of proving the light off position. When Proof of Main Light off position (POLO) is enabled, the Main Light Off state will hold until either the position has been proven, or 60 seconds have elapsed. If the position cannot be proven in the allotted time frame, the system will enter an Alarm state.

Any alarms or waits that occur during Main Light Off still will force the system to transition to an Alarm state or a Waiting state, respectively.

In the Main Light Off state, the status of each powered outputs is as follows:

Powered Output Status
Pilot 1 Energized

Pilot 2

De-energized if disabled

Energized if enabled

Coil 1 /2

SSV

HFV

De-Energized

PROCESS CONTROL

Once the system has determined the mains can be turned on, it enters the Process Control state. In this state, the system actively tries to maintain the process temperature setpoint via the actuation of valves in various configurations. There are three main process control modes offered, and they are:

  1. On/Off Control
  2. Staged Heating
  3. PID Control

Any alarms or waits that occur during this state will force the system to transition to the Alarm state or the Waiting state, respectively.

In the Process Control state, the status of each powered outputs is as follows:

Powered Output Status
Pilot 1

Energized

Pilot 2

De-energized if disabled

Energized if enabled

Coil 1 / 2 De-Energized

SSV

HFV

Energized or De-energized, depending on the process control state. See process control modes below for detailed valve behavior


ON/OFF CONTROL

This mode is the simplest mode of operation, requiring only the SSV outputs. In this mode, the SSV outputs are Energized when the process temperature is below the process setpoint and are De-energized when above the setpoint. In the case that the process temperature exceeded the setpoint, the temperature must fall below the setpoint minus the dead-band in order for the SSV outputs to re-energize.

Note: this process control mode does not utilize the HFV or the TCV outputs.

STAGED HEATING

Staged Heating Mode is a slightly more advanced method of control than the On/Off control, allowing an extra stage of heating. In this mode, the system utilizes the HFV output as another heating level – giving the system a total of three stages:

  • Pilot Only (Pilot)
  • Pilot + SSVs (Stage 1)
  • Pilot + SSVs + HFV (Stage 2)

The diagram below outlines the behavior of the system in Two-Stage Control.

  1. When the process temperature is below the process setpoint, the SSV and the HFV outputs will be energized
  2. for maximum heat output
  3. When the process temperature is above the process setpoint but below the main off setpoint the SSV outputs will remain energized, and the HFV outputs will be de-energized, reducing the burner’s firing rate.
  4. When the process temperature exceeds the main off setpoint, the SSV outputs de-energize. The system will transition to the pilot state to cool down.
  5. When the process temperature cools down to the process temperature setpoint minus the dead band the SSV and the HFV outputs will be energized to heat the system back up

Note: this process control mode does not utilize the TCV output.

PID CONTROL

PID Control is the most advanced process control mode, allowing the system to be able to vary the heat demand in response to the appliance. In this mode, the system utilizes the TCV output to control a temperature control valve, allowing the system to incrementally change output heat.

The main gas valve outputs (SSV) remain on during PID control unless the process temperature exceeds the Main Off Setpoint. In this case, the system transitions to the Pilot state and stops PID control. Once the system cools off such that the process temperature falls below the process setpoint minus the dead-band, the system will proceed to light off the main and resume PID control.

While in PID control, the system will attempt to maintain the process temperature at the process temperature setpoint by modulating the system firing rate via the TCV output. As long as there are no alarms/waits AND the temperature does not exceed the Main Off (or Pilot Off) setpoints, the PID will continue to function.

Note: this process control mode does not utilize the HFV output.

GENERAL REQUIREMENTS

PF2200 DECLARATIONS

System Parameter Value
Maximum Flame Detector Response Time 50ms
Minimum Flame Detector Self-Checking Rate 1Hz
Maximum Flame Failure Lock-Out Time 4s
Maximum Flame-Failure Re-ignition Time Pre-Ignition Time
Maximum Ignition Time 10.6s
Maximum Pilot-Flame Establishing Period 10s
Maximum Post-Ignition Time 2.5s
Maximum Pre-Ignition Time 600ms
Minimum Post-Purge Time 10s
Minimum Recycle Time Post-Purge Time
Maximum Start-up Lock-Out Time 10s[3]
Maximum Number of Start-Up Retries 3
Minimum Waiting Time 5s [1]
Pollution Degree 1 when installed in an enclosure with a rating of IP54 or equivalent
Signal for Presence of Flame -5.56V [2]
Signal for Absence of Flame -5.56V [2]
High Voltage Spark Gap Range 2 – 8mm
Types of Action Type 2: Electronic Disconnection, Non-volatile Lockout, Permanent Operation
Types of Burners Full Rate Start and Low Rate Start
Type of Control Incorporated Control
Types of Ignition Interrupted
Types of Pilot Continuous, Intermittent and Interrupted

  1. Assuming a purge has already elapsed. If the system is purging the start command is delayed until the purge is complete.
  2. A flame signal is an amount the AC signal being applied to the flame rod is rectified (e.g., the DC offset to the AC waveform).
  3. Since recycling is allowed, this time is from fuel flow energizing on start-up to fuel flow de-energize due to no flame presence.

CERTIFICATIONS and APPROVALS

The PF2200-SB (Single Burner BMS) is certified for use in a 1to1 deployment configuration and is pending certification

to the following standards:

  • IEC 61508: 2010 Parts 1-7
  • CSA – C22.2 No. 60730-2-5 / ANSI Z21.20:14
  • UL 60730-2-5
  • CSA – C22.2 No. 213-17 – Class 1 Div 2 Group ABCD; T4; Type 4x, IP66
  • UL 121201 Ed.9

INSTALLATION and COMMISSIONING

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.

