ProFire PF2200-SB User manual

PF2200-SB INSTALLATION MANUAL
DOC-001041 ver 0.9

INTRODUCTION
This guide includes information on the installation of the PF2200 burner management system. PROFIRE recom-
mendations and requirements for installation.
This document covers:
lProduct Overview.
lSafety and Warnings.
lMounting Considerations.
lWiring Guidelines.
lPost Installation Checklist
lProfire Recommendation and Requirements.
To help guide you through the entire install process. The PF2200 comes in two optional enclosures, polyester,
and stainless steel. These distinctions are addressed where necessary in this installation guide. For configuring
the PF2200, please refer to PF2200 Manual.
CERTIFICATIONS
The PF2200-SB (Single Burner BMS) is certified to the following standards:
• IEC 61508, SIL II
• UL 60730-2-5/ANSI Z21.20-2014 & UL 121201
• CSA C22.2 No. 60730-2-5 & C22.2 No. 213
This appliance is a Class 1, Division 2, Group ABCD, T4 Type 4X, IP66.
SAFETY INFORMATION
Before installing the PF2200 system, please review the list of warnings below. Product use in a manner not spe-
cified by PROFIRE is not recommended. Failure to observe the following warnings may result in death, elec-
trocution, property damage, product damage, government fines, or malfunction of the product itself.

GENERAL WARNINGS
lInstallation and product use must conform to the directions in this manual.
lSolenoid powered outputs are rated to 5A max individually; however, the power input to the BMS card is
fused at 10A. Care must be taken not to exceed the 10A max input when installing with high-powered
solenoids.
lDo not jumper solenoid (-) terminals together under any circumstance; this compromises the safety-integ-
rity of the system.
lSafety Functions must be end-to-end proven during commissioning (e.g., when using a high-pressure
switch, ensure a high-pressure event triggers a lock-out).
INSTALLATION WARNINGS
lElectrical devices connected to the controller must meet local electrical codes, and be within voltage lim-
its specified in this manual.
lEnsure the enclosure is securely closed each time after opening. Improper closure may result in mois-
ture and or other environmental damage and may also compromise the integrity, and warranty of the
product.
lThe System must be connected appropriately to earth-ground to prevent electrocution.
lNo more than one conductor is to be used per contact point.
lProperly fuse field wiring to local codes.
lDo not disassemble or modify the cards in any way. The cards are not field repairable and must be sent
back to Profire for a replacement if damaged.
lCard 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.
lFailure to provide a low-impedance path from the burner assembly to the PF2200 may result in acci-
dental electric shock, product damage, failure to ignite the pilot or failure to detect a flame.
lDo not connect wires or handle the electronics when powered.
lDo not modify the product once installed.
lBypass of safety function(s) is required to update software.
EXPLOSION HAZARD WARNINGS
lDo not disconnect power, open the enclosure, or otherwise service this product unless the area is known
to be non-hazardous.
lSubstitutions of components may impair suitability for specified zones.
lReplacement fuses must be ceramic and of a correct rating.
lAvoid unauthorized replacement of the fuse.

INSTALLATION
Installers which integrate the PF2200 and commission the system must meet the following criteria:
lMust understand local codes and how they apply to the installation (for both electrical and mechanical
aspects of the installation).
lMust understand the electrical and mechanical limitations of the product and how that relates to the
installation.
lMust verify all required safety functions prior to completing the commissioning of the appliance.
lMust be fluent in the English language (the only language this product supports).
lMust be familiar with navigating the product menus and modifying settings.
lMust understand the effect modifying a setting has on the safety and operation of the appliance.
ENCLOSURE SPECIFICATIONS
There are two options for enclosure types for the PF2200-SB product:
lPF2200-SB-A: Stainless Steel Enclosure
lPF2200-SB-B: Polyester Enclosure
PF2200-SB-A Stainless Steel Enclosure

Item Description
Enclosure Construction 3/6" Stainless Steel
Ingress Protection IP66/NEMA 4
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

