ProFire PF2200-SB User manual

PF2200-SB PRODUCT MANUAL

PF2200-SB PRODUCT MANUAL
DOC-001043_rev 1.0
The PDF version is available here.

INTRODUCTION
SCOPE and PURPOSE
This document is intended to be a full description of the PF2200-SB product and the
intended use 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, operating sequence, general requirements, and approvals.
•Installation and Commissioning: this section describes the actions needed to
perform installation and commissioning of the PF2200-SB; including
electrical/mechanical ratings, configuration parameters, mounting considerations,
and warnings.
•Operations and Maintenance: This section describes the actions needed for ongoing
operation and maintenance of the PF2200-SB; including troubleshooting,
maintenance, repair and replacement, decommissioning, and manufacturer
notification.
TERMS and ABBREVIATION
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 has two values (Energized or
De-energized).
Electronic Disconnection
Non-cycling interruption by an electronic device of a
circuit for functional disconnection and which provides a
disconnection other than by means of an air gap by
satisfying certain electrical requirements in at least one
pole
Flame Detector
Device which provides the programming unit with a
signal indicating the presence of absence of flame
Flame Detector Response
Time
Period of time between loss of the sensed flame and the
signal indicating the absence of flame
Flame Detector Self-Checking
Rate
Frequency of self-checking function of the flame
detector (in number of operations per unit of time)

Flame Failure Lock-out Time
Period of time between the signal indicating absence of
flame and lock-out
Full Rate Start Condition in which the main burner ignition and
subsequent flame supervision occur at full fuel rate
Ignition Time
Period of time during which the ignition device is
energized
Incorporated Control
Control intended for incorporation in, or on, an
equipment, but which can be tested separately.
Intermittent Pilot
A pilot which is automatically ignited when an appliance
is called on to operate and which remains continuously
ignited during each period of main burner
operation. The pilot is automatically extinguished when
each main burner operating cycle is completed
Interrupted Ignition A type of ignition which is energized prior to the
admission of fuel to the main burner and which is de-
energized when the main flame is established
Interrupted Pilot A pilot which is automatically ignited prior to the
admission of fuel to the main burner and which is
automatically extinguished when the main flame is
established
Lockout
A state in which all powered outputs (Valves and
Ignition) are de-energized and interaction from the user
is required in order to exit the state.
Low Rate Start
Condition in which main burner ignition occurs at low
fuel rate. Once ignition at low fuel rate occurs and the
flame is proven, full main burner fuel rate may be
admitted
Main Permissive
An event which causes the BMS to de-energize the main
solenoid outputs (SSV) and remain in that state until the
event clears (or an alarm / wait condition forces the BMS
out)
Maximum Flame-failure Re-
ignition Time
Period of time between the signal indicating absence of
flame and the signal to energize the ignition
device. During this time period the fuel supply is not
shut off.

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
Period of time between the signal to energize the pilot
fuel flow means and the signal indicating presence of the
pilot flame
Post-Ignition Time
Period of ignition time between the signal indicating
presence of flame and the signal to de-energize the
ignition device
Post-Purge Time
Purge time that takes place immediately following the
shutting off of the fuel supply
Pre-Ignition Time
Period of the ignition time between the signal to ignite
and the signal to energize the fuel flow means
Pre-Purge Time Purge time that takes place immediately following the
shutting off of the fuel supply
Recycle Time
Period of time between the signal to de-energize the fuel
flow means following the loss of flame and the signal to
begin a new start-up procedure
Safety-interlock
A term used to describe an input (either switch or
Transmitter) that must be satisfied to run. If the interlock
is not satisfied (e.g. open switch or out of range
transmitter) the system will proceed to lock-out.
Shutdown
The process the system goes through when it receives
an alarm event while running. This is immediately
followed by entering the state of Lockout.
Signal for Absence of Flame
Maximum signal which indicates the loss of flame
Signal for Presence of Flame
Minimum signal which indicates the presence of flame
when there was previously no flame
Start-up Lock-out Time Period of time between the signal to energize the fuel
flow means and lock-out

Type 2 Action
Automatic action for which the manufacturing deviation
and the drift of its operating value, operating time, or
operating sequence have been declared and tested
under the IEC 60730 standard.
Wait
An event which causes the BMS to proceed to a state
which will de-energize all safety outputs. When all wait
events clear, the BMS is free to automatically recycle.
Waiting Time
Period between the start signal and the signal to
energize the ignition device. For burners without fans,
natural ventilation of the combustion chamber and the
flue passages normally takes place during this time.