SYSTEM CONFIGURATION

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.

PASSWORDS

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.

INTERFACING

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:

  • Inputs
    • 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
  • Outputs
    • 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

INPUT WIRING

 

OUTPUT WIRING

MIXED I/O WIRING

Flame Detect & Ignition Wiring for Single-Rod Application

ELECTRICAL and MECHANICAL RATINGS

The PF2200 Single Burner BMS has been 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 55⁰C
    • Storage: -40 to 55⁰C
  • Humidity
    • External to product: 0-100% Condensing
    • BMS and User Interface Card: 0-90% Non-Condensing
  • Vibration
    • 3g swept form 10-150Hz, 10 consecutive sweeps, 3-axis

USER INTERFACE CARD

Terminals Safety Rated Electrical Rating Wire Gauge / Torque
4&7
(Power Input +/-)
No 7 – 35 VDC
500 mA Max
14-30 AWG
0.22-0.25 Nm
5-6
(PFN A/B)
No -7 to 17 V Common Mode
 
14-30 AWG
0.22-0.25 Nm
1-3
(Modbus A/B/-)
No -7V to 17V Common Mode Range
9600 and 19200 bps (configurable)
8 Data Bits, No Parity, 1 Stop Bit
14-30 AWG
0.22-0.25 Nm
USB No 5VDC
200 mA Max
N/A
Keypad No 3VDC
4.75k Source Impedance
N/A

BMS CARD

I/O Type Terminals Safety Rated Electrical Rating Wire Gauge / Torque

Powered Output

15-16 (Pilot 1)

17-18 (Pilot 2)

19-20 (SSV)

21-22 (SSV)

Yes

12 / 24VDC, 5A Max

Expected Load: Inductive / Resistive

12-30 AWG

0.5-0.6 Nm

Powered Output

55-56 (Coil Pilot 1)

59-60 (Coil Pilot 2)

Yes

12 / 24VDC

Pulsed Output [PWM]

Expected Load: Inductive

12-30 AWG

0.5-0.6 Nm

Ionization I/O

53-54 (Ion Pilot 1)

57-58 (Ion Pilot 2)

Yes

Intermittent 80-130 VRMS Output @ 5kHz (with 20kΩ source resistance)

12-30 AWG

0.5-0.6 Nm

Start/Stop

Switch

Internal (IGN, RUN, PWR)

Yes

Power: 3.3V (1kΩ source resistance)

Ignite / Run: 3.3VDC Max (~10kΩ load)

12-30 AWG

0.5-0.6 Nm

Digital Input

7-8 (Press. High)

11-12 (PoC)

33-34 (ESD)

35-36 (Start)

Yes

Energized State: 10VDC, 1.25mA Min

De-energized State: 3VDC, 500uA Max

30 VDC Max

12-30 AWG

0.5-0.6 Nm

Digital /

4-20mA Input

5-6 (Press.)

9-10 (POL)

41-42 (Level)

43-44 (Aux. Temp)

45-46 (Aux. In 1)

47-48 (Aux. In 2)

Yes

Power Out:

  • 12V Mode = 12VDC, 24V Mode = 13.5 VDC
  • 30mA Max

Digital Input (if applicable):

  • Energized State: 10VDC, 1.25mA Min
  • De-energized State: 3VDC, 500uA Max
  • 30 VDC Max

4-20mA Input:

  • +/- 0.1 mA accuracy
  • 50mA current limit
  • 30 VDC Max

12-30 AWG

0.5-0.6 Nm

Temperature Input

61-66 (Bath)

67-69 (Outlet)

70-72 (Stack)

Bath: Yes*

Outlet &

Stack: No

RTD (PT-100):

  • -100 to 850C [60.25Ω to 390.5Ω]
  • +/- 0.5accuracy

Temperature inputs(Type-K):

  • -100 to 1350 [-3.554mV to 54.1mV]
  • +/- 2accuracy
  • Ground-biased

14-30 AWG

0.22-0.25 Nm

4-20mA Output

13-14 (TCV)

37-38 (Aux. Out 1)

39-40 (Aux. Out 2)

No

20 mA Max

Expected Load: Resistive (< 350Ω)

+/- 0.1mA accuracy

12-30 AWG

0.5-0.6 Nm

Relay Output

25-27 (Status)

No

120 VAC, 170V Peak Max

1ARMS Max

12-30 AWG

0.5-0.6 Nm

Powered Output 23-24 (HFV) No 12 / 24VDC, 5A Max Expected Load: Inductive / Resistive

12-30 AWG

0.5-0.6 Nm

Power Out 1&4 (UI) No 7 – 35 VDC 500 mA Max

14-30 AWG

0.22-0.25 Nm

Communication 2&3 (PFN) No -7V to 7V Common Mode Range

14-30 AWG

0.22-0.25 Nm

Power In 28-32 (Power) No 12-24VDC 10A Max

12-30 AWG

0.5-0.6 Nm


* The Bath Temperature Input is safety rated ONLY if the input is configured as a Dual element. If configured as a single element, the Bath temperature input is NOT safety rated. In order to enable a single element for the Bath temperature, the user will be prompted with a disclaimer.

IMPORTANT SAFETY INFORMATION

All PF2200 installations must be field inspected by the Authority Having Jurisdiction to ensure proper compliance with local electrical and gas codes. In addition, before installing the PF2200, please review the following list of warnings. Failure to observe the following may result in death, electrocution, property damage, product damage, or government fines.

GENERAL WARNINGS

  • 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 should be taken not to exceed the 10A max input when using high-powered solenoids.
  • Do not jumper solenoid (-) terminals together under any circumstance. This will compromise 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 presents a lock-out).

