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USER MANUAL REV 1.8.1 - Profire Energy, Inc.

1. AUX TC Aux Thermocouple negative lead 2 Installation 2 5 Terminal Description Continued TERMINAL EXPECTED CONNECTIONS DESCRIPTION SECTION High Fire Main igh Fire Main Valve positive erminal igh Fire Main Valve negative ter minal Do not connect to ground Low Fire Valve negative terminal Do not connect to ground Pilot Valve negative terminal Do not connect to ground Solenoid valves must be connected between the and 2 6 2 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 2A continuous per valve output 4A peak per valve output if the cor responding Solenoid PWM Setting is 60 or less Flame Detection positive input Con nect to flame rod or external coil lon terminal depending on configura tion A Kanthal rod should be placed directly in the pilot flame and connected to this input The pilot assembly must be grounded for the flame detec tion 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 flame rod to be used for both ignition and flame detection A 65VAC signal is applied to the flame rod The source impedance is very high so there is no danger of sparking Flame Detection negative input Connect to ground screw on pilot assembly
2. ero eor rcm cur A e e e e e 2100 Modbus Expansion Card 1 Overview 1 3 Optional Components The following components may be required to install the PF2100 but are not included with the system Profire offers some of these components for sale individually and also in various kits Please contact Profire Sales for further information 1 MOUNTING HARDWARE Channel Bar Conduit Ports Liquid Tight Ports Rubber Grommets 2 WIRE Ignition Wire Thermocouple Wire 3 RODS AND CONNECTORS Kanthal Ignition Rods Various Lengths 4 VALVES DC Solenoids Safety Valves with Proof of Closure Proportional Valves 5 THERMOCOUPLES Single Type K Dual Element Type K PILOT ASSEMBLY Nozzles Brackets Mixers Orifices AUTONOMY Batteries Solar Chargers Solar Panels ACCESSORIES e 4 20mA Expansion Cards Modbus Expansion Cards External Ignition Coils 1 Overview 1 4 External Diagram DOOR amp KEYPAD SERIAL MODEL LABEL ENCLOSURE 1 Overview 1 5 Internal Diagram FW VERSION LABEL HW SERIAL VERSION LABEL RIBBON CABLE DOOR TO TERMINAL MODBUS CARD OPTIONAL 4 20mA CARD OPTIONAL DOOR CARD INTERNAL COIL OPTIONAL TERMINAL CARD 1 Overview 1 6 Installation Types Below are examples of some of the many applications that the PF2100 can be use
3. 2 Installation uon 9VDC via a 3 75kQ resistance Jumper and if not used All input contacts can use a single common ground return if desired 2 6 Required Wiring The wiring in this section of the document is required for all PF2100 installations Skipping or performing any steps in this section incorrectly will likely result in the PF2100 not functioning properly 2 6 1 Power The PF2100 can be powered from 12VDC or 24VDC The maximum current that the PF2100 can safely handle without blowing the main fuse is 5A The system on its own draws only about 100mA The rest of the current is drawn by loads on attached circuits such as the valves Ensure that you select a power supply that is rated appropriately for the total amount of current that will be con sumed by all devices attached to it WIRING STEPS 1 Wire the Common terminal to the negative terminal of the power supply 2 Wire the Earth Ground terminal to the shield of all conduit ports installed in the enclosure 3 Connect the Earth Ground terminal to an actual earth ground connection 4 Wire the 12 24VDC terminal to the positive terminal of the power supply 2 Installation 2 6 2 Valves There are four valve control outputs on the PF2100 Pilot Low Fire 4 20mA Output and High Fire Main WIRING STEPS 1 Wire the Pilot valve to the Pilot terminals 2 Wire the Main valve to the High Fire Main terminals 3 If Low Fire is required in y
4. 4 4 1 4 20mA Level Input Continued CHART CHART EVENTS EVENT o 1 System started with tank empty _ _ _ _ Pump starts filling tank Burner is off and system is waiting on level input because 4 20mA level input is below the low setpoint 4 20 LEVEL AmA ca M NND MM E Tank level rises above low setpoint System begins running heating tank Tank level rises above the high set CLOSED i Bede point the pump turns off and the i ENS remote alarm turns on to signal a truck to come and empty the tank CONTACT n operater arives on site and be gins emptying the tank into a tanker truck The pump turns back on and the alarm turns off E e S CLOSED The tank level drops below the low setpoint and the level delay timer WAITING RUNNING WAITING begins counting down The level delay timer reaches zero after 2 or 20s depending on the Pressure Level Delay setting and the system stops heating the tank and returns to the Waiting on Level state The tank is empty and the tanker truck leaves the site The tank level begins rising again 4 Modes and Behaviour 4 4 2 4 20mA Pressure Input The 4 20 Pressure Input is used to monitor fuel train pressure in the same way that the Pres sure Contacts are The behaviour and features are identical to those described in the previo
5. Optional internal or external ignition coil INPUTS amp OUTPUTS 6 Digital inputs for safety interlock device connections 5 Digital outputs 4 20mA output Flame rod input 3 Thermocouple inputs TECHNICAL SPECIFICATIONS Operating Range 40 C 40 F 55 C 130 F Storage Range 40 C 40 F 80 176 F POWER CONSUMPTION LANE w Controller only display ON 2 6W 2 9W Ignition Voltage Internal Coil up to 20kV up to 40 kV TERMINAL BLOCKS VALUE Maximum Wire Gauge 12 AWG STATUS CONTACT VALUE mpedance When Closed PHYSICAL DIMENSIONS VALUE Width 30 9 cm 12 15 in p TE po M E Em ER E0000 Model 4 0165 1 8kg Model 6 0lbs 2 6kg FUSES VALUE Q ain Fuse Rating 250V Ceramic Fast Blow Replacement Status Contact Fuse LittelFuse 0453 250 or 0451 250 www profireenergy com 2013 PROFIRE