ACRONYMS
BMS
Burner Management System
ESD Emergency Shut Down – a mechanism that shuts down the system in
the event of a safety emergency
FMEDA Failure Mode, Effects and Diagnostic Analysis
HFT
Hardware Fault Tolerance
HFV High Fire Valve
I/O
Generic name for a terminal that can be an input, output, or a
combination or both.
PFDAVG
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, and enclosure.
PSC
Product Safety Constraint provides safety relevant restrictions on the
architectural design of the system.
PFN
ProFire Network. Method of communication between User Interface
Card and BMS Card.
PWM
Pulse Width Modulation
RTD Resistive Thermal Device
RMA
Return Merchandise Authorization
RTD Resistive Thermal Device
RTL
Real Time Loop. The software execution loop that runs in the
processor of a logic solver.
SIL
Safety Integrity Level. A discrete level (one out of a possible four) for
specifying the safety integrity requirements of the safety functions to
be allocated to the E/E/PE safety-related systems where Safety
Integrity Level 4 has the highest level of safety integrity and Safety
Integrity Level 1 has the lowest
SIF
Safety Instrumented Function. A set of equipment intended to reduce
the risk due to a specific hazard (a safety loop)

SIS
Safety Instrumented System – Implementation of one or more Safety
Instrumented Functions. A SIS is composed of any combination of
sensor(s), logic solver(s) and final element(s)
SFF
Safe Failure Fraction. The fraction of the overall failure rate of a
device that results in either a safe fault or a diagnosed unsafe fault
SFR
Safety Function Requirements define relevant safety functionality the
system is to perform to maintain the safety integrity function.
SSC
Symmetrical Safety Core. It is a combination of two microprocessors
which makes up the brain of the safety machine.
SSV
Safety shutoff valve. A valve that shuts off for safety reasons.
TCV
Temperature Control Valve

RELATED LITERATURE
PF2200 Single Burner BMS – Modbus Registers PF2200 Single Burner BMS – Software
Release Notes.
REFERENCE STANDARDS
•IEC 61508:2000 Functional Safety of Electrical / Electronic / Programmable Electronic
Safety-Related Systems CSA 22.2 No. 60730-2-5 / ANSI Z21.20:14
•UL 60730-2-5
•CSA 22.2 No. 213-17
•UL 121201. ED9
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 five main pieces:
•User Interface Card: The card which provides interaction to the user/operator. This
card monitors user input and displays all relevant status / setting information to the
user.
•BMS Card: The “safety brain” of the product. This card stores all the relevant safety
information, and performs the operating sequence in accordance with the timings in
the safety settings.
•Keypad: Allows the user/operator to interact with the product through a series of
buttons.
•Enclosure: Provides protection for the product against environmental conditions.
•Ignition Switch: Allows the user/operator to Start and Stop the system via an external
switch located on the side of the enclosure.
•
USER INTERFACE CARD
The User Interface Card allows interaction with the system through the use of the keypad
and a display. This card interacts with the BMS card through a proprietary communication
protocol, called PFN, which utilizes the RS-485 physical transport layer. PFN and power to the
User Interface are factory wired to the BMS card through a wiring harness.

MODBUS
Remote access to status information, and non-safety critical settings, can be achieved via the
Modbus port of the User Interface card. The Modbus port supports Modbus RTU over the
RS-485 physical layer.
For a complete register list, see PF2200 Single Burner BMS – Modbus Registers. By design,
safety-critical settings are not accessible via Modbus.
USB
The USB port located on the User Interface card has two main purposes, Firmware Update,
and extracting the Event Log. Profire recommends using a 1GB or larger USB stick.
The Firmware Update is only supported by using authorized Firmware bundles supplied by
Profire Energy. Contact "PROFIRE CONTACT INFORMATION " on page 95 to get an authorized
Firmware bundle.
For more information of the Firmware Update process, go to the PF2200 FIRMWARE UPDATE
GUIDE.
The Event Log can be extracted by navigating to the Event Log which is located on the
System screen. Once in the Event Log screen you can choose to Export the log by pressing
the OK button.
Note: Data Logging will be in a future feature release. Please contact Profire Energy to get
more information on this features release date.