EXPLOSION HAZARD WARNINGS

  • Do not disconnect power, open the enclosure, or otherwise service the 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 the correct rating (10A, 150VDC, Slow Blow).
  • Avoid unauthorized replacement of the fuse. Contact Profire Energy for fuse replacements.
  • Do not remove or replace fuse when the system is powered.

INSTALLATION WARNINGS

  • 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 other environmental damage and may also compromise the integrity of the product.
  • The system must be properly connected to earth-ground to prevent electrocution.
  • No more than one conductor is to be used per contact point.
  • Ensure field wiring is properly fused and sizes in accordance with 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 Energy for replacements 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.
  • All screw connections must not rely on the structural integrity of insulating materials.

MOUNTING CONSIDERATIONS

The PF2200 Single Burner BMS cards must be mounted in an enclosure of IP54 rating or greater. There are two enclosure options for this product, the PF2200-SB-A, and the PF22000-SB-B – both of which are outlined in section ENCLOSURE SPECIFICATIONS .

Both enclosure options have four holes, located in the four corners of the product. These holes are intended to be used in conjunction with a fastening device (e.g., nut or bolt) to secure the product to a rigid platform.

ORIENTATION & LOCATION

  • The PF2200 enclosure shall be mounted upright in such a way that the screen is clearly visible and the keypad is easy to access. Recommended height of 1.5m (5ft) above ground.
  • Adequate space must be given such that the enclosure door can open during maintenance/commissioning.
  • The enclosure should be mounted to minimize run-lengths to valve train (solenoids), burner assembly (ignition coil/rod and flame detect rod) and thermocouple elements.
  • When wiring ignition and flame detection circuits, the wire length between the ignition coil and the pilot should be no more than 5m (15ft). The longer the run-length, the less energy delivered when sparking.
  • The PF2200 should be mounted in such a way to avoid direct sunlight exposure to the screen. Extended UV exposure may compromise viability.

MOUNTING CARDS

If the need arises where the cards need to be remounted (e.g., field repair/replacement), both cards should be securely fastened with the appropriate screw size and number of screws. For the BMS card, there are 6 x #10-32 machine screws [11] that secure the card [3] to the enclosure. For the User Interface card, there are 4 x #10-32 nuts [10] that secure the card [2] to the enclosure through the cover [7]. See the exploded view below for more details.

Ensure that the earth ground connection is restored when remounting BMS cards. The User Interface card is grounded through the board-to-board connector [9] and thus should not need a separate terminal.

 

PROTECTIVE EARTHING

For the PF2200-SB-A, the metal enclosure must be adequately bonded to earth ground by the installer. Bonding must be carried out in accordance with the local electrical code (e.g., NEC in the United States and CEC in Canada).

To ensure proper functionality of the flame detection circuit, Profire recommends the DC power supply reference be tied to Earth Ground.

OPERATIONS and MAINTENANCE

  • Operators working on or maintaining the PF2200 must meet the following criteria:
  • Be fluent in the English language (the only language this product supports).
  • Be familiar with navigating the product menus and modifying settings.
  • Understand the effect modifying a setting has on the safety and operation of the appliance.

Assumptions Specific to Use

  • All powered outputs that are in a de-energized state are assumed to be in a safe state (e.g., a de-energized pilot output should connect to a normally closed valve to shut off gas flow in the de-energized state).
  • All digital inputs are energized-to-run (e.g. an open contact presents an alarm / shutdown).
  • Power supply and external fusing should be determined using the local electrical code (e.g., NEC in the United States or CEC in Canada)

Note: Holding the switch in the Ignite position for more than 4.5 seconds will result in a system shutdown on an External Stuck Switch event.

STATUS SCREEN

The Status screen displays various information relevant to the operation of the burner.

To change the zoom level of the Status Screen, use the , or keys.

The Status screen displays information in accordance with the configurable status priority settings.

Refer to the Status Priority section for information on adjusting how and what information is shown on the status screen.

The user interface display remains on at all times to allows operations personnel to check key system status information without any required interaction.

SETTINGS

The settings screen contains all controller settings grouped by type for easy settings adjustment and commissioning.

Operator Mode Commissioning Mode

COMMISSIONING

Commissioning Mode is a mode that allows read-only access to all settings within the system.

Users must enter a valid password when prompted in order to enable settings modifications.

SETTINGS MODIFICATION

Below is an example of the navigational sequence to enter the Bath Sensor type setting. This sequence is typical for all settings adjustments.

In this example there is an assumption the user has entered Commissioning Mode by pressing the Commission Mode Key.

DROP-DOWN MENU CHANGES

To make changes to a Drop-down menu option there are two methods as follows.

Method One:

  1. Highlight the drop-down menu you wish to change and press the or key.
  2. Enter the password if prompted then press and repeat step 1.

Method two:

  1. Highlight the drop-down menu you wish to change and press .
  2. Enter the password sequence if prompted then press .
  3. Press again to expand the Drop-down menu.
  4. Use the and keys to highlight your selection.
  5. Press the key to set the selection.

Numerical Setting Changes

Numerical settings can be changed as follows:

  1. Highlight the numerical setting you wish to change, and press the or key.
  2. Enter the password sequence if prompted then press the key and repeat step 1.

MENU MAPS

SETTINGS MAPS

Supplied for you below is a set of menu maps for each of the elements in the settings screen of the PF2200. These maps show the pathways and the options for each setting.