6. Sets the adjustment speed of the control loop for the 4 20mA Output when used for Valve Control 0 1 to 196 s 0 5 s 3 3 6 Expansion Cards MENU 6 This menu contains settings relating to expansion cards ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING MORE INFO 4 20 Input Card Enable 4 20 Input Card Enable the 4 20mA Expansion Card and No Yes Enabled setpoints 4 20 Pressure Low Setpoint 4 20 PRS Low Adjusts 4 20 Low Pressure trip point O High Hidden 3 0 PSI 3 4 1 Setpnt Setpoint 4 20 Pressure High Setpoint 4 20 PRS High Adjusts 4 20 High Pressure trip point Low set Hidden 25 0 PSI 3 4 1 Setpnt point Max Pressure 4 20 Pressure Range 4 20 PRS Range Adjusts Max pressure of the fuel train 0 2000 4 20 Pressure Units 4 20 PRS Adjusts the display units for the PSI kPa Units 4 20mA Pressure Input inWC cmWC ksc Enable control and address for Modbus Card Enable control and address for the Disabled Disabled 247 the Modbus Module Modbus Expansion Card 1 128 4 20 Card FW Version 4 20 FW Display Expansion Card FW Version N A N A SAN SoS MODBUS Card FW Version MBUS FW Display Expansion Card FW Version N A N A Suis 3516 3 User Interface amp Settings 3 3 7 Calibration MENU 7 This menu is used to adjust the calibration of thermocouples 4 20mA Output and 4 20mA Expansion Card inputs This menu is hidden by default le ON SCREEN DESCRIPTION RANGE DEFAULT SETTING SEC
7. running was any of the following 1 Asaresult of normal process control Examples Include 1 System Input Voltage too low including power cycle a The system is started by a user by switching to Auto Mode 2 System Input Voltage too high b The system is started remotely via the Start Contact 3 Low Pressure Contact open c The Pilot Turns off as a result of process control and then is automatically turned back on after the temperature drops 4 4 20mA Pressure Input below Low Setpoint below the Pilot Off Setpoint d The system automatically restarts after recovering from one of the situations described in the Auto Restart or Level Restart sections LEVEL EVENT RESTART MENU 4 2 As a result of the pilot flame unexpectedly going out Examples If this setting is enabled the system will restart automatically once Include all alarm conditions are cleared and if the reason that the system stopped running was any of the following a The gas supply is cut off b Excessive wind blows out the burner flame 1 Level Contact open c Insufficient oxygen supply snuffs out the burner flame d The flame detection rod becomes dirty and unable to 2 4 20mA Level Input below Low Setpoint detect flame 3 User Interface amp Settings 3 4 12 System Voltage The PF2100 is designed to operate with a nominal 12VDC or 24VDC Power Supply It will not be damaged by applying any voltage in or near this range regardless of menu settings The valves
8. Modes and Behaviour CHART EVENTS System is started Pilot Valve opens Proc Temp beings to in crease slowly Pilot to Main Delay elapses Low Fire Valve opens Proc Temp in creases faster Low to High Fire Delay elapses Main Valve opens 4 20mA output begins increasing Proportional Valve begins opening Proc Temp exceeds Process Setpoint 4 20mA output begins to decrease Proportional Valve begins to close Proc Temp drops below Process Setpoint minus Deadband 4 20mA output begins to increase again Proportional Valve begins to open again Proc Temp stabilizes 4 2 6 Aux Temp Mode Temp Main Ctl This scenario is the same as the basic scenario except that Aux Temp Mode has been set to CHART EVENTS Temp Main Ctl to enable the Auxiliary Temperature input The Proc Temp signal measures the outlet temperature of a line heater and the Aux Temp signal measures the bath tempera ture If the heat demand increases the bath temperature may rise quickly The Aux Setpoint is used to shut off the Main Valves to protect the bath and fire tube in the event of excessive Pilot to Main Delay elapses Low bath temperature Fire Valve opens and Proc Temp increases faster System started Pilot turns on and temperature begins to increase CHART Proc Temp exceeds Process a Setpoint Main Valve closes and EVENT the Proc Temp begins to decrease HIGH TEMP ESD SP ae que Q9 P
9. State because the Proof of Closure PF2100 may attempt to light the burner while a dangerous amount of gas is present result PoC Contact is open while it is not ing in an explosion To prevent this the Proof of Closure Input Contact can be used to monitor running the mechanical position of the Main Valves This feature requires the use of valves that have a built in Proof of Closure output If more than one Main Valve is used the Proof of Closure Q Proof of Closure closes purge time begins counting down system outputs from each valve are wired together in series before being connected to the PF2100 s dem notst rt Proof of Closure input cally The Proof of Closure contact must be closed in order for the Purge Timer to count down If it_ amp User starts system in Auto Mode is ever opened while the system is not running the Purge Timer is reset and must count down System counts down the remaining purge time on the display again before the system can be started In short the Proof of Closure contact must be closed for the entire duration of the Purge Time or the system will not start While running if the Proof Purge Time Elapses system ignites of Closure contact ever opens when it is not expected to be open the system will shutdown pilot detects flame and begins counting down the Pilot to Main delay CHART EVENT Q o 4 5 Proof of Closure opens before Main Valves turn on the syst
10. System Storage Setting Process Control Settings Process Setpoints High Temp ESD Pilot Off Process Low Fire Low Alarm Deadband 3 User Interface amp Settings 3 4 1 4 20mA Expansion Card Settings These settings all apply to the 4 20mA Expansion Card which must be installed in the PF2100 s expansion slot These settings can all be found in Menu 6 Some of these settings will be hidden if the card is not installed or enabled 4 20 EXPANSION CARD ENABLE MENU 6 For the Tank Level Settings to be visible the LVL DIP Switch on the 4 20mA Input Card must be enabled For the Tank Level Settings to be visible the LVL DIP Switch on the 4 20mA Input Card must be enabled 4 20 LOW LEVEL SETPOINT MENU 6 If the 4 20mA LVL input drops below this setpoint the burner will turn off to prevent damage to the tank and fire tube 4 20 HIGH LEVEL SETPOINT MENU 6 If the 4 20mA LVL input exceeds this setpoint the LVL output contacts on the 4 20mA Input Card will toggle 4 20 LEVEL RANGE MENU 6 Specifies the maximum capacity of the tank s 4 20mA level transmitter 4 20 LEVEL UNITS MENU 6 Specifies the units of measurement Note that this may have an impact on measurement accuracy For the Fuel Train Pressure Settings to be visible the PRS DIP Switch on the 4 20mA Input Card must be enabled 4 20 LOW PRESSURE SETPOINT MENU 6 If the 4 20mA PRS input drops below this setpoint the burner will turn off to prevent fla
