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ProFire PF3100 FARC User Manual

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PROFIRENERGY.COM | 1.855.PRO.FIRE
November 26, 2020
PF3100 FARC USER GUIDE v5.0
This user guide contains a general overview of the PF3100 FARC system features and operation. For more specific BMS related
operation please review the PF3100 BMS operating manual. This guide is applicable to the NA-41.1 firmware release only.
1
SOLUTIONS@PROFIREENERGY.COM

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Summary of Contents for ProFire PF3100 FARC

  • Page 1 PF3100 FARC USER GUIDE v5.0 This user guide contains a general overview of the PF3100 FARC system features and operation. For more specific BMS related operation please review the PF3100 BMS operating manual. This guide is applicable to the NA-41.1 firmware release only.

  • Page 2: Table Of Contents

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 Contents Feature Overview ....................................3 Peripherals ....................................... 3 Status Screen....................................3 Alerts ......................................... 4 Fuel Air Ratio Table ..................................5 Installation Guide ....................................6 FARC Commissioning ..................................7 Configuring the IO Expansion Module ............................7 Configuring BMS Settings ................................

  • Page 3: Feature Overview

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 FEATURE OVERVIEW PERIPHERALS The PF3100 system can be configured to operate as a parallel positioning fuel/air ratio control system for forced draft applications. In addition to the standard fuel train, the following peripherals are required: A fuel gas control valve (TCV) where valve position is controlled by a 4-20 input signal.

  • Page 4: Alerts

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 FARC Valve – This shows the BMS’s currently FARC Damper – This shows the BMS’s currently ▪ ▪ requested valve output. requested damper/fan output. ALERTS All system alarms including any FARC related alarms are annunciated on the alerts screen. These include any configuration or input faults related to the FARC settings or physical I/O.

  • Page 5: Fuel Air Ratio Table

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 FUEL AIR RATIO TABLE The fuel air ratio table has a total of 21 points of adjustment for each fuel and air curve. The adjustment points are located at 5% increments across the firing rate 0 to 100% range. The table may be adjusted in 1% increments. Points may be added at any 5% interval by ▪...

  • Page 6: Installation Guide

    IO operation. Connect the BMS IO to the corresponding peripheral. Wiring diagrams for common installations are available from Profire. In addition to this table any IO expansion card inputs may be configured to be used as fault alarms for peripheral equipment. Commonly these will be configured as an additional fault feedback from a motor driver.

  • Page 7: Farc Commissioning

    Prior to configuring FARC, make sure the BMS system has been configured per the installation. This may include configuring temperatures, ignition modules, fuel gas pressure transmitters, level transmitters, etc. FARC specific settings have a level 3 authentication. Please contact Profire for the password to modify these settings. CONFIGURING THE IO EXPANSION MODULE The following instructions provide an overview of how to configure the IO expansion module required for FARC control.

  • Page 8: Configuring Bms Settings

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 CONFIGURING BMS SETTINGS The following settings must be configured on the BMS for the system to currently work In the FARC Mode. If any of the settings are not set a FARC configuration alarm will be set. The settings may be configured in the BMS settings tab. Enable low fire mode Process control >...

  • Page 9: Farc Configuration Dialog Settings

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 FARC CONFIGURATION DIALOG SETTINGS The following settings are available for adjustment in the settings dialog. This is accessible from the appliance status screen by selecting and pressing the OK button on any of the FARC labeled IO. All FARC related settings are level 3 password protected unless otherwise noted.
  • Page 10 PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 Valve Purge 0% to When in the purge state the valve will be at this 100% position. Position (%) Valve Pilot 0% to When in the pilot state the valve will be at this 100% position.

  • Page 11: Alarms

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 ALARMS The following alarms are a subset of the burner managements systems alarms that are related to the FARC control system. A general description is offered here. For specific alarm details refer to the PF3100 alarm and shutdown code document. IO EXPANSION INPUT INVALID This alarm will appear if an IO expansion input is out of range.