TEMPERATURES

BATH TEMPERATURE INPUT

Name Default Options / Range Description Configuration Notes
Type RTD TC
RTD
Temperature sensing element type. Can be Type K Thermocouple (grounded or ungrounded) or PT100 RTD  
Input Dual DualSingle Configuration control for the Bath input. Dual requires two unique temperature sensing elements, whereas single only requires one. Bath Input mode is required to be set to Dual if the Bath Input is specified as a safety function.
Mode Process Control Process Control
High Temp ESD
Mode for the temperature input, used by the system to determine how the input is to be used. See the Temperature Inputs section for more details. At least one of Bath Mode, Outlet Mode, or Aux Temp Mode must be set to Process Control.
High Temp Setpoint 90 °C
194 °F
0 °C - 1350 °C
32 °F - 2462 °F
Temperature threshold at which, if exceeded, the system shuts down. High Temp Setpoint must be greater than Pilot Off Setpoint and In RTD mode must be less than 850 °C.
Pilot Off Setpoint 85 °C
185 °F
0 °C - 1350 °C
32 °F - 2462 °F
Temperature threshold at which, if exceeded, the system turns off the pilot valve(s). Pilot Off Setpoint must be greater than Main Off Setpoint and less than High Temp Setpoint.
Main Off Setpoint 85 °C
185 °F
0 °C - 1350 °C
32 °F - 2462 °F
Temperature threshold at which, if exceeded, the system turns off the main valve(s). Main Off Setpoint must be greater than Process Setpoint and less than Pilot Off Setpoint.
Process Setpoint 80 °C
176 °F
0 °C - 1350 °C
32 °F - 2462 °F
Temperature setpoint the system attempts to maintain when in Process Control mode. must be greater than Low Temp Setpoint and less than Main Off Setpoint.
Low Temp Setpoint 0 °C
32 °F
0 °C - 1350 °C
32 °F - 2462 °F
Temperature threshold at which, if not exceeded, the system warns the user. Low Temp Setpoint must be less than Process Setpoint.
Deadband 2 °C
3.6 °F
0 °C - 100 °C
0 °F - 180 °F
The deadband prevents the system from bouncing between states when the input reading is close to the corresponding setpoint. See the Temperature Inputs section for more details.  

OUTLET TEMPERATURE

Name Default Options / Range Description Configuration Notes
Type RTD TC
RTD
Temperature sensing element type. Can be Type K Thermocouple (grounded or ungrounded) or PT100 RTD  
Mode Disabled Disabled
Process Control
High Temp
ESD
Display Only
Mode for the temperature input, used by the system to determine how the input is to be used. See the Temperature Inputs section for more details. At least one of Bath Mode, Outlet Mode, or Aux Temp Mode must be set to Process Control.
High Temp Setpoint 90 °C
194 °F
0 °C - 1350 °C
32 °F - 2462 °F
Temperature threshold at which, if exceeded, the system shuts down. Only applicable if the mode is set to High Temp ESD or Process Control. High Temp Setpoint must be greater than Pilot Off Setpoint and In RTD mode must be less than 850 °C.
Pilot Off Setpoint 85 °C
185 °F
0 °C - 1350 °C
32 °F - 2462 °F
Temperature threshold at which, if exceeded, the system turns off the pilot valve(s). Pilot Off Setpoint must be greater than Main Off Setpoint and less than High Temp Setpoint.
Main Off Setpoint 85 °C
185 °F
0 °C - 1350 °C
32 °F - 2462 °F
Temperature threshold at which, if exceeded, the system turns off the main valve(s). Main Off Setpoint must be greater than Process Setpoint and less than Pilot Off Setpoint.
Process Setpoint 80 °C
176 °F
0 °C - 1350 °C
32 °F - 2462 °F
Temperature setpoint the system attempts to maintain when in Process Control mode. Process Setpoint must be greater than Low Temp Setpoint and less than Main Off Setpoint.
Low Temp Setpoint 0 °C
32 °F
0 °C - 1350 °C
32 °F - 2462 °F
Temperature threshold at which, if not exceeded, the system warns the user. Low Temp Setpoint must be less than Process Setpoint.
Deadband 2 °C
3.6 °F
0 °C - 100 °C
0 °F - 180 °F
The deadband prevents the system from bouncing between states when the input reading is close to the corresponding setpoint. See the Temperature Inputs section for more details.  

STACK

Name Default Options / Range Description Configuration Notes
Type RTD TCV
RTD
Temperature sensing element type. Can be Type K Thermocouple (grounded or ungrounded) or PT100 RTD  
Mode Disabled Disabled
High Temp ESD
Display Only
Mode for the temperature input, used by the system to determine how the input is to be used. See the Temperature Inputs section for more details.  
High Temp Setpoint 90 °C
194 °F
0 °C - 1350 °C
32 °F - 2462 °F
Temperature threshold at which, if exceeded, the system shuts down. Only applicable if the mode is set to High Temp ESD. High Temp Setpoint must be greater than Pilot Off Setpoint and In RTD mode must be less than 850 °C
Deadband 2 °C
3.6 °F
0 °C - 100 °C
0 °F - 180 °F
The deadband prevents the system from bouncing between states when the input reading is close to the corresponding setpoint. See the Temperature Inputs section for more details.  