11. The circuit from the rod through the flame to the nozzle to ground is not being completed Check the grounding to the pilot nozzle Check for cracked ceramic on the flame rod It is possible that the terminal card is faulty pressure Recheck the orifice size Did placing the grounded rod in the flame improve the DC voltage reading NO and increase the pilot QE Try replacing the pilot nozzle YES Set the system up to use separate rods for flame detection and ignition 5 Troubleshooting 5 6 Thermocouple Troubleshooting Guide Problem with Thermocouples QUESTION ARE IN WHITE RECTANGLES E o NO ALWAYS MOVES TO THE RIGHT Ensure that both the High Temp and Process thermocouples are connected YES ALWAYS MOVES DOWN 2 System reading Process TC ProcTC 2 System reading TC s not equal or HH Thermocouple or ProcH TC TC Mismatch 3 Check the thermocouple wiring ensure 3 Set a Multi Meter to read mili volts DC that the thermocouples are paired correctly mVDC and measure across and not reversed HighTemp_TC and HighTemp_TC 4 The thermocouple indicated by the system 4 Also measure across Process_TC may be faulty Install a jumper across HighTemp_TC and HighTemp_TC Also install a jumper across Process_TC Are the voltages measured across the The system is likely reading
12. and after password times out Clear Cal 10 Required after password times out 11 Viewable in Debug Mode 3 User Interface amp Settings 3 3 1 Setpoints MENU 1 This menu is used to adjust the Process Control Setpoints ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING SECTION Pilot Off Setpoint Pilot Off emperature at which 349 C 85 C Setpn te il turn off when Pilot ot zd 185 F is enabled Low Fire Setpoint Low Fire Adjusts the tempera Setpn Low Fire Valve will tu Fire is enabled Process Setpoint Proc Adjusts the temperature at which the 1 to 1349 C 80 C 3 4 10 Setpn High Fir Main Valve will turn off 34 to 246 176 F Low Temp Alarm Setpoint Low Temp Alarm Adjusts the temperature where the Disabled Disabled 3 4 10 Setpn Status Contact will close if enabled 1 to 1349 C Deadband Deadband Adjusts Deadband Used with the Process Setpoint and sometimes Low 1 to 240 F 3 F Fire and Aux Setpoints Aux Setpoint AUX Setpnt Adjusts the Auxiliary Setpoint 0 to 1350 C Hidden 3 4 10 32 to 2462 F 20 C 68 F 3 3 2 History MENU 2 This menu contains read only event counters and the event log ie ON SCREEN BRIEF DESRIPTION RANGE DEFAULT SETTING SECTION Relights Number of Pilot Relight attempts Flame Fails Flame Fails Number of Shutdowns due to failure to to 1000 N A light the pilot 3 User I
13. hidden from menus The order of the setpoints will vary depending on the value of the Process Control Input setting The following diagrams illustrate the upper and lower bounds of each setpoint and their order Setpoints that are shaded may be disabled When a setpoint is disabled the upper and lower bounds of the adjacent setpoints are adjusted accordingly Process Control Input Setting Proc TC 1350 C HIGH TEMP ESD SETPOINT E PILOT OFF SETPOINT oa al 5 LOW FIRE SETPOINT AUX SETPOINT 9 5 PROCESS SETPOINT LOW TEMP ALARM DEADBAND oc oc Setting can be hidden disabled Deadband Max 150 C 1350 C Process Control Input Setting Aux TC 1350 C 1350 C PILOT OFF SETPOINT HIGH TEMP ESD SETPOINT LOW FIRE SETPOINT PROCESS SETPOINT sey PROC TEMP AUX TEMP LOW TEMP ALARM DEADBAND 0 Setting can be hidden disabled Deadband Max 150 C In the Process Control Algorithm the Proc Temp signal is the one that is compared to the Pilot Off Low Fire Process and Dead band setpoints HIGH TEMP ESD SETPOINT MENU 5 This setting is used to protect the burner and other equipment from overheating If either the High Temp or Process thermocouple read ings exceed this setpoint the burner will immediately shut down This setting can be set to a maximum of 1350 C The minimum value is 1 C higher than th
14. 213 M1987 Grp ABCD CSA E60079 0 2007 CSA Type 4x CSA E60079 15 2005 UL 508 17th Edition ANSI ISA 12 12 01 2007 Gb UL 60079 0 2005 c us UL 60079 15 2002 MC 248705 FOR ANY QUESTIONS PLEASE CALL 1855 PRO FIRE 1855 776 3473 OR VISIT WWW PROFIREENERGY COM 1 2 Overview 1 1 Ava 13 Opt 1 4 External Diagram 1 5 Internal Diagram 1 6 Inst Installation 2 1 Inst ilable Models ional Components allation Types allation Warning dae tat ah aa na naa Jenks 2 2 Mounting Locations 2 3 Mounting Instructions 2 4 Terminal Card Diagram 2 5 Terminal Descriptions 2 6 Required Wiring 2 6 1 POWOL s ect 2 6 2 2 6 3 Thermocouples 2 6 4 Ignition Coil Flame Detection 2 6 5 Internal Coil Dual Rod 2 6 6 External Coil Dual Rod 2 6 7 External Coil Single Rod 2 7 Optional Wiring 2 41 Status Contact 2 22 Contact Inputs 273 4 20mA Temperature Output 2 74 Modbus Expansion Card 275 4 20mA Expansion Card 1 2 lneluded GCornpotherts osse otro Raided e E socer kin eot Det etr tn E SH AN a Pe Eve dut 1 7 Regulatory Requirements 3 Userlnterface amp mme nenne 33 3 1 Hardware User Interface HH He meme heme ee he nnne ee rne nnne ean 3b 3 1 1 Keypad eee
15. Control algorithm takes over When the PF2100 changes states while in Auto mode the new state will be shown momentarily on the display In Manual Mode the current state is always shown on the display 4 1 1 Power Sequence When power is applied to the system it will display PF2100 in large text followed by the firmware versions of the Door and Termi nal Card The system will then display the Home Screen which will show the system state The system state will be Ready if no alarms or present Otherwise the state will be Alarm DC FU E1 8 115 Ready PFz188 El 8 161 Proc Teme 25C 4 Modes and Behaviour 4 1 2 Starting in Auto Mode When the system is started in Auto Mode by pressing the Mode and OK Keys it will run NOTE through the ignition sequence automatically In Auto Mode the PF2100 will automatically at The Process Control state in tempt to relight the pilot if it ever goes out unexpectedly the diagram is actually a collec tion of several states that will be explained in more detail later OK Key POWER ON No Alarm 4 Modes and Behaviour No Flame PROCESS CONTROL 5s Flame START 4 1 3 Starting in Manual Mode When the system is started in Manual Mode using the Pilot Ignite and Main Keys it must NOTE be manually moved through the ignition sequence In Manual Mode the PF2100 will NOT The Process Control state in automatically attempt to reli
