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Profire Energy PF2200-SB Product Manual

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PF2200-SB
PRODUCT MANUAL
DOC-001043 / v5.2

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  • Page 1 PF2200-SB PRODUCT MANUAL DOC-001043 / v5.2...

  • Page 2: Table Of Contents

    PROPRIETARY INFORMATION: THIS DOCUMENT IS PREPARED BY PROFIRE ENERGY FOR THE USE OF OUR CUSTOMER. PROFIRE ENERGY ASSUMES NO LIABILITY TO ANY OTHER PARTY FOR ANY REPRESENTATIONS CONTAINED HEREIN. TABLE of CONTENTS INTRODUCTION ................................4 SCOPE PURPOSE .................................... 4 TERMS ABBREVIATIONS ................................
  • Page 3 DECOMMISSIONING ..................................79 USEFUL LIFE ......................................79 MANUFACTURER NOTIFICATION ..............................79 DOCUMENT REVISION HISTORY ..........................81 APPENDIX A: ALARM CODES & RESPONSE TIMES ....................83 APPENDIX B: FUNCTIONAL SAFETY DESIGN PF2200-SB ..................89 SAFETY NON-SAFETY I/O ................................91 SAFETY FUNCTIONS ....................................92 SAFETY INTEGRITY ....................................93 9.3.1...

  • Page 4: Introduction

    INTRODUCTION 1.1 SCOPE and PURPOSE This document is intended to be a full description and the intended use of the PF2200-SB product 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, •...

  • Page 5: Terms And Abbreviations

    1.2 TERMS and ABBREVIATIONS 1oo1 One out of one deployment configuration. 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 can be one of only two states (Energized or De-energized).
  • Page 6 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 of time between the signal to energize the pilot fuel flow means and the signal indicating Period...

  • Page 7: Acronyms

    Generic name for a terminal that can be an input, output, or a combination or both. 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, enclosure and ignition switch Profire Network.

  • Page 8: Product Support

    1.4 PRODUCT SUPPORT Product support can be obtained from: Profire Energy 1.855.776.3473 321 South, 1250 West Suite 1 Lindon, UT 84042, USA support@profireenergy.com 1.5 RELATED LITERATURE PF2200 Single Burner BMS – Modbus Registers PF2200 Single Burner BMS – Software Release Notes 1.6 REFERENCE STANDARDS...

  • Page 9: Pf2200-Sb Product Description

    PF2200-SB PRODUCT DESCRIPTION 2.1 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 four main pieces: User Interface Card: the card which provides interaction to the user / operator. This card monitors •...

  • Page 10: User Interface Card

    Data-logging is enabled by going to the Firmware Update screen on the User Interface and is limited by the size of USB stick-- a USB stick of size 1GB or larger is recommended. Firmware update is only supported using authorized firmware bundles. Contact Profire Energy for an authorized firmware bundle. 2.1.1.3 STATUS LED The User Interface Card has a tricolor Status LED which is visible on the front panel of the product.

  • Page 11: Bms Card

    2.1.2 BMS CARD The BMS card provides the necessary I/O and functionality to reliably and safely control a burner. In addition, the BMS card also has tertiary features that are not safety rated but provide a functional benefit to the overall product.
  • Page 12 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.
  • Page 13 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) remain energized (Stage 1). 2.1.2.6 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...
  • Page 14 2.1.2.8 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 transmitter.
  • Page 15 2.1.2.9 LEVEL INPUT The Level input (terminals 41-42) is meant to monitor an external level or flow measurement and provide the necessary feedback in the event of a high and/or low level/flow 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.
  • Page 16 2.1.2.10 TEMPERATURE INPUTS The PF2200-SB has three distinct temperature inputs: Bath, Outlet and Stack; each of which are configurable to be either a Type-K thermocouple or PT-100 RTD input. Each of the three distinct temperature inputs mentioned above have the following set points that can be configured via the user interface (note: depending on the mode, the temperature input may or may not utilize all the set points below;...
  • Page 17 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.
  • Page 18 2.1.2.12 REMOTE START INPUT The Remote Start input (terminals 35-36) is a digital input intended to provide the ability to start the system from an external source (e.g. a switch or PLC). The remote start input is an energized-to-run input, meaning that if the contact is de-energized the system will proceed to a WAIT state.
  • Page 19 2.1.2.14 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. 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.
  • Page 20 2.1.2.15 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.
  • Page 21 Note that either Auxiliary Input 1 or 2 can be configured as an Appliance Firing Rate Input, but not both. Process Setpoint Adjustment Input In addition to the features mentioned above, both auxiliary inputs also support 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.
  • Page 22 2.1.2.17 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 state of the system, as outlined by the table below: System State TCV Position...
  • Page 23 2.1.2.18 AUXILIARY OUTPUTS The Auxiliary Outputs 1 and 2 (terminals 37-38 and 39-40 respectively) are configurable 4-20mA output signals. Configuration modes and corresponding behavior are shown below: Mode Behavior Disabled The output will follow the selected temperature input of the system. The output range Temperature will be between 4-20mA spanned between user configurable Min and Max temperature Echo...
  • Page 24 2.1.2.19 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 De-energized when in Power On, Lockout, Ready, and Alarm states Run Status Energized when in Waiting, Ignition, Pilot, Main Light Off and Process Control states De-energized when in Power On, Lockout, Ready, Alarm, and Waiting states...