STATUS LED
The User Interface Card has a Status LED which is visible on the front panel of the product.
Capable of producing Red, Green and Amber colors, the states of the Status LED are defined
below:
LED Behavior
State
Fast blinking red
System is not running and is in the lockout state.
Blinking red
System is not running and is in an alarm state.
Solid red
System is not running and is in the ready state.
Solid green
System is running - no warnings or waits present
Blinking green
System is running - in wait state.
Blinking amber
System is running and is in a waiting state with a warning
present.
Solid amber
System is running - with a warning present.

BMS CARD
The BMS card provides the necessary I/O, and functionality to reliably, and safely control a
burner. Additionally, the BMS card also has tertiary features that are not safety rated but
provide a functional benefit to the overall product.

OUTPUTS
PILOT VALVE OUTPUTS (Pilot 1 and 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 pilot. When Pilot 2 is enabled, both outputs work in
conjunction with one another meaning, that they energize, and de-energize in unison. If Pilot
2 is disabled, the Pilot 2 output will stay de-energized. The Pilot Outputs are capable of 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.
MAIN VALVE OUTPUTS (SSV)
Two powered outputs (terminals 19-20 and 21-22) are intended to be connected to solenoid
valves which control the main fuel line for the burner. Both outputs work in conjunction with
one another, meaning that they energize and de-energize in unison. The Main Valve Outputs
are capable of 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.
IGNITION OUTPUTS (Coil +/-)
Two powered outputs (terminals 55-56 and 59-60) are intended to be connected to an
ignition source (e.g. ignition transformer). When Pilot 2 is enabled, both outputs work in
conjunction with one another meaning they energize and de-energize in unison. If Pilot 2 is
disabled, the Pilot 2 Coil output will stay de-energized. Two ignition modes are supported by
the system and configurable via the user interface: Coil Mode, and High Energy Ignition (HEI)
mode. Coil mode sends a pulsed signal of fixed frequency and duty cycle and is intended to
be used in conjunction with an ignition transformer. In HEI mode, the output is energized
with a steady-state DC voltage that can be used to enable an external High Energy Ignition
source.

FLAME DETECTION I/O (Ion +/-)
Two Ionization flame detection I/O (terminals 53-54 and 57-58) are supported by the PF2200-
SB. These terminals are intended to be connected to a flame rod which makes physical
contact with the flame.
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.
Pilot 1 flame detection is always enabled, whereas Pilot 2 flame detection can be enabled or
disabled via the user interface. If Pilot 2 flame detection is enabled, both Pilot 1 and Pilot 2
flames must be established and present in order for the system to continue to run.
HIGH FIRE VALVE (HFV) OUTPUT
One powered output (terminals 23 and 24), is intended to be connected to a safety shut off
valve when a staged heating appliance is needed. In this application, the high fire valve
output is intended to be the highest level 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) will be energized (Stage 1).

INPUTS
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
Behavior
Switch State Mode
Stop
Hold the system in lockout
ESD or Shutdown
Run
Transition to a ready state or maintain a
running state.
Ready
Ignite If held for 1 second or more, transition
into the Confirm Start state.
System Start
Run -> Stop -> Run
Acknowledge and clear lockout condition
N/A
Note: if the switch is held in the Ignite state for longer than 5 seconds, the system will alarm.
EMERGENCY SHUTDOWN (ESD) INPUT
The ESD input (terminals 33-34) is an energized-to-run digital input that is always enabled. If
the contact is de-energized, the system will present an alarm and proceed to lockout (if
running). If the contact is energized, the alarm will clear.