16. HH m He eee he rene nne ene ine n e e 50 3 3 6 Expansion Cards Menu 6 eaaa eaaa aee eaaa eaaa aaa aana eaaa aaa rr ERER annaran 51 3 3 7 Calibration Menu 7 sasae e aaa meme e ehem emen rien anan anana 52 53 3 8 8 Review Menu eI ee ee nene hee rese rire KANE ga aaa e e iter rise trs enis 53 54 3 4 Settings Grouped Alphabetically 0 cccccc cece cece ecceeceecsueceeeseeseueseeseeeseeesaeeseneeeeeaeenes 55 3 4 1 4 20mA Expansion Card Settings e eene rhe rne 56 342 20m OUtpulb SENS c costis oo oes OE PEU peri ai latens 57 3 4 3 Alarm Status Contact Settings saene eaaa aaa Naane aana 58 3 44 Auxiliary Temperature Settings aaa eee eaaa eaaa eaaa Na 59 3 4 5 Commissioning Settings areenaaaa m ene en 60 EE E OMEISE VECINOS 60 3 4 7 Modbus Expansion Card Settings eene 61 3 4 8 Password Setting esee meme eeess eee eee reme esse ss etre terere sees 61 3 4 9 Process Control Settings ies te dett eee tete idee Pe prem ebd etn 62 3 4 10 Process SEDO 63 64 3 4 1 Restart Settings cei es tee pese esos Penes 65 3 4 12 SystembVoltage eee eee aee eee I I eee hee eese eere aa eaaa aaa aaa aaa aee eee 66 3 4 13 Timing Delay eee enne eee e nane wanan 67 3 4 14 Valve Modulation settings saosan sai saa Sapa a EEN AN ee e n
17. KEY Used in Manual Mode to test the Pilot Valve IGNITE KEY Used in Manual Mode to test the Igni tion Circuit MAIN KEY Used in Manual Mode to test the Main Valve 3 User Interface amp Settings 3 1 4 Display The display on the PF2100 has two lines of text which are used to show system status warnings alarms prompts and menus It is illuminated for ease of reading in both bright sunlight and dark locations The display is the means through which the software user interface is presented When the system first powers on the display will show the system name and firmware version for a few seconds after this it will show the Home Screen 3 2 Software User Interface The software user interface is shown on the PF2100 display Through it the state of the system is presented to the user The user can also change settings via this interface Below is a diagram showing the various types of information that can be accessed through the interface Most items are accessed through what is known as the Home Screen whereas others can be accessed from anywhere in the interface Some items are accessible in all modes whereas others can only be accessed in Manual Mode or only in Auto Mode Each of these items will be discussed in further detail in the sub sections that follow MANUAL MODE AUTO MODE HOME SCREEN HOME SCREEN GUICK System State Process Temperature Process Setroint State Transitions SETPOINT ADJUST Process Temperat
18. Key Stuck he Ignite Key was held for more than 30s while in manual mode KEY STUCK ERROR DOWN Down Key Stuck at System Startup This may indicate a defective keypad his error must be resolved in order to continue using the system Key Stuck at System Startup This may indica ror must be resolved in order to continu KEY STUCK ERROR MAIN Main Key Stuck at System Startup This may indicate a defective keypad This error must be resolved in order to continue using the system KEY STUCK ERROR MODE Mode Key Stuck at System Startup This may indicate a defective keypad This error must be resolved in order to continue using the system KEY STUCK ERROR OK OK Key Stuck at System Startup This may indicate a defective keypad This error must be resolved in order to continue using the system KEY STUCK ERROR PLT Pilot Key Stuck at System Startup This may indicate a defective keypad This error must be resolved in order to continue using the system KEY STUCK ERROR MENU Menu Key Stuck at System Startup This may indicate a defective keypad This error must be resolved in order to continue using the system 5 Troubleshooting 5 2 Shutdown Messages Continued ON SCREEN DESCRIPTION KEY STUCK ERROR STOP odbus Card Shutdown Remote Cmd Error Solenoid Feedback Error Check Solenoid Wiring Stop Key Stuck at System Startup This may indicate a defective keypad This error must be res
19. Level Input amp Output Contacis aee een 117 118 4 42 4 20mA Pressure Input HH e e e me hene nne en ene ee nee nenne 119 122 45 Example ADDIICatOFIS cree or etre to oa orta waded CERE ED ea eter bubo dues mte OR 123 c MU e ee 123 4 5 2 Sidck Prove EIOS oeste tei Sees ah aa A a dotes tuno cates 124 4 5 3 Outlet Temperature Control aee aee eaaa aee ec ee eee eee nee ee ese sese se eese sei 125 4 5 4 Remote Temperature Monitor sesssssssssssessesseseeene ennemi restes serene nenne 126 5 Troubleshooting ooi DC eR 127 5 1 Common Issues S SOlUMIONS sasap E CERES a ee es 129 131 5 2 Shutdown 5 id ee v Ee Maa 132 136 5 3 Alarm Code Sieni M 137 138 5 4 sanagara c apa aa aa ga anaa da aaa TAR E A Na a 136 139 5 5 Flame Detection Troubleshooting nanas cece cece cence ka dnd NE 140 141 5 6 Thermocouples Troubleshooting Guilde sae ee ene eH eee meme esee 142 1 Overview The PF2100 BMS Burner Management System is an electronic control and monitoring system designed for use on a wide array of natural draft burner industrial applications It provides electronic pilot ignition flame detection temperature control and remot
20. PF2100 please review the following list of warnings Failure to observe the following may result in death electrocution property damage product damage and or government fines The PF2100 is not intended for use on burners greater than 12 5 5 Never leave the PF2100 running unattended without the door MMBtuh It is against code in many jurisdictions screws securely tightened down This is to prevent moisture from penetrating inside of the enclosure and damaging the To use the PF2100 on burners greater than 5 MMBtuh it is product Moisture damage to the internal circuitry is not covered recommended to use the low fire feature with two safety shutoff by the product warranty if the door has been left open valves at least one of which has Proof of Closure This is re quired in many jurisdictions 6 conduit ports drilled into the PF2100 enclosure must be Failure to properly ground the pilot assembly back to the PF2100 s lon terminal may result in accidental electrocution product damage or simply failure to ignite the pilot The PF2100 generates 20kV 40 at its high voltage output terminal which can cause burns or cardiac arrest Do not touch or place any object near the ignition coil s high voltage terminal or connected ignition wire while the product is operating Even without making physical contact with the terminal it is pos sible to draw a spark from several inches away especially if the pilot bracket is not properly gr