  • Page 25: Keypad

    2.1.3 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 outlines button functionality: Button Behavior When pressed the user interface will prompt for confirmation of system shutdown.

  • Page 26: Enclosure

    ANY safety function. If user shut- down is a required safety function, then the user input must be hard-wired into the ESD input of the BMS card. 2.1.4 ENCLOSURE There are two options of enclosure-types for the PF2200-SB product: DOC-001043 / v5.2...
  • Page 27 PF2200-SB-A: Stainless Steel Enclosure • PF2200-SB-B: Polyester Enclosure (Coming Soon) • Both enclosure styles cannot be opened without the use of a tool (screwdriver). 2.1.4.1 PF2200-SB-A Stainless Steel Enclosure Enclosure Construction 304 Stainless Steel Ingress Protection / NEMA IP 66, Type 4X Temperature Rating -40 to +55⁰C...

  • Page 28: Operating Sequence

    2.2 OPERATING SEQUENCE Auto Restart Enabled Previous Lo ckout on B oot AND No Alarms Present Power On Alarm Condition User Acknowlege Lockout Ready Alarm Alarm Alarm, Condition Start Flame Fail, or Clear User Stop Any Process Waiting Control State Wait Condition Set All Wait...

  • Page 29: Power On

    2.2.1 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 lockout 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 startup.

  • Page 30: Ready

    2.2.3 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 start •...

  • Page 31: Waiting

    2.2.5 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 –...

  • Page 32: Pilot 1

    In this system state, the status of each powered outputs is as follows: Powered Output Status De-energized during Pre-Ignition Pilot 1 Energized after Pre-Ignition De-energized if disabled Pilot 2 Same as Pilot 1 if enabled Energized during and after pre-ignition Coil 1 De-energized during startup delay De-energized if disabled...

  • Page 33: Main Light Off

    2.2.8 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).

  • Page 34: Process Control

    2.2.9 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. The three process control modes are: 1.
  • Page 35 2.2.9.2 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) •...
  • Page 36 2.2.9.3 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.

  • Page 37: General Requriements

    2.3 GENERAL REQURIEMENTS 2.3.1 PF2200 DECLARATIONS System Parameter Value Maximum Flame Detector Response Time 50ms Minimum Flame Detector Self-Checking Rate Maximum Flame Failure Lock-Out Time Maximum Flame-Failure Re-ignition Time Pre-Ignition Time Maximum Ignition Time 10.6s Maximum Pilot-Flame Establishing Period Maximum Post-Ignition Time 2.5s Maximum Pre-Ignition Time Minimum Post-Purge Time...

  • Page 38: Certification And Approvals

    2.4 CERTIFICATION and APPROVALS The PF2200-SB (Single Burner BMS) is certified for use in a 1oo1 deployment configuration and is certified to the following standard(s): IEC 61508: 2010 Parts 1-7 • CSA – C22.2 No. 60730-2-5 / ANSI Z21.20:14 •...

