ProFire PF2100F User manual

PF2100F MANUAL REV 1.0

DO NOT SERVICE UNLESS AREA IS KNOWN TO BE NON-HAZARDOUS
DO NOT OPEN WHEN ENERGIZED
SUBSTITUTION OF COMPONENTS MAY IMPAIR THE SUITABILITY FOR
USE IN CLASS 1, DIVISION 2
REPLACEMENT FUSES MUST BE CERAMIC
THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS 1, DIVISION 2,
GROUPS ABCD OR NON-HAZARDOUS LOCATIONS ONLY.
WARNING: EXPLOSION HAZARD
DO NOT DISCONNECT WHILE CIRCUIT IS LIVE UNLESS AREA IS KNOWN
TO BE NON-HAZARDOUS OR EQUIVALENT
WARNING: EXPLOSION HAZARD
SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR
CLASS 1, DIVISION 2.
MUST CONFORM TO THE DIRECTIONS IN THIS MANUAL
THE UNIT MUST BE PROPERLY CONNECTED TO EARTH-GROUND FOR
EFFECTIVE IONIZATION OPERATION
ELECTRICAL DEVICES CONNECTED TO THE CONTROLLER MUST MEET
ELECTRICAL STANDARDS AND BE WITHIN VOLTAGE LIMITS
FOR ANY QUESTIONS PLEASE CALL 1 855 PRO FIRE
WARNING
Class 1, Division 2, Grp
ABCD
IEC Ex nA IIC
IP54
NEMA Type 4x
CSA C22.2 No. 0-M91
CSA C22.2 No. 0.4-04
CSA C22.2 No. 94-91
CSA C22.2 No. 142-M1987
CSA C22.2 No. 213-M1987
CSA E60079-0:2007
CSA E60079-15:2005
UL 508, 17th Edition
ANSI-ISA-12.12.01-2007
UL 60079-0:2005
UL 60079-15:2002
APPROVALS
MC#248705
( 776-3473 )

•Designed for the natural draft-re, tube heater industry
•Meets or exceeds all relevant codes and standards
•Easy installation with clearly marked component I/O
•Easily accessible removable terminal connections
•Rapid 3 second shut-down on ame-out
•DC voltage spark ignition
•Low-power design to accommodate solar panel
or TEG applications
•Auto-relight or manual operation
•Transient protected and fail-safe circuits
GENERAL FEATURES
ENCLOSURE
CIRCUT BOARDS
Polyester
309 x 234 x 134 mm (12.15” x 9.23” x 5.28”)
overall dimensions 2.3 kg (5 lb)
CSA and UL compliant for Class 1, Division 2 locations
Enclosure type 4, 4X, 12, 13
All solid state
CSA compliant for Class 1, Division 2 locations
Certied for use on B.149 compliant valve trains
IGNITION BASE AND COIL
For non-hazardous mounting area only
Ignition coil mounted in the 2100 is optionally available.
POWER REQUIREMENTS
10VDC to 28VDC (voltage must match solenoid rating) 5A MAX
POWER COMSUMPTION 12V 24V
Controller only, display ON 2.6 W 2.8 W
Controller only, display OFF 1.1 W 1.4 W
TEMPERATURE RATING
(6) Digital inputs for safety interlock device connections
(5) Digital outputs
(1) 4-20mA output
(1) Flame-rod input
(3) Thermocouple inputs
See Section 1.3 for thermocouple inputs
Only equivalent fuse should be used to replace a blown fuse.
Factory fuse: LittleFuse 0314005.HXP
(5A, 250V Ceramic, Fast Blow)
FUSE
INPUTS & OUTPUTS
-40°C to +55°C (Tested to -60°C)
-40˚F to +130°F (Tested to -76°F)

1
1Installation
•The control panel can be mounted on the unit skid or on a
building wall providing it does not infringe on a Class 1,
Division 1 area.
•Use control panel mounting tabs to mount in a location that
faces away from the burner housing so the operator is facing
both the enclosure and the burner housing while operating.
Other considerations may include panel access, trafc,
wire-runs and visibility.
•The control panel should be mounted about 1.5m (5’) above
ground level.
•If an external ignition coil is used, it must be mounted in a
Class 1, Division 2 enclosure or a non-hazardous location,
ideally inside the burner housing.
1.1 Mounting Locations
Any design used, should be approved by a qualied inspector
and approved by the gas authority having jurisdiction at the site
where the system is to be installed.
Additional P&ID and wiring diagrams are provided in a separate
application note.
1.2 P&ID and Wiring Diagram

21Installation
E
E
A
GROUND
COIL +
ION +
ION -
COIL -
+
-
-
+
ABCD
D
B C
A
1.3.1 External Coil

3
1Installation
A
A
B
COIL +
ION +
ION -
COIL -
+
-
-
+
ABCD
GROUND
1.3.2 Internal Coil