21. can be set to a maximum of the 150 C or the Process Setpoint whichever is lower The minimum value is 1 C AUX SETPOINT MENU 1 This setpoint is enabled only if Aux Temp Mode in Menu 5 is set to Temp Main Ctl or Temp ESD In the first case if the Auxiliary Temperature goes above the Aux Setpoint the Main Valves will close The pilot will remain on until the Process Temp exceeds the Pilot Off Setpoint if Pilot Off is enabled In the second case the system will shut down if the Auxiliary Temperature goes above the Aux Setpoint This setting can be set to a maximum of 1350 C The minimum value is 0 3 4 11 Restart Settings The PF2100 can be configured to automatically restart after certain alarm conditions clear The number of restart attempts that the system will make under certain circumstances can be configured There are three settings that affect restart behaviour Auto Restart Level Event Restart and Restart Attempts The number of restart attempts the system will make differs depending on the mode and the reason that the burner is being relit MODE PROCESS CONTROL FLAME OUT Manual 3 0 Auto 3 User Configurable AUTO RESTART MENU 4 RESTART ATTEMPTS MENU 4 If this setting is enabled the system will restart automatically once all restart attempt is an attempt by the system to light the burner alarm conditions are cleared and if the reason that the system stopped These can occur under two types of circumstances
22. correctly Set and Process_TC two thermocouples within 0 1mVDC NO gt the meter to read continuity and check that the thermocouples are paired correctly and not reversed Did the error clear oe One of the circuit boards may be YES The system is likely out of calibration If the thermocouples are paired correctly YES and not reversed it is possible that one of m gt Re calibrate the HighTemp_TC and Process_TC the thermocouples is faulty and will need There is likely a problem with the to be replaced thermocouple or the wiring If the calibration did not resolve the problem it is possible that of the circuit boards Verify that there is continuity between the will need to be replaced red and yellow for each thermocouple NS 5 Troubleshooting GENERAL FEATURES Designed for use with natural draft fire tube heaters Meets or exceeds all relevant codes and standards e Easy installation with clearly marked component I O Easily accessible removable terminal connections e Rapid 3 second shut down on flame out Electronic spark ignition Low power operating mode to accommodate solar panel or TEG applications e Auto relight or manual operation e Transient protected and fail safe circuits All solid state circuit components e CSA compliant for Class Division 2 locations Certified for use on B 149 compliant valve trains
23. drops below the Process Setpoint minus Deadband System is started Pilot Valve opens Proc Temp beings to in crease slowly Pilot to Main Delay elapses Low CHART Fire Valve opens Proc Temp in creases faster event 00 00 0 0000 i KEN i Low to High Fire Delay elapses HIGH TEMP ESD SP EE High Fire Valve opens Proc Temp increases even faster LOWFIRESP EN o Proc Temp exceeds Proc Setpoint PROCESS SP High Fire Valve closes Proc Temp begins to drop PROC TEMP o Proc Temp drops below Proc Setpoint minus Deadband High Fire Valve opens again Proc Temp begins to increase again Decreased Heat Demand Q The demand for heat decreases and the Proc Temp begins to rise The Proc Temp exceeds the Low Fire Setpoint Low Fire Valve closes and Proc Temp begins to drop The Proc Temp drops below Proc Setpoint minus Deadband both Low Fire and High Fire Valves open and Proc Temp begins to rise again 4 Modes and Behaviour 4 2 3 Low Fire On at Low Fire Setpoint This scenario is the same as the basic scenario except that the Low Fire feature has now been CHART EVENTS enabled It has been set to turn on at the Low Fire Setpoint In this case the Low Fire Valve ill cl hen it exceeds the Low Fire Setpoint and will reopen after it drops below the Low tom started valve will close when point p p opens Proc Temp beings to in Fire Setpo
24. electrical noise that is common on some sites If long periods of severe noise are common on a particular site the delay can be increased to 6s by enabling the Pressure Level Delay feature in Menu 4 If this contact is not needed it must be shorted out with the provided jumper or a wire 4 Modes and Behaviour 4 3 6 Low Pressure Input Continued CHART 1 LOW PRESSURE RESTART DISABLED CHART 1 EVENTS Pressure contact closed EVENT Q 0 69 System already running with Low o9 Low Pressure contact opens timer begins counting down LOW PRS CONTACT CLOSED Timer expires system shuts down RUNNING SHUTDOWN Low Pressure contact closes sys tem does not restart automatically CHART 2 LOW PRESSURE RESTART ENABLED CHART 2 EVENTS EVENT Q o O System already running with Low ii Pressure contact closed Low Pressure contact opens timer begins counting down LOW PRS CONTACT CLOSED Timer expires system waits for Low Pressure contact to close RUNNING RUNNING Q Low Pressure contact closes sys tem starts running again 4 Modes and Behaviour 4 3 7 High Pressure Input The High Pressure Input Contact is used to monitor fuel train pressure when excess fuel pressure may result in damage to the pilot nozzle or otherwise cause improper operation A high pressure switch is installed on the fuel train and then connected to the High Pressure Input Contact on the
25. installed Recommended Settings SETTING USER SETTING Process Control Process TC AuxTemp Mode Display Only THERMOCOUPLE LOCATION Process High Temp Bath Aux Inlet 4 Modes and Behaviour 5 Troubleshooting This section of the manual is designed to aid you in troubleshooting the PF2100 It begins with a list of Common Issues and Solu tions Following this are reference tables containing Shutdown Messages Alarm Codes and Warning Messages This section concludes with a pair of step by step guides for troubleshooting issues with Flame Detection and thermocouples If you are having trouble with your PF2100 System please consult the following resources in this order Consult this section for solutions to see if one matches your needs Consult the support section of our website at www profireenergy com Contact us on our support line at 1 855 PRO FIRE 776 3473 5 1 Common Issues amp Solutions The following list of issues is organized alphabetically by topic Under each issue is a list of possible solutions EXPANSION CARDS b Check that the flame detection wiring does not exceed the recommended maximum length 1 CannotWrite Setpoints via Modbus Check that the wire is securely connected as per the a Check that the system has the latest firmware appropriate wiring diagram Firmware older than v1 8 005 did not support this feature d Check that the ground connection between