INPUTS

LEVEL/FLOW

Name Default Options / Range Description Configuration Notes
Type Digital Disabled
Digital
4-20
Level/Flow sensor type. It can be configured as a switch (digital), transmitter (4-20), or disabled.  
Digital Mode Alarm Alarm
Wait
Warning
Action the system takes when a de-energized contact occurs. Type is must be set to Digital
4-20 Low Trip Mode Alarm Alarm
Wait
Warning
Action the system takes when a low-trip event occurs. Type is must be set to 4-20
4-20 High Trip Mode Alarm Alarm
Wait
Warning
Action the system will take when a high-trip event occurs. Type is must be set to 4-20
4-20 Span Min 0 L
0 gal
0 L - 100000 L
0 gal - 26417 gal
Level/Flow value corresponding to 4mA output from the 4-20mA transmitter. Span Min must be less than Span Max and 4-20 Low Trip
4-20 Span Max 120 L
31.7 gal
0 L - 100000 L
0 gal - 26417 gal
Level/Flow value corresponding to 20mA output from the 4-20mA transmitter. Span Max must be greater than Span Min and 4-20 High Trip
4-20 Low Trip 12 mA 4 mA - 20 mA Input threshold at which, if not exceeded, the system initiates a low-trip event. The low-trip event is defined by the 4-20 Low Trip Mode setting. Type is must be set to 4-20
4-20 High Trip 19.6 mA 4 mA - 20 mA Input threshold at which, if exceeded, the system initiates a high-trip event. The 4-20 High Trip Mode setting defines the high-trip event. Type is must bet set to 4-20
4-20 Deadband 0.2 mA 0 mA - 1 mA The deadband prevents the system from bouncing between states when the input reading is close to the corresponding trip point. To clear a low trip, the input must be greater than 4-20 Low Trip plus deadband. To clear a high trip, the input must be less than 4-20 High Trip minus deadband.
Level/Flow Delay 2 sec 2 sec - 20 sec The amount of time the system requires a low-input event to be consistent before performing the low-trip action.  

PRESSURE

Name Default Options / Range Description Configuration Notes
Type Digital Disabled
Digital
4-20
Pressure sensor type. It can be configured as a switch (digital), transmitter (4-20), or disabled.  
4-20 Span Min 0 kPa
0 psi
0 kPa - 100000 kPa
0 psi - 14504 psi
Pressure value corresponding to 4mA output from the 4-20mA transmitter. Span Min must be less than Span Max and 4-20 Low Trip
4-20 Span Max 206.843 kPa
30 psi
0 kPa - 100000 kPa
0 psi - 14504 psi
Pressure value corresponding to 20mA output from the 4-20mA transmitter. Span Max must be greater than Span Min and 4-20 High Trip
4-20 Low Trip 4 mA 4 mA - 20 mA Pressure threshold that, if not exceeded, the system initiates a low-pressure event. The Low-Pressure Mode setting defines the low-pressure event. Type is must be set to 4-20
4-20 High Trip 17.73 mA 4 mA - 20 mA Pressure threshold that, if exceeded, the system will shutdown. Type is must be set to 4-20
4-20 Deadband 0.2 mA 0 mA - 1 mA The deadband prevents the system from bouncing between states when the input reading is close to the corresponding trip point. To clear a low trip, the input must be greater than 4-20 Low Trip plus deadband. To clear a high trip, the input must be less than 4-20 High Trip minus deadband.
Low-Pressure Delay 2 sec 2 sec - 20 sec The amount of time the system requires a low-pressure event to be consistent before performing the low-pressure action.  
Low-Pressure Mode Alarm Alarm
Wait
Warning
Main Permissive
Action the system takes when a low-pressure event occurs.  

PRESSURE HIGH

Name Default Options / Range Description
Pressure High Enabled Disabled
Enabled
Controls whether the High-Pressure input is enabled or disabled. See the High-Pressure Input section for more details.

AUX IN 1&2

Name Default Options / Range Description Configuration Note
Type Digital Disabled
Digital
4-20
Input sensor type. It can be configured as a switch (digital), transmitter (4-20), or disabled.  
4-20 Mode High/Low Trip High/Low Trip
Appliance Firing Rate
Bath Process SP Adjust
Outlet Process SP Adjust
Aux Temp Process SP Adjust
Various modes for the Aux input when configured as a 4-20 type. See the Auxiliary Inputs section for more details. Type is must be set to 4-20
Digital Mode Alarm Alarm
Wait
Warning
Main Permissive
Action the system takes when a de-energized contact occurs. Type is must be set to Digital
4-20 Low Trip Mode Alarm Alarm
Wait
Warning
Main Permissive
Action the system takes when a low-trip event occurs. Type is must be set to 4-20
4-20 High Trip Mode Alarm Alarm
Wait
Warning
Main Permissive
Action the system takes when a high-trip event occurs. Type is must be set to 4-20
4-20 Low Trip 0% 0 – 100% Input threshold at which, if not exceeded, the system initiates a low-trip event. The 4-20 Low Trip Mode setting defines the low-trip event. Type is must be set to 4-20
4-20 High Trip 100% 0 – 100% Input threshold at which, if exceeded, the system initiates a high-trip event. The 4-20 High Trip Mode setting defines the high-trip event. Type is must be set to 4-20
4-20 Deadband 1.2% 0 – 6.2% The deadband prevents the system from bouncing between states when the input reading is close to the corresponding trip point. To clear a low trip, the input must be greater than 4-20 Low Trip plus deadband. To clear a high trip, the input must be less than 4-20 High Trip minus deadband.
4-20 Span Min 0% 0% - 100% Input value corresponding to 4mA output from the 4-20mA transmitter. Span Max must be greater than Span Min
4-20 Span Max 100% 0% - 100% Input value corresponding to 20mA output from the 4-20mA transmitter. Span Max must be greater than Span Min

PROOF OF CLOSURE

Name Default Options Description
Proof Of Closure Enabled Disabled
Enabled
Controls whether the Proof of Closure input is enabled or disabled. See Proof of Closure section for more details.

REMOTE START

Name Default Options Description
Remote Start Enabled Disabled
Enabled
Controls Whether the Remote Start input is enabled or disabled. See the Remote Start input section for more details.