  • Page 39: Installation And Commissioning

    Furthermore, modification of any safety critical settings must be validated prior to starting the appliance. Password protection and authentication of safety critical settings is done locally on the PF2200-SB BMS card, making it more resilient to unauthorized modification.

  • Page 40: Interfacing

    3.1.2 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 • o Switch Contact Inputs: digital switch connection to the PF2200 o 4-20mA Loop Powered Inputs: 4-20mA input powered by the PF2200 o 4-20mA Self Powered Inputs: 4-20mA input powered from an independent supply Outputs...
  • Page 41 DOC-001043 / v5.2...
  • Page 42 3.1.2.2 OUTPUT WIRING DOC-001043 / v5.2...

  • Page 43: Electrical And Mechanical Ratings

    3.1.2.3 MIXED I/O WIRING Flame Detect & Ignition Wiring for Single-Rod Application 3.1.3 ELECTRICAL and MECHANICAL RATINGS The PF2200 Single Burner BMS has been designed, validated and verified under the following environmental conditions System Voltage Range: • o 12V mode: 10.2 – 16.2 V o 24V mode: 20.4 –...
  • Page 44 3.1.3.1 USER INTERFACE CARD Terminals Safety Electrical Rating Wire Gauge / Rated Torque 4&7 7 – 35 VDC 14-30 AWG (Power Input +/-) 500 mA Max 0.22-0.25 Nm 5&6 -7 to 17 V Common Mode 14-30 AWG (PFN A/B) 0.22-0.25 Nm -7V to 7V Common Mode Range 9600 and 19200 bps 14-30 AWG...
  • Page 45 3.1.3.2 BMS CARD I/O Type Terminals Safety Electrical Rating Wire Rated Gauge / Torque 15-16 (Pilot 1) 17-18 (Pilot 2) 12 / 24VDC, 5A Max 12-30 AWG Powered Output 19-20 (SSV) Expected Load: Inductive / Resistive 0.5-0.6 Nm 21-22 (SSV) 55-56 (Coil Pilot 12 / 24VDC 12-30 AWG...
  • Page 46 I/O Type Terminals Safety Electrical Rating Wire Rated Gauge / Torque 13-14 (TCV) 20 mA Max 12-30 AWG 4-20mA Output 37-38 (Aux. Out 1) Expected Load: Resistive (< 350Ω) 0.5-0.6 Nm 39-40 (Aux. Out 2) +/- 0.1mA accuracy 120 VAC, 170V Peak Max. Rated to withstand 12-30 AWG Relay Output 25-27 (Status)

  • Page 47: Important Safety Information

    Substitution of components may impair suitability for specified zones. • Replacement fuses must be ceramic and of 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 system is powered. •...

  • Page 48: Installation Warnings

    Do not disassemble or modify the cards in any way. The cards are not field reparable and must be • sent back to Profire Energy for replacement if damaged. Card installation shall be performed in accordance with local electrical code(s) by a capable electrician.

  • Page 49: 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 2.1.4. 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.

  • Page 50: Mounting Cards

    3.3.2 MOUNTING CARDS If the need arises where the cards needs 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.

  • Page 51: Protective Earthing

    Due to the variability of installation (e.g. load configuration, wiring, etc.), a ferrite bead may be required to suppress power supply related noise on the input power to the PF2200-SB-B. Typically this is only needed for long power line / load line run lengths and at higher load currents (e.g. >2A).

  • Page 52: Operations And Maintenance

    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. •...

  • Page 53: Operator User Interface

    4.3 OPERATOR USER INTERFACE 4.3.1 STATUS SCREEN The Status Screen displays various information relevant to operation of the burner. To change the zoom level of the Status Screen, use the 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 is shown on the Status Screen.
  • Page 54 4.3.2.1 COMMISSIONING MODE 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 modification. Commissioning Mode Operator Mode DOC-001043 / v5.2...
  • Page 55 4.3.2.2 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. DOC-001043 / v5.2...
  • Page 56 Drop-Down Menu Changes Drop-down menu options can be selected using either of the following methods: Method One: 1. Highlight the drop-down menu you wish to change and press 2. Enter the password sequence if prompted then press the key and repeat step 1 Method two: 1.