26. its entirety and follow these instructions closely STEPS 1 Review Installation Warnings Choose a Mounting Location Mount the System Get Familiar with the Terminal Card gu a Connect the Required Wiring including Power Valves Thermocouples and Ignition Coil Flame Detection wiring 6 Connect the Optional Wiring including Status Contact Dry Contact Inputs 4 20mA Temperature Output and Expansion Cards At the end of this section is a table for looking up information about specific terminals and circuits Keep in mind that the PF2100 is a versatile system which can be used in many different applications As such it is important to know the application for which you are installing the system before you begin your work The steps provided here are general and will help you to identify questions that need to be answered to complete the installation properly To know which options are required you should consult the engineer or technician who designed the site You should also consult your local electrical and gas code Profire also offers a number of Application Guides for installing the PF2100 in various application and jurisdictions These include rec ommended fuel trains bill of materials system settings and P amp ID diagrams These can be found on our website or you can contact a member of the Profire Sales team to discuss your application further 2 Installation 2 1 Installation Warnings Before installing the
27. long the PF2100 may not be able to deliver enough energy to the ignition rod to ignite the pilot or it may not receive enough signal from the flame rod to be able to detect flame Generally lon and lon must each be less than 8m 25 when using 16AWG wire If 7mm diameter ignition wire is used for lon this distance can be increased to 15m 507 In addition the 7mm diameter ignition wire from the coil s High Voltage Output terminal to the Ignition Rod must be less than 5m 15 GROUNDING Properly grounding the pilot assembly back to the PF2100 is critical for proper ignition and flame detection This can be accomplished in many ways It should be noted that the lon COM and EGND terminals on the PF2100 Terminal Card are all the same electrically Often times the pilot assembly is grounded back to the PF2100 through the mechanical connection of the pilot to the piping to the burner housing and then to earth ground which is in turn connected to the PF2100 EGND terminal If it is not connected in this manner a ground wire should be run from the lon terminal of the PF2100 to the burner housing or even directly to a screw on the pilot assembly To check the grounding disconnect the power from the system and use a multimeter to measure the continuity from the pilot assembly to the PF2100 lon terminal 2 Installation ROD POSITIONING Rod positioning must also be carefully considered to ensure proper ignition and flame detection The
28. open See sections 3 4 9 Process Control Settings Temp ESD In this mode the Aux Temp signal is used as an auxiliary ESD input In addition to the normal process control algorithm if the Aux Temp signal ever rises above the Aux Setpoint the system will shut down 3 User Interface amp Settings 3 4 5 Commissioning Settings The date and location of commissioning can be stored in the PF2100 This information is optional and is purely for the customer s use These two settings can be viewed in menu 3 and edited in menu 4 COMMISSION DATE MENU 4 This is the date on which the PF2100 was commissioned Use the Up and Down keys to edit the date and OK to advance to the next date field COMMISSION LOCATION MENU 4 This is the location where the PF2100 was installed Use the Up and Down keys to edit each character and OK to advance to the next character 3 4 6 Display Settings There are two settings that affect the behavior of the display Display Sleep and Temperature Display Units DISPLAY SLEEP MENU 4 When enabled the display will turn off to conserve power after 10 minutes of inactivity no user key presses Otherwise the display will always remain on TEMPERATURE DISPLAY UNITS MENU 4 The PF2100 always operates in Celsius This includes storage of temperature setpoints thermocouple measurements temperature calculations and modbus communications This setting only affects the temperature units on the display T
29. starts it will ignore this input It will light the pilot and open the main valve as it normally would If the High Pressure Contact remains open 2s after the mains are turned on the system will then shutdown This 2s delay is to relieve any pressure that might have built up in the fuel train as a result of regulator leak age Any time the main valves are open the system will shutdown if the High Pressure Contact opens and remains open for 2s See section 2 75 4 20mA Expansion Card section for details 2 72 Dry Contact Inputs Continued LOW PRESSURE CONTACT The Low Pressure Contact can be connected to a Low Pressure Switch installed in the fuel train Typically this switch is placed imme diately before the Main valve in the fuel train The Low Pressure Contact is time averaged to help reject brief fluctuations in gas pressure The contact must be open continuously for 2 or 6 seconds depending on the Pressure Level Delay setting before the system will shutdown If Auto Restart is enabled the system will restart automatically when the Low Pressure Contact recloses See section 2 75 4 20mA Expansion Card section for details LEVEL CONTACT The Level Contact can be connected to a Level Switch installed right above the fire tube This is used to signal when the tank level drops below a certain minimum This is often the point at which the fluid in the tank is no longer covering the fire tube Running the burner with an empt
30. waiting state as opposed to shutting down Note that these delays only apply to the contacts opening and the 4 20mA signals dropping below their respective low setpoints The system does not have a delayed response to the contacts closing or rising above their 4 20mA low setpoints There is also no delay applied to rising above or falling below the 4 20mA high setpoints This setting can be set to either enabled or disabled When disabled there is a small delay When enabled the delay is lengthened There are separate delays for Pressure and Level The following table lists the delays used in all cases SETTING LOW PRESSURE DELAY LEVEL DELAY Enabled 6s 20s Disabled 2s 2s 3 User Interface amp Settings 3 4 14 Valve Modulation Settings The Pilot and Main Valve outputs can be modulated with a pulsed DC signal to conserve power through a technique known as Pulse Width Modulation PWM The duty cycle of the modulation can be adjusted independently for each valve Each can be set to 10096 8096 6096 4096 or 2096 The 10096 setting applies continuous DC voltage ie no modulation to the valve and is the highest power option The 2096 setting applies DC voltage only 2096 of the time and is the lowest power option Only valves that are compatible with modulation should be used with a duty cycle less than 10096 These valves are sometimes called Low Power or Peak and Hold valves since they require only short periodic voltage pulses to hold