PROOF OF LIGHT OFF

Name Default Options Description
Type Disabled Disabled Digital 4-20mA  
Setpoint 50.0% 0.0% - 100%  
Tolerance 1.5% 0.0% - 6.2%  

OUTPUTS

STATUS

Name Default Options Description
Status Contact Mode Disabled Disabled
Enabled
Defines the behavior of the Status Contact.

VALVES

Name Default Options Description
Pilot Valve PWM 60% 10% - 100% The duty cycle of the output. The higher value corresponds to higher average output.
SSV PWM 60% 10% - 100% The duty cycle of the output. The higher value corresponds to higher average output.
Aux PWM 60% 10% - 100% The duty cycle of the output. The higher value corresponds to higher average output.

AUX 1 & 2

Name Default Options Description
Mode Disabled Disabled
Level/Flow Echo
Aux In 1 Echo
Aux In 2 Echo
Modbus Echo
Bath Temp Echo
Outlet Temp Echo
Stack Temp Echo
Aux Temp Echo
Defines the behavior of the Auxiliary Output. See the Auxiliary Outputs section for more details.
Temp Echo Span Min 0 °C
32 °F
-100 °C - 1350 °C
-148 °F - 2462 °F
Temperature value corresponding to 4mA from the Auxiliary Output.
Temp Echo Span Max 1350 °C
2462 °F
-100 °C - 1350 °C
-148 °F - 2462 °F
Temperature value corresponding to 20mA from the Auxiliary Output.

TCV

Name Default Options Description
Min Position 40% 0 % - 70 % Minimum position for the TCV output. See Temperature Control Valve (TCV) output section.
Purge Position 0% 0 % - 100 % Position for the TCV output during the Purge state. See Temperature Control Valve (TCV) output section.
Pilot Position 0% 0 % - 100 % Position for the TCV output during the Ignition and Pilot states. See Temperature Control Valve (TCV) output section.
Manual Override Disabled Disabled
Enabled
Manual override TCV functionality, used in conjunction with Manual Position setting. See Temperature Control Valve (TCV) output section.
Manual Position 0% 0 % - 100 % Position of TCV when Manual Override is enabled. See Temperature Control Valve (TCV) output section.

PROCESS CONTROL

CONFIGURATION

Name Default Options Description
Process Control Mode On/Off Control On/Off Control
Staged Heating
Bath PID Control
Outlet PID Control
Aux PID Control
Cascaded PID Control
Control mode of the system. Refer to the Process Control section for more details.
Pilot Off Mode Disabled Disabled
Off At Pilot Off Setpoint
Follow Main
Defines when the system turns off the Pilot valve, specifically:
• Disabled: Pilot remains on so long as the burner is running
• Off at Pilot Off Setpoint: Pilot remains on so long as the burner is running and no configured temperature is above Pilot Off Setpoint
• Follow Main: Pilot remains on so long as the main valves are on
Pilot 2 Disabled Disabled
Enabled
Enables the second Pilot valve output and flame detection input.

TIMING

Name Default Options Description
Purge Time 60 sec 10 sec – 900 sec The time which the system remains in the Purge state.
Pilot Startup Delay Time 15 sec 15 sec – 600 sec The minimum time in which the system remains in the Pilot state when starting.
Main Startup Delay Time 30 sec 30 sec – 600 sec The minimum time in which the system remains in a minimum firing state when before entering the Process Control state.

IGNITION

Name Default Options Description
Relight Attempts 3 0 - 3 attempts Determines the number of relighting attempts the system does use when establishing flame.
Ignition Mode Coil Coil
HEI
Controls the Coil output behavior when in the ignition state:
• Coil: Pulsed output mode, typically connected to a rated ignition coil
• HEI: constant output mode, typically connected to a high-intensity ignitor

PID CONTROL

Name Default Options Description
Process Proportional Band 10 °C 18 °F 0 °C - 1000 °C
0 °F - 1800 °F
This is the proportional Band used for the PID calculation. In cascaded control mode, this value applies to the bath PID loop.
Process Integral Time 4 mins/rep 0 mins/rep - 1000 mins/rep This is the integral time used for the PID calculation.
Process Derivative Time 0 min 0 min - 1000 min This is the derivative time used for the PID calculation.
Process Integral Reset Range 10 °C 18 °F 0 °C - 1000 °C
0 °F - 1800 °F
This is the boundary of the integral windup range. If the process temperature is outside of this range the integral term does not accumulate.
Cascade Proportional Band 10 °C 18 °F 0 °C - 1000 °C
0 °F - 1800 °F
This is the proportional Band used for the cascaded PID calculation for the outlet temperature. If cascaded PID is not used, this value has no effect.
Cascade Integral Time 0 mins/rep 0 mins/rep - 1000 mins/rep This is the integral time used for the cascaded PID calculation for the outlet temperature. If cascaded PID is not used, this value has no effect.
Cascade Derivative Time 0 min 0 min - 1000 min This is the derivative time used for the cascaded PID calculation for the outlet temperature. If cascaded PID is not used, this value has no effect.
Cascade Integral Reset Range 10 °C 18 °F 0 °C - 1000 °C
0 °F - 1800 °F
In cascaded mode, this is the boundary of the integral windup range for the outlet temperature. If the outlet temperature is outside of this range, the integral term does not accumulate.
Output Rate Limit 100 %/sec 0.1 %/sec - 100 %/sec This is the limit for the maximum output change of the TCV per second. A larger value allows for a quicker change in output. A smaller value slows down any change in output. This can help prevent fast movements from the TCV.
Ramp Time 10 sec 0 sec - 255 sec Once the system enters process control mode after the light-off delay, it slowly ramps to the requested firing rate over this time. This can prevent the firing rate from jumping hard from the minimum opening position to the maximum firing rate too quickly.

