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)

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

GROUND

COIL +

ION +

ION -

COIL -

ABCD

B C

1.3.1 External Coil

1Installation

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.

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...

1Installation

CONNECTION DESCRIPTION EXPECTED CONNECTIONS RATINGS

High

Pressure -

Ground Ground return for switch. All switches can use a single common

ground return.

Low

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.

Low Pressure - Ground Ground return for switch. All switches can use a single common

ground return.

Level + Input from a oat-switch

mounted in the bath.

Dry contact switch is expected. The input is internally pulled up to

9VDC via a 3.75kΩ resistance. Jumper “+” and “-” if not used.

Level - Ground Ground return for switch. All switches can use a single common

ground return.

1.4 Terminal Description Continued...

81Installation

Provides high-temp shutdown. 20 AWG or larger “TYPE K”

extension wire must be used. System will shutdown if an

open circuit, short-circuit or short-to-ground is detected.

Should be placed in the same thermowell as PROCESS

THERMOCOUPLE.

Provides a ame detection indication based on the temperature of

the pilot. The system will shutdown if an open circuit is detected.

Primary temperature control device provides high-temp shut-

down. 20 AWG or larger “TYPE K” extension wire must be

used. System will shutdown if an open circuit or short circuit

is detected. Should be placed in the same thermowell as

HIGH TEMPERATURE THERMOCOUPLE.

“TYPE K”

ALL THERMOCOUPLES MUST BE ISOLATED FROM THE GROUND

1.5 Thermocouples

PROCESS THERMOCOUPLE

HIGH TEMPERATURE THERMOCOUPLE

PILOT THERMOCOUPLE (AUX)

* TE101 and TE102 may be different elements in the same

head of a “TYPE K” thermocouple

* For all thermocouples, avoid locating extension wire near

high-voltage lines. Shield if necessary.

2Control & Programming

2.1 Keypad Layout

RUN LIGHT

MENU NAVIGATION

STOP BUTTON

DISPLAY WINDOW

MODE BUTTON

PILOT BUTTON

IGNITE BUTTON

MAIN BUTTON

The system must be in manual mode in order to access the menus.

Press the “MENU” button to step through the menus. When the desired

menu is displayed, press the “OK” button to enter that menu. Once in the

menu, the “MENU” button will step through the parameters.

While viewing the desired parameter use the and buttons to adjust

the setting and “OK” to accept the change. To exit back to the “Ready”

screen, press the “OK” button without making any changes. From the

“Ready” screen, the and buttons will scroll through the current

system status.

2.2 Menu Operation

10 2Control & Programming

System History

Logging

READY

2 - HISTORY

Modbus Enable/Address

6-EXPANSION MODULES

MENU OK

MENU MENU MENU

CYCLE THROUGH WITH MENU BUTTON, CONFIRMING WITH OK BUTTON

1 - SETPOINTS

NAVIGATION

WILL CYCLE

NAVIGATION

WILL CYCLE

OPERATE USING

SELECTED BUTTONS

READ ONLYREAD ONLY

Pilot Low Setpoint

Pilot High Setpoint

Pilot Low Setpoint

Pilot High Setpoint

OK MENU

3 - SYSTEM INFO

4-20mA Output Status

Ambient Temp

Input Voltage

Commission Date

Location

STATUS

HOLD FOR 3

SECONDS TO CLEAR

Control State

Auto Mode

4 - SYSTEM SETUP

Level Event Restart

Pilot Timeout

High Temp ESD Setpoint

5 - CONTROL SETUP

MENU OK

MENU MENU

OK MENU

Password Enable (menus 1-3)

Spark Mode

High Temp Setpoint

High Temp TC Reading

Flame Fails

ReLights

Display Sleep

Pilot Power Setting

Commission Date Entry

Reset to Factory Defaults

Commission Location Entry

Main Power Setting

System Voltage

Temperature Display Units

2.3 Menu Map

2Control & Programming

System History

Logging

READY

2 - HISTORY

Modbus Enable/Address

6-EXPANSION MODULES

MENU OK

MENU MENU MENU

CYCLE THROUGH WITH MENU BUTTON, CONFIRMING WITH OK BUTTON

1 - SETPOINTS

NAVIGATION

WILL CYCLE

NAVIGATION

WILL CYCLE

OPERATE USING

SELECTED BUTTONS

READ ONLYREAD ONLY

Pilot Low Setpoint

Pilot High Setpoint

Pilot Low Setpoint

Pilot High Setpoint

OK MENU

3 - SYSTEM INFO

4-20mA Output Status

Ambient Temp

Input Voltage

Commission Date

Location

STATUS

HOLD FOR 3

SECONDS TO CLEAR

Control State

Auto Mode

4 - SYSTEM SETUP

Level Event Restart

Pilot Timeout

High Temp ESD Setpoint

5 - CONTROL SETUP

MENU OK

MENU MENU

OK MENU

Password Enable (menus 1-3)

Spark Mode

High Temp Setpoint

High Temp TC Reading

Flame Fails

ReLights

Display Sleep

Pilot Power Setting

Commission Date Entry

Reset to Factory Defaults

Commission Location Entry

Main Power Setting

System Voltage

Temperature Display Units

12 2Control & Programming

2.4.2 (MENU 2) History

No adjustments are available in the History menu; the items are display only.

ON SCREEN DESCRIPTION FUNCTION RANGE DEFAULT SETTING USER SETTING

ReLight = x Displays the number of relights Incremented when an automatic

ignition attempt is made.

0 to 1000 0

FlmFails = x Displays the number of ame

fails

When all retries attempts have failed,

the unit shuts down and increments

the Flame Fail counter

0 to 1000 0

Resets = x Displays the number of resets. This number will increment every time

the board is reset by a power loss or by

pressing the reset button

0 to 1000 0

2.4.1 (MENU 1) Setpoints

Can only be accessed in manual mode. High Temp Setpoint is adjusted in MENU 5 - Control Setup (level 2 password)

ON SCREEN DESCRIPTION FUNCTION RANGE DEFAULT SETTING USER SETTING

Pilot Low

Setpoint 200˚C

Low setpoint for pilot

thermocouple.

When the Pilot temperature rises above

this setpoint, the status contacts will

close and the ame light will come on.

0 to 1350˚C

(32 to 2462˚F)

200˚C

(392˚F)

Pilot High

Setpoint 600˚C

High setpoint for pilot

thermocouple.

When the pilot temperature is above

this setpoint and the Spark Mode is

set to “Spark Only <PHI” the system

will stop sparking. The “Pilot Timeout”

timer will start counting down when

the pilot temperature drops below this

setpoint.

0 to 1350˚C

(32 to 2462˚F)

600˚C

(1,112˚F)

Hold to reset history.

2Control & Programming

2.4.2 (MENU 2) History Continued...

ON SCREEN DESCRIPTION FUNCTION RANGE DEFAULT SETTING USER SETTING

ESDs = x Displays the total number of

ESDs

This number will increment any time a

fault causes the system to shutdown.

0 to 1000 0

HPR ESDs = x Displays the total number of

High Pressure ESDs