Item Description
Enclosure Construction Polyester
Ingress Protection / NEMA Type 4
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)
MOUNTING CONSIDERATIONS
The PF2200 has the approvals for installation in a Zone 2 or Class 1 Division 2 locations. The enclosure is typ-
ically mounted near the burner it is controlling or in another location that is both safe and easily accessible. The
recommended mounting height is 1.5m (5ft) above the ground or a platform for the comfort of the operators.
Ensure that the BMS is mounted in a safe area for operation. Look for tripping, high heat exposure, and other
potential hazards.
ACCESSIBILITY
PF2200 enclosures shall be mounted upright in such a way that the screen is clearly visible, and the keypad is
easy to access. Adequate space should be provided so that the enclosure door can fully open during main-
tenance and commissioning.
SECURITY
In some situations, it may be desirable to mount the system in a location not accessible to the general public to
prevent accidental or intentional tampering.

OPERATOR SAFETY
Avoid placing the system in locations that are dangerous to the operator. Examine the area surrounding the
potential installation site and look for such things as nearby open flames or close proximity to tanks that might
overflow, and other potentially harmful situations.
PERFORMANCE
Enclosures should be mounted to minimize the run-lengths to the burner assembly (ignition coil/rod and flame
detect rod), as well as the valve train (solenoids) and temperature inputs elements.
PRODUCT PROTECTION
To protect the system from being damaged, it should not be mounted:
1. Where chemicals may splatter or bubble over from a tank onto the system. Chemicals on the keypad may
interfere with an operator’s ability to control the product or view the display and LED indicators.
2. Directly to a heated tank where excessive heat may damage the product. Refer to the maximum oper-
ating temperature listed in this document.
3. Where anything may tip over due to wind or snow, some examples include poles that are not appro-
priately secured into the ground or tripods not secured with anchor bolts or guy wires.
4. In locations that have a tendency of flooding.
IMPORTANT NOTE: It is recommended to avoid drilling into the top of the enclosure. If possible, side access is
better.

CONDUIT/CABLE/ENVIRONMENTAL CONSIDERATIONS
It is essential to ensure the cable and conduits to meet local code requirements to ensure the best compliance,
performance as well as a safe environment.
The PF2200 Single Burner BMS is designed, validated and verified under the following environmental conditions
lSystem Voltage Range:
l12V mode: 10.2 – 16.2 V
l24V mode: 20.4 – 32.4 V
lAmbient Temperature Range
lOperating: -40 to 55°C / -40°F to 131°F
lStorage: -40 to 55°C / -40°F to 131°F
USER INTERFACE CARD ELECTRICAL RATINGS
The User Interface card is mounted on the back of the door panel of the enclosure.
Terminals Electrical Rating Wire Gauge / Torque
4 & 7 (Power Input +/-) 7 – 35 VDC
500 mA Max
14-30 AWG
0.22-0.25 Nm
1-3
(Modbus A/B/-)
-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 5VDC
200 mA Max N/A
Keypad 3VDC
4.75k Source Impedance N/A

BMS CARD
BMS Card Specifications
The ambient temperature rating for the BMS Card is -40°C (-40°F) to +60°C (+140°F).
BMS Card Diagram

BMS CARD ELECTRICAL RATINGS
I/O Type Terminals Electrical Rating Wire Gauge
/ Torque
Powered Output 15-16 (Pilot 1) 19-20 (SSV)
17-18 (Pilot 2) 21-22 (SSV)
12 / 24VDC, 5A Max
Expected Load: Inductive / Res-
istive
12-30 AWG
0.5-0.6 Nm
Powered Output 55-56 (Coil Pilot 1)
59-60 (Coil Pilot 2)
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)
Intermittent 80-130 VRMS Output
@ 5kHz (with 20kΩ source res-
istance)
12-30 AWG
0.5-0.6 Nm
Start/Stop
Switch
Switch Internal (IGN, RUN,
PWR)
Power: 3.3V (1kΩ source res-
istance)
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)
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)
Power Out:
l12V Mode = 12VDC, 24V
Mode = 13.5 VDC
l30mA Max
Digital Input (if applicable):
lEnergized State: 10VDC,
1.25mA Min
lDe-energized State: 3VDC,
500uA Max
l30 VDC Max
4-20mA Input:
l+/- 0.1 mA accuracy
l50mA current limit
l30 VDC Max
12-30 AWG
0.5-0.6 Nm
Temperature
Input
61-66 (Bath)
67-69 (Outlet)
70-72 (Stack)
RTD (PT-100):
l-100 to 850C [60.25Ω to
390.5Ω]
l+/- 0.5°C accuracy
14-30 AWG
0.22-0.25 Nm