SETUP

COMMISSIONING

Name Default Range Description
Voltage Setting 12V 12V
24V
Sets the voltage mode of the system. Setting this mode affects the thresholds for the low and high voltage alarms/warnings.
Voltage Restart Disabled Disabled
Enabled
Enabling this mode allows the system to restart from a low voltage event, provided the system was running when the low voltage event occurred.
L1 Password Enable Disabled Disabled
Enabled
Enabling this mode allows L1 password control on some non-safety critical settings.
Commissioning Complete Incomplete Incomplete
Complete
Setting to confirm commissioning is complete. While this setting is Incomplete, the system is incapable of running.

UNITS

Name Default Range Description
Temperature Units Celsius Celsius
Fahrenheit
Display units for Temperature inputs.
Pressure Units kPa kPa
psi
inch wc
oz/in2
kg/cm2
Percent
Milliamps
Display units for Pressure input.
Level/Flow Units Litres Litres
m3
US Gallons
bbl
ft3
L/sec
L/min
m3/sec
m3/min
US Gal/sec
US Gal/min
bbl/sec
bbl/min
ft3/sec
ft3/min
Percent
Milliamps
Display units for Level/Flow input.
Aux In 1 &
Aux In 2 Units
Percent Percent
Milliamps
Temperature
Pressure
Level/Flow
Display units for Auxilliary inputs.

MODBUS

Name Default Range Description
Slave Address 1 1 - 247 Modbus slave address of the PF2200.
Baud Rate 9600 9600
19200
Baud rate for the RS-485 link.
Stop Bits 1 1
2
The number of stop bits. Used for configuring the RS-485 protocol.
Parity None None
Odd
Even
Parity bit support. Used for configuring the RS-485 protocol.
Modbus Termination Disabled Disabled
Enabled
Termination enable. Used for configuring the RS-485 protocol.
Modbus RTU Communication Disabled Disabled
Enabled
Modbus enable.

SYSTEM SCREEN

The System screen contains a variety of tools and diagnostic information for customization, troubleshooting, and commissioning support.

EVENT LOG

The PF2200-SB event log continuously records Alarms, Warnings, Shutdowns, and Process control decisions as well as general system information and stores it on the USB storage device (if installed).

While in the Event Log screen, press the key to open the filters screen. Use the Arrow Up and Down keys to underline the desired filter. Press the key to make the selection. When complete, use the Down Arrow key to go to navigate to highlight the “Accept” button. Press the key to accept the selections and return to the filtered event log.

When the supplied USB storage device is installed in the USB port on the back of the enclosure door, the system will automatically log events to the storage device. The data saved is stored on a provided USB storage device, and when the USB device becomes full the oldest data will be overwritten by the newest data.

DATA LOGGING

The PF2200-SB data logging tool will monitor various input and output data and will automatically log the data to the supplied USB storage device.

Use the keypad to choose up to 8 items to log 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.

The statistics dialog will show an approximation of logging time remaining on the USB before old logs start getting deleted.

DIAGNOSTICS

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:
  • System Voltage.
  • System Current.
  • Valve status and current draws.
  • Burner run time.
  • Average firing rate.
  • Daily energy consumption.

FLAME DIAGNOSTICS

The Flame Diagnostics screen shows a real-time evaluation of the pilot status, and indicates whether the flame is Strong, Weak, or not present.

Flame failures, and relights are also recorded for troubleshooting and maintenance scheduling.

STATUS PRIORITY

The Status Priority screen allows you to change how and what data is shown on the Status screen.

Use the and keys to order all settings as desired for display on the 3 Status screen zoom levels.

ABOUT

The About screen displays all the information about the Hardware and Software for the PF2200. This includes Firmware Versions, Hardware Models, Serial Numbers and, Manufacturing Dates.

RESET SETTINGS

Reset Settings allows the user to reset all 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.

BACKUP / RESTORE SETTINGS

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 copy settings to another unit.

Settings can be restored between different firmware version, however 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.


FIRMWARE UPDATE

The user interface and BMS can be firmware updated via USB with approved firmware bundles. The system must not be running for the update to take place.

The firmware bundle is selected via a user interface (UI) dialog from the USB stick.

The UI may be updated separately if the bundle supports the current BMS version. This allows for changes that are only on the UI side to not affect the BMS unit.

If the UI and the BMS version do not match a warning will be displayed on the UI.

To update the firmware, follow the steps below:

  1. Save the firmware bundle supplied by Profire to the supplied USB storage device.
  2. Ensure it is safe to open the enclosure.
  3. Open the enclosure and install the USB device into the USB port.
  4. Enter Commissioner Mode by pressing the and pressing to the acknowledgment prompt.

7. Navigate to the Systems screen using the .

8. Navigate to Firmware Update and press the key.

9. The contents of the USB storage device will be displayed. Select the desired firmware bundle and press the key.

10. Confirm bundle selection.

11. Select whether to update UI only or both UI and BMS together and press .

13. The system will update the software and restart the unit.

14. To confirm the update is successful, navigate to the System screen and select the About menu item. Confirm the new firmware and UI software versions are correct.

TROUBLESHOOTING

For a complete list of Alerts and there meaning, refer to the PF2200 ALERT CODES.

Problem Diagnosis

The System has visible flame but cannot detect

  1. Ensure pilot assembly, flame rod, and the gap between are fully engulfed in flame. If not, adjust rod position
  2. Ensure flame detection wiring does not exceed the recommended maximum.
  3. Ensure burner assembly has a low impedance path to Ion- terminal of BMS.
  4. For longer run lengths, ensure ignition cable is used to avoid ground-loading.