31. when the PF2100 is gt 5m 15ft from the burner and you want to save cost by using a single rod WIRING STEPS 1 Connect the Pilot Assembly ground screw to the PF2100 s lon terminal using a 16 AWG or thicker ground wire Connect the lon terminal on the External Coil to the lon termi nal on the PF2100 It is recommended to use 7mm Ignition Wire but 16 AWG may be acceptable for shorted runs Connect the Coil terminal on the External Coil to the Coil terminal on the PF2100 using 16 AWG or thicker wire Connect the Coil terminal on the External Coil to the Coil termi nal on the PF2100 using 16 AWG or thicker wire Connect the single Kanthal Rod to the free High Voltage termi nal on the External Coil Use the included 90 degree Bakelite Connector to ensure that the connection is robust 7mm Ignition Wire must be used Use a 90 Bakelite connector and 7mm lgnition Wire to connect the other High Voltage terminal on the External Coil to the lon terminal on the coil base plate Adjust the Kanthal Rod positioning bend it if necessary so that 2 to 3 of the rod will be inside the pilot flame and so that there is a 1 8 to 1 4 gap between the rod and the front of the pilot nozzle 2 Installation MAX WIRE LENGTHS ION 8m 25ft if using 16AWG Wire 15m 50ft if using 7mm Ignition Wire Ignition Rod Wire 5m 15ft must use 7mm Ignition Wire 2 7 Optional Wiring The wiring in this section of the document is o
32. 20 Input Card s Level Input is reading a value below the 4 20 Level Low Setpoint and Level Event Restart is set to Off 4 20Prs The 4 20 Input Card s Pressure Input is reading a value below the 4 20 Pressure Low Setpoint and Auto Restart is set to Off AuxTC The system is in a mode that requires the Aux Thermocouple and the Aux Thermocouple is open or otherwise wired incorrectly DC TC The TC430 temperature sensor on the Door Card is not responding ro noc cm M p e EX LII n r Wc o aa adana kag D asa aga mi Dite I i ros r um ys r T mc au MM R LowPrs The Low Pressure Contact is Open or the 4 20mA Expansion Card s Pressure Input is reading a value below the 4 20 Pressure Low Setpoint In either case Auto Restart is set to Off The Low Level Contact is Open or the 4 20mA Expansion Card s Level Input is reading a value below the 4 20 Level Low Setpoint In either case Level Event Restart is set to Off busErr e Modbus Card is not responding This may indicate that it is not installed correctly or that it is enabled when not present at all
33. 5 Troubleshooting 5 3 Alarm Codes Continued ON SCREEN DESCRIPTION ProcTC 5 4 Warning Messages The Process Thermocouple is open or otherwise wired incorrectly System Error The Terminal Card is not communicating with the Door Card This may indicate a faulty ribbon cable or incompatible firmware he High Temp and Process Thermocouples are reading temperatures that are too far apart This may indicate a failed thermocouple improper wiring or a damaged Door or Terminal Card The Door and Terminal Card s setpoints do not match The following is a list of warning messages that may flash periodically on the PF2100 display These messages indicate a problem that may be developing or a condition from which the system may automatically restart once cleared Use the table below to determine the meaning of these messages ON SCREEN DESCRIPTION Check all settings Other settings have changed Low Temp Alarm 5 Troubleshooting A major process control setting was changed and the process control setpoints were reset to factory defaults This includes the High Temp ESD Setpoint the Pilot Off Setpoint the Low Fire Setpoint the Process Setpoint the Low Temp Alarm Setpoint the Deadband setting and the Aux Setpoint The High Pressure Contact is open or the 4 20 Pressure Input is above the 4 20 Pressure High Setpoint Shortly after the main valve opens the contact must be closed and the 4 20 Pressure must b
34. 6 Press the Main Key to open the Main Valve The system will count down the Pilot to Main Delay and then open the Main Valve if the Process Temperature warrants it 7 From this point on the system s process control algorithm will take over to turn the valves on and off as required by the sys tem s settings and the current Process Temperature 8 Press the Mode Key to switch the system fully into Auto Mode which will allow the system to automatically restart from faults specified in the system settings AUTOMATICALLY WHEN POWER IS APPLIED If the Auto Restart feature is enabled the system will attempt to Automatically Start after a power failure This will only succeed if all alarms are clear 3 User Interface amp Settings 3 5 1 Starting the System Continued REMOTELY VIA THE START CONTACT This method can be used to start the system from a remote switch mounted elsewhere on the site or via a PLC output contact The steps to do this are as follows 1 Open the Start Contact and then close it again to acknowledge any Shutdown Message that may be showing on the display If no Shutdown Message is present it is not required to do this but it will still work if you do Repeat the step above once to remotely start the system in Auto Mode This will only work if all alarms are clear REMOTELY VIA THE MODBUS CARD IF INSTALLED This method can be used to start the system via a remote device over a Modbus RTU network The s