  • Page 57: Settings Descriptions

    4.3.3 SETTINGS DESCRIPTIONS 4.3.3.1 BATH TEMPERATURE INPUT Options / Configuration Name Default Description Range Notes Temperature sensing element type. Can be Type Type K Thermocouple (grounded or ungrounded) or PT100 RTD Bath Input mode is Configuration control for the Bath input. Dual required to be set to Dual Input...
  • Page 58 4.3.3.2 OUTLET TEMPERATUR INPUT Options / Configuration Name Default Description Range Notes Temperature sensing element type. Can be Type Type K Thermocouple (grounded or ungrounded) or PT100 RTD At least one of Bath Disabled Mode for the temperature input, used by the Mode, Outlet Mode, or Process Control system to determine how the input is to be...
  • Page 59 4.3.3.3 STACK TEMPERATURE INPUT Options / Configuration Name Default Description Range Notes Temperature sensing element type. Can be Type Type K Thermocouple (grounded or ungrounded) or PT100 RTD Mode for the temperature input, used by the Disabled system to determine how the input is to be Mode Disabled High Temp ESD...
  • Page 60 4.3.3.4 AUX TEMPERATURE INPUT Options / Configuration Name Default Description Range Notes At least one of Bath Disabled Mode for the temperature input, used by Mode, Outlet Mode, or Process Control the system to determine how the input is to Mode Disabled Aux Temp Mode must...
  • Page 61 4.3.3.5 PROOF of CLOSURE INPUT Name Default Options Description Disabled Controls whether the Proof of Closure input is enabled or disabled. Proof of Closure Enabled Enabled See Proof of Closure (PoC) Input section for more details. 4.3.3.6 REMOTE START INPUT Name Default Options...
  • Page 62 4.3.3.8 PRESSURE (LOW SWITCH / 4-20) INPUT Name Default Options / Range Description Configuration Notes Disabled Pressure sensor type. Can be configured as a Type Digital Digital switch (digital), transmitter (4-20), or 4-20 disabled. Span Min must be less 4-20 Span 0 kPa 0 kPa - 100000 kPa Pressure value corresponding to 4mA output...
  • Page 63 4.3.3.11 AUX IN 1 & AUX IN 2 INPUTS Name Default Options / Range Description Configuration Notes Disabled Input sensor type. Can be Type Digital Digital configured as a switch (digital), 4-20 transmitter (4-20), or disabled. High/Low Trip Various modes for the Aux input Appliance Firing Rate High/Low when configured as a 4-20 type.
  • Page 64 4.3.3.12 STATUS OUTPUT Name Default Options / Range Description Configuration Notes Run Status Defines the behaviour of the Status Contact Heating Status Run Status Status Contact. See Status Relay Mode Low Temp Warning Output section for more details. Level/Flow Control 4.3.3.13 AUX OUT 1 &...
  • Page 65 4.3.3.15 TCV OUTPUT Name Default Options / Range Description Minimum position for the TCV output. See Temperature Min Position 40 % 0 % - 70 % Control Valve (TCV) output section. Position for the TCV output during the Purge state. See Purge Position 0 % - 100 % Temperature Control Valve (TCV) output section.
  • Page 66 4.3.3.18 IGNITION Name Default Range Description Determines the number of relight attempts the system will use Relight Attempts 0 - 3 attempts when establishing flame. Controls the Coil output behaviour when in the ignition state: • Coil: Pulsed output mode, typically connected to a rated Coil Ignition Mode Coil...
  • Page 67 4.3.3.20 COMMISSIONING Name Default Range Description Sets the voltage mode of the system. Setting this mode affects the Voltage Setting thresholds for the low and high voltage alarms / warnings. Enabling this mode allows the system to restart from a low voltage Disabled Voltage Restart Disabled...
  • Page 68 4.3.3.22 MODBUS Name Default Range Description Slave Address 1 - 247 Modbus slave address of the PF2200. 9600 Baud rate for the RS-485 link. Baud Rate 9600 19200 Number of stop bits. Used for configuring the RS-485 protocol. Stop Bits None Parity bit support.