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 a transmitter.
In digital input mode, the input can be configured as either an Alarm, Wait, Warning, or Main
Permissive when the contact opens. This is intended to be connected to a low-pressure
switch.
In 4-20mA mode, a high-pressure trip event will cause an Alarm, and a low-pressure trip
event can be configured as an Alarm, Wait, Warning, or Main Permissive. The
aforementioned high-pressure trip event will only Alarm the system if the high-pressure
event persists after the mains have opened. This mode is intended for use with a pressure
transmitter.
The following table outlines the behavior of the Pressure Input:
Input Configuration
Event
System
Behavior
Disabled
Any
No Effect
Digital Input
De-energized with low-pressure mode set to
Wait
Wait
De-energized with low-pressure mode set to
Alarm
Alarm
De-energized with low-pressure mode set to
Main Permissive
Main
Permissive
Energized
Run
4-20mA
Out of range
Alarm
Low trip with low-pressure mode set to
Alarm
Alarm
Low trip with low-pressure mode set to Wait
Wait
Low trip with low-pressure mode set to Main
Permissive
Main
Permissive

Input Configuration
Event
System
Behavior
Active range
Run
High trip with mains ON
Alarm
High trip with mains OFF
Run
LEVEL INPUT
The Level input (terminals 41-42) is meant to monitor an external level (e.g., tank level) and
provide the necessary feedback in the event of a high and or low-level 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.
In digital mode, the level input can be used as a Wait, Warning or, an Alarm when the contact
opens. This Input can be connected to a low or high-level trip switch, depending on the
application.
In 4-20mA mode, the level input used in conjunction with the low-trip, and high-trip modes.
These modes are independent of one another and can be configured as either a wait,
warning, or an alarm. This input is intended to be connected to a level transmitter.

The following table outlines the behavior of the Level Input:
Input
Configuration
Event
System Behavior
Disabled
Any
No Effect
Digital Input De-energized with digital mode set to wait Wait
De-energized with digital mode set to warning
Warning
De-energized with digital mode set to alarm Alarm
Energized
Run
4-20mA Out of range Alarm
Low trip with low trip mode set to wait
Wait
Low trip with low trip mode set to warning Warning
Low trip with low trip mode set to alarm
Alarm
Active range
Run
High trip with high trip mode set to wait
Wait
High trip with high trip mode set to warning
Warning
High trip with high trip mode set to alarm
Alarm

TEMPERATURE INPUTS
The PF2200-SB has three distinct temperature inputs: Bath, Outlet, and Stack; each of which
is configurable to be either a Type-K thermocouple or PT-100 RTD input.
Each of the three distinct temperature inputs mentioned above has the following set points
that can be configured via the user interface (note: dependent on the mode, the
temperature input may or may not utilize all the set points below; see Temperature Mode
for more details):
Setpoint
Description
High-
Temperature
ESD Setpoint
The temperature at which the system shuts down. If the temperature
input exceeds this trip point, the system will generate an alarm and if
running proceeds to lockout.
Pilot Off Setpoint
The temperature at which the system de-energizes all valves,
including the pilot, and enters a waiting state. When the temperature
falls back down below this value minus the deadband, the system will
reignite the pilot.
Main Off
Setpoint
The temperature at which the system de-energizes the main valves
and enters the Pilot state. The main valves will be turned back on
when the temperature drops below the Process Control Setpoint
minus the deadband.
Process Control
Setpoint
The setpoint at which the process temperature will be controlled. In
PID mode, the TCV will be actuated in relation to this setpoint. In
Staged Heating mode, the HFV will be actuated by this setpoint.
Low-
Temperature
Warning Setpoint
If the temperature drops below this trip point the system will display a
warning on the user interface and will continue to run.

The three temperature inputs listed above also have a user-configurable mode. The various
temperature modes are defined below:
Setpoint Description
Disabled The temperature input is ignored.
High Temp ESD The temperature input is monitored for High Temp ESD events only.
Setpoints used in the mode are High Temperature ESD, and Lowe
Temperature Warning.
Process Control
Mode
The temperature input is monitored for High Temp ESD events, as well
as used for Process Control. Setpoints used in this mode are High-
Temperature ESD, Pilot Off, Process Control, and Low-Temperature
Warning.
Display Only
The temperature inputs are read only and displayed on the User
Interface of the PF2200. The system does NOT act on this information
in any way. There are NO setpoints in this mode.
The following table shows Input Temperature Modes:
Input
Terminals
Type
Modes Supported
Bath
61-66
Dual Element with cross
comparison
Single Element
High Temp ESD
Process Control
Outlet
67-69
Single Element
Disabled
High Temp ESD
Process Control
Display Only
Stack
70-72
Single Element
Disabled
High Temp ESD
Display Only
Aux Temp
43-44
4-20mA Input
Disabled
Process Control
High Temp ESD
Display Only