41Installation
1.4 Terminal Description
CONNECTION DESCRIPTION EXPECTED CONNECTIONS RATINGS
12/24VDC Input power 10VDC - 28VDC, 5A MAX Input power from a DC source 10VDC - 28VDC
Internally fused at 5A
Common Common Ground from DC source Internally connected
to EGND
EGND Earth Ground Earth or Chassis ground Internally connected
to Common
4-20mA Out + 4-20mA output intended to drive a
proportional control valve. This out-
put will be connected to a Current
to Pressure converter which will
drive a proportional control valve.
A software control loop is impli-
mented to tune the ame to match
the demand. Proportional control is
optional.
A resistance of 120Ω to 250Ω is expected.
4-20mA Out - Ground Ground return for the 4-20mA output
HighTemp_TC +
(YELLOW)
Thermocouple input. High Temp
shutdown thermocouple.
“TYPE K” thermocouple must be connected between
the “+” and “-” terminals and must not be electrically
connected to ground.
An uninterrupted connection using “TYPE K” thermocouple
wire is required for an accurate reading.
HighTemp_TC -
(RED)
Thermocouple Input. Negative
terminal of High Temp Shutdown
thermocouple.
Process_TC +
(YELLOW)
Thermocouple input.
Process thermocouple.
“TYPE K” thermocouple must be connected between
the “+” and “-” terminals and must not be electrically
connected to ground.
An uninterrupted connection using “TYPE K” thermocouple
wire is required for an accurate reading.
Process_TC -
(RED)
Thermocouple Input. Negative
terminal of Process thermocouple.

5
1Installation
CONNECTION DESCRIPTION EXPECTED CONNECTIONS RATINGS
AUX_TC +
(YELLOW)
Thermocouple Input Pilot
Thermocouple.
A “TYPE K” thermocouple must be connected between
the “+” and “-” terminals and must not be electrically
connected to ground.
An uninterrupted connection using “TYPE K” thermocouple
wire is required for an accurate reading.
AUX_TC -
(RED)
Thermocouple Input. Negative
terminal of Auxiliary thermocouple.
High Fire/Main + Positive terminal
of the High Fire / Main valve
Solenoid valves must be connected between the “+” and “-”
terminals. The negative terminal is not directly connected to ground
so a common return wire for the High Fire, Low Fire and Pilot
valves cannot be used.
Maximum continu-
ous current is 2A. If
“Low Power” mode is
enabled, a peak load of
4A is permitted.
High Fire/Main - Negative terminal
of the High Fire / Main valve
Low Fire + Positive terminal
of the Low Fire valve
Solenoid valves must be connected between the “+” and “-”
terminals. The negative terminal is not directly connected to ground
so a common return wire for the High Fire, Low Fire and Pilot
valves cannot be used.
Low Fire - Negative terminal
of the Low Fire valve
Pilot + Positive terminal
of the Pilot valve
Solenoid valves must be connected between the “+” and “-”
terminals. The negative terminal is not directly connected to ground
so a common return wire for the High Fire, Low Fire and Pilot
valves cannot be used.
Pilot - Negative terminal
of the Pilot valve
Ion + Flame Detection Input.
Connected to a Flame-rod.
A Kanthal rod should be placed directly in the pilot ame and
connected to this input. The pilot assembly must be grounded for
the ame detection to function properly. Input is protected from
high voltage and can be connected in series with the high voltage
terminals of an external ignition coil, allowing a single ame-rod to
be used for both ignition and ame detection.
A 65VAC signal is ap-
plied to the ame rod.
The source impedance
is very high so there is
no danger of sparking.
Ion - Ground Ground return for ame detection. Must be connected to the
burner housing.
1.4 Terminal Description Continued...

61Installation
CONNECTION DESCRIPTION EXPECTED CONNECTIONS RATINGS
Coil + Driver for the low voltage primary of
the ignition coil.
The primary of the ignition coil should be connected to this termi-
nal. The 12/24VDC input power will be applied for 1 ms and turned
off for 50 ms while sparking.
This output is pro-
tected by a 250mA
thermal fuse.
Coil - Ground Ground return for the ignition coil.
Status + The status “+” and “-” contacts will
be closed when the system is run-
ning and opened when the system
is shutdown.
Dry contact output to indicate system status to an external device.
ie. PLC.
250VAC/DC, 200mA,
15Ω
Status -
Start + Remote start input from an external
device. ie. PLC.
Dry contact switch is expected. The input is internally pulled up to
9VDC via a 3.75kΩ resistance. Jumper “+” and “-” if not used.
Start - Ground Ground return for switch. All switches can use a single
common ground return.
ESD + External Shutdown input. Dry contact switch is expected. The input is internally pulled up to
9VDC via a 3.75kΩ resistance. Jumper “+” and “-” if not used.
ESD - Ground Ground return for switch. All switches can use a single common
ground return.
Proof of
Closure +
Proof of Closure from main valve(s). Dry contact switch is expected. The input is internally pulled up to
9VDC via a 3.75kΩ resistance. Jumper “+” and “-” if not used.
Proof of
Closure -
Ground Ground return for switch. All switches can use a single common
ground return.
High
Pressure +
Input from a mechanical
pressure switch.
Dry contact switch is expected. The input is internally pulled up to
9VDC via a 3.75kΩ resistance. Jumper “+” and “-” if not used.
1.4 Terminal Description Continued...