  • Page 69: System Screen

    4.3.4 SYSTEM SCREEN The PF2200 Systems screen holds the more global settings and information on the PF2200. Here you will find troubleshooting information such as Diagnostics, Logging, Reset, Backup, Restore, as well as Status Priority, and Firmware tools. 4.3.4.1 TEMPERATURES The Temperatures diagnostics screen delivers a real-time temperature status of all the commissioned elements the system controls.
  • Page 70 4.3.4.3 OUTPUTS The Outputs diagnostics gives real-time conditions of the configured system Outputs. 4.3.4.4 FLAME DIAGNOSTICS The Flame Diagnostics screen shows a real- time evaluation of the Pilot status, including flame strength, DC High voltage as well as AC voltage in millivolts. Along with the real-time flame status, this screen also provides Flame Fails and Relights.
  • Page 71 4.3.4.5 POWER The Power Diagnostics displays the Voltage, Current, System Power, as well as the Hourly Energy Consumption of the system in real-time. 4.3.4.6 RUN TIMES Run Time diagnostics gives a summation of the run times of the System, Pilot Solenoid, SSV, and Fan. 4.3.4.7 MODBUS The Modbus diagnostics allows for diagnosing the health of the Modbus connection to the BMS.
  • Page 72 4.3.4.8 KEYPAD The Keypad diagnostics is a tool to test the functionality of the keypad. Upon opening the Keypad diagnostics screen, the Keypad test starts by instructing the user to press the Start Button then leading the user through a test of each key on the keypad.
  • Page 73 4.3.4.10 DATA LOGGING The Data Logging tool monitors various inputs and outputs data and automatically logs this data to the USB storage device. Navigate to the Systems screen and highlight the Data Log menu item. Press the OK key to display the Dato Log Configuration screen.
  • Page 74 4.3.4.12 INFORMATION The Information screen shows all the information about the Hardware and Software for the PF2200. This includes, but not limited to such information like Hardware Model, Serial Number, Manufacturing Date, Testing Date, Firmware Version, as well as information on the User Interface software. 4.3.4.13 RESET SETTINGS Reset Settings allows the user to reset all the Burner Management Systems settings back to the factory defaults.
  • Page 75 4.3.4.14 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 used to configure other units to the same settings. Settings can only be restored to another single burner BMS unit, settings are not compatible between Profire product lineups.

  • Page 76: Troubleshooting

    TROUBLESHOOTING Problem Diagnosis 1. Ensure pilot assembly, flame rod, and the gap between are fully engulfed in flame. If not, adjust rod position System has visible flame 2. Ensure flame detection wiring does not exceed the recommended maximum but cannot detect 3.
  • Page 77 If there is not adequate wetting current, the digital input either has • too high of an impedance or the wiring has been compromised DOC-001043 / v5.2...

  • Page 78: Maintenance

    MAINTENANCE During maintenance, with respect to software and setup, 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 •...

  • Page 79: Repair And Replacement

    PF2200 annunciates the appropriate alarm. 6.1 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.
  • Page 80 UNITED STATES CANADA 1.801.796.5127 1.780.960.5278 321 South, 1250 West Suite 1 9671 – 283 Street Lindon, UT 84042, USA Acheson, Alberta T7X 6J5, Canada support@profireenergy.com support@profireenergy.com DOC-001043 / v5.2...

  • Page 81: Document Revision History

    Initial Release AUG-12-2019 Modified Flame Presence/Absence threshold in section 2.3.1 to - • 2.54V Added a sentence in section 7.3 specifying the PF2200-SB is a • Type B product Revamped alarm descriptions in Appendix A for Alarm Codes • NOV-05-2019 Modified SIL-related information in section 7.1 of Appendix B...
  • Page 82 DOC-001043 / v5.2...