Card is unresponsive or BMS card will not communicate with User Interface card

  1. Ensure the Status LEDs for both cards are functioning. If status LED is not functioning, cycle power (if safe to do so) and check again.
  2. If status LED is still not functioning, attempt a firmware update of both cards.
  3. If firmware update fails, card is likely faulty.

Ignition transformer “clicks” but no visible spark

  1. Ensure all wires in the ignition path are properly terminated and that there is a low impedance path from the primary-windings to the BMS card as well as the secondary-windings to the ignition rod.
  2. Ensure the gap between the ignition rod and the burner housing is within the tolerances specified in this manual under PF2200 Declarations section under ”High Voltage Spark Gap Range”. Often times there is either excess buildup or the rod has drooped to compromise the gap distance.

Solenoids are not turning on, or turning on then over time turn off

  1. Ensure the solenoid is wired correctly and to the appropriate terminals.
  • To ensure proper solenoid wiring, a multi-meter in OHM mode can be used to measure the resistance between the + and – terminal of the associated output. Note: this measurement should be done with the BMS card powered off.
  • If properly wired, the multi-meter should read a resistance of the solenoid coil plus the run length (i.e. if the multimeter reads open, there is likely a problem with wiring).
  1. Ensure the PWM setting is correct for the appropriate solenoid.
  • If using a peak-and-hold solenoid, the appropriate PWM setting can be found in the solenoid data sheet. Typically add a margin of 5-10% to allow for temperature variance
  • If using a non-peak-and-hold solenoid, ensure the PWM setting is set to 100%

Digital input will not energize

  1. Ensure the input is properly wired. See section 4 for Interfacing / Wiring configurations.
  2. In the case of a dry contact, ensure the PWR terminal is connected and is sourcing the correct voltage.
  3. Ensure adequate amount of wetting current is being applied to through contact.
  • Run a current meter in series with the digital input switch and verify the energized state meets the requirements outlined in the “Electrical and Mechanical Ratings” section of this document
  • If there is not adequate wetting current, the digital input either has too high of an impedance or the wiring has been compromised

MAINTENANCE

During maintenance, with respect to software and setup, a visual inspection should be done to determine the following:

  • What is the firmware version being used?
  • What are the appliance specific settings? An example list of settings can be found below
  • Is Pressure used? Is Level Used? Is TCV Used?
  • Is Pilot 2 Used? Is Outlet Temp Used? Is Stack Temp Used?

When a gas fitting installation is done, a visual inspection should be done to determine the following:

  • Whether drip legs are installed on the final drop and condensation points?
  • Whether the pilot piping is taken off the top or the side of the supply and not the bottom?
  • Whether piping and fittings are clear from burrs and defects?
  • Whether an overpressure protection device is required and installed?
  • Whether the regulator is of a positive shut off type for supply above 0.5 psig?
  • Whether gas pressure is indicated at shutoff valves and penetrations are required?
  • Whether piping is supported securely and the support spacings do not exceed 8 feet?
  • Whether gauges are correctly sized to match the pressure range?
  • Whether the gas line is painted or marked according to code?
  • Whether swing joints are installed if they are required?
  • Whether all exposed gas piping is painted?
  • Whether the ends of piping are reamed?
  • Whether the appliance vents are mounted securely?
  • Whether all indicators and gauges can be read easily?
  • Whether gas shutoffs in the upstream pilot valve train are present and easily accessible?
  • Whether gas shutoffs in the downstream pressure regulator are present and easily accessible?
  • Whether gas shutoffs in the upstream pressure regulator are present and easily accessible?
  • Whether appliance gas shutoffs are present and easily accessible?

When any electrical installation is done, a visual inspection should be done to determine the following:

  • Whether all wires are stripped correctly (no copper should be seen out of the connectors)?
  • Whether all wires and conduits are appropriately secured?
  • Whether the correct conduit, cable seals and fittings are used for the zone?
  • Whether the enclosure lugs are wired to earth ground?

A functional test should be performed to verify all appropriate user-configurable I/O ring in as alarms. The best way to verify this is to tabulate a list of all safety-critical sensors and I/O that is wired into the PF2200 and test their functionality one at a time. This can be done by forcing an alarm on each I/O separately and verifying the PF2200 annunciates the appropriate alarm.

REPAIR and REPLACEMENT

Profire Energy does not support on-site repairs for cards. For replacement cards, contact Profire Energy customer service.

In the event replacement card(s) are used, care must be taken to ensure proper firmware is loaded on both the User Interface and BMS cards. If the User Interface and BMS cards have different software bundles loaded on them, the system will fail to operate correctly and will require a firmware update to match.

For more details on the firmware update procedure, contact Profire Energy.

DECOMMISSIONING

When decommissioning the system, the appliance should be safely shut down (i.e. all safety outputs are turned off and there are no gas leaks on site). Once the appliance is in a safe state, the power should be disconnected from the PF2200. All cards should be treated like any other piece of electronics (e.g. be sent to a recycling depot).

USEFUL LIFE

The useful life of the PF2200 is 10 years. Prior to the expiry of that period the customer should contact Profire Energy for a suitable replacement.

MANUFACTURER NOTIFICATION

Any detected failures that compromise the functional safety of the system should be reported to Profire Energy immediately. Please contact Profire Energy customer service.

PROFIRE CONTACT INFORMATION

If you have any concerns or questions about this product, please contact PROFIRE as follows:

United States Canada

1.801.796.5127

321 South, 1250 West Suite 1

Lindon, UT

84042, USA

support@profireenergy.com

1.780.960.5278

9671 - 283 Street

Acheson, AB

T7X 6J5, Canada

support@profireenergy.com