I/O Type Terminals Electrical Rating Wire Gauge
/ Torque
Temperature inputs (Type-K):
l-100 to 1350°C [-3.554mV
to 54.1mV]
l+/- 2°C accuracy
lGround-biased
4-20mA Output
13-14 (TCV)
37-38 (Aux. Out 1)
39-40 (Aux. Out 2)
20 mA Max
Expected Load: Resistive (< 350Ω)
+/- 0.1mA accuracy
12-30 AWG
0.5-0.6 Nm
Relay Output 25-27 (Status) 120 VAC, 170V Peak Max
1ARMS 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. If configured as a Single
element, the Bath temperature input is NOT safety rated.

WIRING
The wiring in this section is required for all PF2200 installations. Skipping or performing any steps in this section
incorrectly will result in the PF2200 functioning improperly. Conduct pull tests on terminating wires in the BMS to
ensure proper installation. Install tags identifying that electrical seals have not been poured on electrical con-
nectors entering the PROFIRE BMS.
POWER
The PF2200 can be powered from 12V or 24V. The maximum current that the PF2200 can safely handle without
blowing the main fuse is 10A. The system on its own draws about 100mA. The rest of the current is used by addi-
tional hardware such as valves. Make sure that you select a power supply that is rated appropriately for the total
amount of current that is consumed by the system, and all devices attached to it.
For more information on the wiring guidelines see WIRING in the Product Manual.
VALVES
PILOT VALVE OUTPUTS (Pilot 1 & 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 pilots. When Pilot 2 is enabled, both outputs work in conjunction with one another. Meaning
that they open and close in unison. If Pilot 2 is disabled, the Pilot 2 output stays de-energized. The Pilot Outputs
are capable of peak and hold 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. Depending on the selected input type, the Pilot
valve has a maximum of 5 amps and 12 / 24 volts.

MAIN VALVE OUTPUTS (SSV)
Two powered outputs (terminals 19 and 20) are intended to be connected to solenoid valves which control the
fuel line for the main burner. Both outputs work in conjunction with one another. Meaning that they open and
close in unison. The Main Valve Outputs are capable of peak and hold PWM output mode at a fixed 3 kHz fre-
quency. Supported duty cycles for PWM mode are 10-100% and are configurable via the user interface.
TEMPERATURE INPUTS (Thermocouples)
The Bath input is mandatory and must be connected to a Dual Element temperature inputs. The Outlet Stack and
Auxiliary temperature inputs are only needed when a second process temperature (such as the outlet tem-
perature on a line heater) must be monitored. Otherwise, the Auxiliary temperature inputs terminals can be left
unconnected. Please note that Type-K temperature inputs wire and connectors should be used exclusively.
Ensure the Type K temperature input wire is used. (Yellow = positive and red = negative). Point to point wiring is
a must with temperature inputs wires (no cold junctions). A cold junction can cause inaccurate temperature read-
ings and therefore, poor temperature performance. Do not hook up shield wires; this should be done in the field
if necessary. It is common to terminate the shield wires to earth ground or ground grid of each vessel skid; how-
ever, this can only be done upon field installation. The temperature inputs are shipped loose and installed in the
vessel on location. This is when the wiring is installed as well.

COIL
The PF2200 system must be connected to a PROFIRE ignition coil.
SINGLE ROD CONFIGURATION
FLAME DETECTION WIRE LENGTH LIMITATIONS
Distance Between 2200 and Pilot * Wire Size
0 - 10 feet 14 - 16 gauge
10 - 25 feet 7mm Ignition Wire
25 - 60 feet 7mm Ignition Wire
*For single rod installations, the distance is defined as the length from the positive ion terminal, to the ignition
coil, plus the distance from the ignition coil, to the ignition/flame rod as shown in the Single Rod Wiring Diagram.
Note that the ignition wire should be no longer than 3m (10 ft).