  • Page 83: Appendix A: Alarm Codes & Response Times

    APPENDIX A: ALARM CODES & RESPONSE TIMES The following is a complete list of all Alarms the PF2200-SB can generate. Note: the following list has been generated for the SB 1.3 bundle package. Description Alarm Condition Set Time Proof of Closure Contact Open...
  • Page 84 Description Alarm Condition Set Time Aux In 1 Input In 4-20 mode: Input is less than Aux In 1 Low Trip setting • Aux In 1 Low Trip Aux In 1 Input In Digital mode: This alarm cannot be set •...
  • Page 85 Description Alarm Condition Set Time Bath Temperature Input settings are configured incorrectly with respect to one another, mainly: Pilot Off setpoint less than Main Off Or Process setpoints • Bath Temp Configuration High Temp setpoint less than Main Off OR Pilot Off OR Process setpoints •...
  • Page 86 Description Alarm Condition Set Time Stack Temperature Input in RTD Mode: Input is measuring a short circuit • Stack Sensor Short Stack Temperature Input in Thermocouple Mode: This alarm cannot be set • Stack Temperature Input in RTD Mode: Input is measuring outside of the valid range for RTD •...
  • Page 87 Description Alarm Condition Set Time NOT USED Settings have been corrupted and cannot be verified. Settings CRC Failed Note: a settings reset is usually required. The primary and secondary processors of the BMS card disagree on the process control State Mismatch 0.8s state.
  • Page 88 Description Alarm Condition Set Time Brownout Reset Voltage BMS card has been programmed with the incorrect brownout reset voltage. Incorrect Flame 1 DC Input Open BMS card internal circuit fault associated with Pilot 1 flame input. Flame 2 DC Input Open BMS card internal circuit fault associated with Pilot 2 flame input.

  • Page 89: Appendix B: Functional Safety Design Pf2200-Sb

    Start / Stop Switch • Final Elements Safety Shut-off Valves for Fuel Flow Control • Ignition Coil for sparking • The following diagram is an example of the PF2200-SB safety system integrated with sensors / final elements: DOC-001043 / v5.2...
  • Page 90 Pilot 1 Switch To Pilot Nozzle 1 Pilot 2 To Pilot Dual Nozzle 2 Temp Bath Sensor To Main Nozzle Switch To Igniter Coil 1 / PLC Start Output External To Igniter Ignition Switch Start / Stop Coil 2 Switch Switch To Flame PF2200 Single...

  • Page 91: Safety Vs Non-Safety I/O

    9.1 SAFETY vs NON-SAFETY I/O The PF2200 supports the following interfaces for safety-related functionality o Pilot and Main Valve Outputs (Pilot 1&2, SSV) o Ignition Outputs (Coil 1&2) o Flame Detection Inputs (Ion) o External Start/Stop Switch o ESD Input o Pressure Input o Level Input o Dual-Element Bath Temperature Input...

  • Page 92: Safety Functions

    9.2 SAFETY FUNCTIONS The PF2200 Single Burner BMS monitors and controls a burner using a pre-defined operating sequence. This operating sequence includes controlling gas valves and ignition coils while continually monitoring flame presence and interlock inputs. In the event of a loss of flame, the system will proceed to de-energize the gas flow means with the user-configurable option of re-lighting.

  • Page 93: Safety Integrity

    The above alarm response times are the maximum response times of the PF2200-SB as a logic solver only. To understand the impact of these response times on the SIF Process Safety Time, the full safety function must be analyzed. For example, a simple safety function consists of an ESD switch connected to the ESD input and solenoid(s) connected to the Pilot &...

  • Page 94: Hardware Versions

    PF2200 User Interface v3.2 9.3.5 SOFTWARE VERSIONS The latest version of software for the PF2200 Single Burner BMS is SB 1.3.1. See the PF2200-SB Software Release notes for detailed changes associated with this and previous versions of software. 9.3.6 SAFETY PARAMETERS The following failure rates of the PF2200 safety function(s) are derived using a Site Safety Index of 2 (SSI=2).
  • Page 95 9.3.6.1 EVALUATING a SAFETY FUNCTION The Safety Parameters in the above table provide a synopsis of the failure rates in the PF2200 Single Burner BMS from a component perspective. In order to utilize the parameters in a safety function, the safety function must first be identified and the associated failure rates must be formulated together.
  • Page 96 Example 2) A Safety Function must exist which turns off Pilot 1, SSV and Coil 1 outputs if the ESD input is de- energized OR if the Temperature Input (RTD) reports a high temperature OR if the Pressure Input reports a high pressure.

  • Page 97: Suggested Proof Test

    3. Get the system into a fired state (e.g. with flame present and being monitored by the PF2200) 4. Remove the flame and confirm all PF2200-SB safety critical outputs (main valve, pilot valve, and coil outputs) have become de-energized and a manual reset is required to return to normal operation.

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