  • Page 12: Cross Limit Error

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 The output signal from the BMS controller is open or shorted. Meaning that the valve or damper is not ▪ receiving the signal. CROSS LIMIT ERROR The cross-limit error alarm will occur if fuel position exceeds the desired fuel position requested by the current air position by more than the cross-limit error % setting for a period of 2 seconds or more.

  • Page 13: Operating Overview

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 The proof of airflow setpoint setting may not be configured correctly. ▪ OPERATING OVERVIEW The PF3100 system can be configured as a FARC system to regulate the ratio of fuel to air. The FARC control system requests the valve and damper positions and compares them to the feedback positions.
  • Page 14 PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 SOLUTIONS@PROFIREENERGY.COM...

  • Page 15: Cross Limiting And Position Error

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 CROSS LIMITING AND POSITION ERROR FARC systems often have a position error that is used to define the allowable operating limits of the system. The PF3100 system uses a position error (the allowable difference between requested and feedback position) to define the limit of tolerance in each individual peripheral device.
  • Page 16 PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 SOLUTIONS@PROFIREENERGY.COM...

  • Page 17: Firing Rate Transitions

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 FIRING RATE TRANSITIONS As the firing rate changes, the internal FARC control system will step the fuel/air outputs in 0.5% increments up to the maximum excess air limit. In some systems positioning to the maximum excess air may not be enough of a change to affect a movement of the actuator/fan, etc., possibly due to a deadband.

  • Page 18: Start Sequence

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 START SEQUENCE The following is a summarized overview of the startup sequence of the PF3100 system when in FARC mode. All timeouts listed below will exit immediately if the condition that is being checked is satisfied. This is to speed up the startup process and minimize down time between any shutdown cycles.
  • Page 19 PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 PILOT IGNITION After the purging sequence has been completed and the air damper is at the pilot light off position, the pilot trial for ignition will begin. The pilot position must be maintained during this state or the system will shut down on a position failure alarm.

  • Page 20: Stop Sequence

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 STOP SEQUENCE The system may shutdown via an alarm or user stop. When this occurs the stop sequence will begin. The stop sequence may occur from any running state. POST PURGE POSITION Once initiated, the fan output is turned ON if not already, and the purge position is requested. In this case the proving of the position is not required (the system does not care if it achieved the purge position or not as it is already moving towards a shutdown and needs to purge regardless).

  • Page 21: Wait Transition

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 WAIT TRANSITION The system may enter a waiting state while running. This can be from several wait events including low fuel pressure, or a low voltage restart or others. When entering wait from a flame state the system will perform a post purge sequence. Proof of purge position and proof of airflow are not required as the system must do this during the startup sequence before any valves are opened.

  • Page 22: Canadian Field Approval Requirements

    BMS Controller card runs the FARC control algorithm and may be configured to use IO on additional PF3100 family cards. Option to use a non- The PF3100 FARC feature set is not certified (as per ISO PF3100 certified system compliant 23552-1) and does comply with the following with the following requirements.
  • Page 23 PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 D.2.b.ii The inability of any The requested position is compared to the feedback PF3100, actuator/fan to achieve position. If this difference is larger than the position error System Design the requested position setting for a duration greater than the Position Error shall be detected and the Timeout setting the system will alarm.
  • Page 24 PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 accurately measured. This may be done by using a shaft position sensor. Any linkages between the position sensor and the actual damper must be fully secured. D.2.b.vii The actuator assembly This requirement must be met via the equipment used. System Design must have indication of position.
  • Page 25 PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 proper operation. The verified, if they are lost then the system will alarm and shut following must be proven down. before starting the Purge position is verified before beginning the purge state. system: All If an airflow transmitter is used, it is verified to indicate no communication links, airflow before starting the fan.
  • Page 26 PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 SOLUTIONS@PROFIREENERGY.COM...

  • Page 27: Version History

    PROFIRENERGY.COM | 1.855.PRO.FIRE November 26, 2020 VERSION HISTORY Document Version Release date Contributor Changes V1.0 April 2, 2020 Ryan Baron Initial release V2.0 April 4, 2020 Ryan Baron Version number update. V3.0 April 17, 2020 Ryan Baron Changed references to fuel flow and air flow to fuel position and air position where related to the positioning of the actuators.

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