INSTALLATION DIAGRAMS
Figure 1: Burner with Ferrofix nozzle – side view.
Figure 2: Burner with Ferrofix nozzle – top view.
Figure 3: Burner with bell nozzle - isometric.

Figure 4: Burner with bell nozzle – top view.
Figure 5: Burner with Ferrofix nozzle and Inline Igniter – Side View.
Figure 6: Burner with Ferrofix nozzle and inline Igniter – Top View.

Figure 7: Burner with Bell nozzle and Inline Igniter – Side View.
Figure 8: Burner with Bell nozzle and Inline Igniter – Top View.

PRE / POST-ASSEMBLY CHECKLIST
The following checklist will help ensure proper installation techniques for the PF2200 Burner Management Sys-
tem, fuel train components, and burner components. This checklist should be consulted before and after install-
ation, to ensure requirements are met for the installation of the system.
1. Ensure that the BMS is mounted in a safe area for operation. Look for tripping, high heat exposure, and
other potential hazards.
2. Conduct pull tests on terminating wires in the BMS to ensure proper installation.
3. Install tags identifying that electrical seals have not been poured on electrical connectors entering the
PROFIRE BMS.
4. Ensure the Type K temperature inputs wire is used. (Yellow = positive and red = negative).
5. Point to point wiring is a must with temperature inputs wires (no cold junctions). A cold junction can cause
inaccurate temperature readings and therefore, poor temperature performance.
6. Do not hook up shield wires; this should be done in the field if necessary. It is common to terminate the
shield wires to earth ground or ground grid of each vessel skid; however, this can only be done upon field
installation. The temperature inputs are shipped loose and installed on location in the vessel. The wiring
is completed at that time.
7. For flame detection to work correctly, the flame must be in physical contact with both the flame detection
rod and the grounded pilot nozzle. This allows a current path from the flame detection rod through the
flame to ground. When nozzle velocity is high, the flame may not make contact with the nozzle. This situ-
ation is referred to as "poor flame anchoring." To resolve poor flame anchoring, add a second grounded
Kanthal rod can be placed further in front of the nozzle so that it catches the flame.
COMMISSIONING
STARTING/STOPPING
Starting, and stopping the burner can be done by selecting the Start, or Stop button on the
PF2200. The system prompts for an acknowledgment of this action. Press the OK button to
continue with the safe start-up or shutdown of the burner. When shutting down the burner,
press the Stop button. The system prompts the user to confirm the shutdown, press OK.
When the shutdown process is complete, the system will prompt for an acknowledgment
that the shutdown is complete. Press OK to acknowledge the shutdown.
With the optional manual Start/Stop switch, startups and shutdowns of the burner are
achieved. This switch has three functional positions, as shown. When in the Stop position
the burner is shut down and de-energizes the system. Moving the switch from the run pos-
ition to the Ignite position, and holding the switch in the Ignite position for more than 2
seconds, starts the ignition sequence, and return to the Run position. By moving the switch
from Stop to Run positions, you can clear a lock state.
The optional Manual Switch (part# PFA-004260 ) mentioned above can be ordered by contacting Profire Energy.

Note: Holding the switch in the Ignite position for more than 4.5 seconds results in a system shutdown on an
External Stuck Switch event.
NAVIGATION
Cycle through the PF2200 Status, Settings, and Systems screens using the Carousel button.
Arrow keys are used to navigate screen menu items. The OK Key is also used in combination
with the Arrow Keys to navigate drop-down menus.
Using the + and – keys, allow the user to change view modes on the status screen, increases or
decreases settings, or drop-down menus enumeration in the settings screen.
Once the desired changes are input, click the OK button to save the changes. The OKkey is
also used to acknowledge any prompt screens.
To escape the current dialog, return to the previous screen, or escape from drop-down menus
and spin boxes, use the Back key.
Enter Commissioning Mode by pressing the Commissioning button, and acknowledging the
on-screen prompt. This mode indicated with the commissioning icon in the top right corner of
the screen.

MENU MAP
Below is a mapping of the PF2200-SB in Commissioner mode.
For more information on system navigation visit the User Guide section on NAVIGATION.