35. IGH ON START BUT CLEARS WHEN MAIN OPENS 9 EVENT 4 20 PRESSURE 20mA PRESSURE HIGH SP PRESSURE LOW SP 4mA PILOT DELAY 4 Modes and Behaviour o CHART 2 EVENTS 1 System started by user with pres sure above high setpoint Main turns on and timer starts counting down 2s The timer expires and the pressure signal does not drop below the high setpoint The system shuts down CHART 3 EVENTS 1 System started by user with pressure above high setpoint due to a slow leak in the regulator Pressure begins to drop slowly through pilot valve Main valve opens and pressure begins to drop faster through main valves The pressure drops below the high setpoint within 2s of the main valves opening and the system continues running 4 4 2 4 20 Pressure Input Continued CHART 4 AUTO RESTART ENABLED CHART 4 EVENTS EVENT Q 600 System already running with a pressure between High and Low setpoints o9 Hand valve on fuel train closed Pressure begins to drop 4 20 PRESSURE Pressure falls below the low set point Delay timer starts counting i a down max valve depends on the Bc Level Pressure Delay setting Q Delay timer expires and burner RUNNING WAITING ON PRESSURE RUNNING turns off System state is now Waiting on Pressure Hand valve is opened and pressure increases quickly Q Pressure rises above low setpoint and sy
36. PF2100 If the fuel pressure increases above the switch s mechanically set pressure setting the switch opens and the PF2100 will close all valves and stop running The system always shuts down from a High Pressure Event and cannot be programmed to automatically restart if the event clears The system can be started when the High Pressure Contact is open This is to allow for easy recovery from the common issue of leaky regulators If the regulator upstream from the high pressure switch is leaky it can allow pressure to accumulate at the switch s position over time while the system is not running Since there is no way to relieve this pressure other than to open a downstream valve the system must be allowed to start running under this condition So the system will start light the pilot and open the main valve to allow the built up pressure to be relieved If the pressure does not drop low enough to close the High Pressure Contact within 2s after the main valve has been opened the system will shutdown Otherwise it will continue running The response to the contact opening is always immediate and cannot be configured If this contact is not needed it must be shorted out with the provided jumper or a wire 4 Modes and Behaviour 4 3 7 High Pressure Input Continued CHART 1 HIGH PRESSURE CONTACT OPENS WHILE RUNNING EVENT Q HIGH PRS CONTACT PILOT DELAY SHUTDOWN CHART 2 HIGH PRESSURE CONTACT OPEN ON START DOES NO
37. PF2100 USER MANUAL 12 BURNER MANAGEMENT SYSTEM e WARNINGS HW amp FW VERSIONING THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS 1 DIVISION 2 This version of the manual was written for use with PF2100 GROUPS ABCD OR NON HAZARDOUS LOCATIONS ONLY systems that have the following hardware and firmware versions DO NOT DISCONNECT WHILE CIRCUIT IS LIVE UNLESS AREA IS KNOWN TO BE NON HAZARDOUS OR EQUIVALENT E ER zio MEN Terminal Card v1 7 E1 8 101 Minh sp dete GA M memes T SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY CLASS 1 DIVISION 2 Modbus Card v2 0 v4 0 v4 1 DO NOT SERVICE UNLESS AREA IS KNOWN TO BE NON HAZARDOUS System hardware and firmware versions can be found printed on separate labels inside of the enclosure on each circuit board DO NOT OPEN WHEN ENERGIZED Sections 1 5 2 4 INSTALLATION amp USE MUST CONFORM TO THE DIRECTIONS IN THIS MANUAL Please refer to the Profire Energy Inc website for the latest documentation SYSTEM MUST BE PROPERLY CONNECTED TO EARTH GROUND FOR EFFECTIVE OPERATION OF FLAME DETECTION CIRCUITRY APPROVALS ELECTRICAL DEVICES CONNECTED TO THE CONTROLLER MUST MEET CSA 22 2 No 199 2007 CSA C22 2 No 0 M91 CERTAIN ELECTRICAL STANDARDS AND BE WITHIN VOLTAGE LIMITS ANSI 721 20 2007 CSA C22 2 No 0 4 04 REPLACEMENT FUSES MUST BE CERAMIC AND OF CORRECT RATING 19952004 22 2 142 1987 Class 1 Div 2 CSA C22 2 No
38. RIAL VERSION LABEL 4 20mA OUTPUT IGNITION TERMINALS FLAME DETECTION TERMINAL POWER TERMINALS FW VERSION LABEL STATUS CONTACT FUSE STATUS CONTACT OUTPUT THERMOCOUPLE INPUTS MISC DRY CONTACT INPUTS VALVE OUTPUTS PRESSURE DRY CONTACT INPUTS Low Fire Low Fire Pilot Pilot LEVEL DRY CONTACT INPUT 2 Installation 2 5 Terminal Descriptions This table provides a brief description of each terminal and references to further detail TERMINAL EXPECTED CONNECTIONS DESCRIPTION SECTION 12 24VDC Input power from a DC source Input power 10VDC 28VDC 5A MAX 2 6 1 Common Ground back to DC source Internally connected to EGND 2 6 1 S EEE E E EE WHERE RUE SIE HI IU teat 4 20mA Proportional Valve positive terminal This output can be used for either Proportional Valve Control or echoing 2 6 2 2 73 or PLC 4 20mA positive input the Process Temperature to a PLC A resistance of 1200 to 2500 is expected HighTemp TC igh Temp Thermocouple positive A TYPE K thermocouple must be connected between 2 63 YELLOW ead the and terminals and must not be electrically ESSERE NNI ENSE ENDIE AES SERE SN VENUE NA KANEA TAA connected to ground HighTemp TC igh Temp Thermocouple negative RED ead An uninterrupted connection using TYPE K thermocouple wire is required for an accurate reading
39. S CONTROL 5s Flame START 4 Modes and Behaviour 4 2 Process Control Behaviour This section illustrates the behaviour of the process control algorithm in response to real world situations 4 2 1 Basic Process Control In this scenario the Low Fire Pilot Off and Low Temp Alarm features are disabled This results CHART EVENTS in the most basic Process Control configuration If the Process Temperature exceeds the falls System is started Pilot Valve Process Setpoint the main valve closes until the temperature a s below the Process Setpoint opens Proc Temp beings to in minus the Deadband setting This setup fires the main fully until the thermocouple reading crease slowly exceeds the Process Setpoint Pilot to Main Delay elapses Main Valve opens Proc Temp increases faster CHART EVENT Proc Temp exceeds Process Set point Main Valve closes Proc Temp HIGH TEMP ESD SP begins to drop Q Proc Temp drops below Process Setpoint minus Deadband Main Valve opens Proc Temp begins to increase again PROCESS SP B S amp 4 Modes and Behaviour 4 22 Low Fire On at Proc Setpoint This scenario is the same as the basic scenario except that the Low Fire feature has now been CHART EVENTS enabled It has been set to turn on at the Process Setpoint In this case the Low Fire Valve will close when it exceeds the Low Fire Setpoint but will not reopen until it
40. T 1 LEVEL EVENT RESTART DISABLED CHART 1 EVENTS EVENT Q 0 69 System already running with Level Contact closed Level Contact opens timer begins counting down LEVEL CONTACT CLOSED Timer expires System shuts down RUNNING SHUTDOWN Level Contact closes system does not restart automatically CHART 2 LEVEL EVENT RESTART ENABLED CHART 2 EVENTS EVENT Q System already running with Level a Contact closed Level Contact opens timer begins counting down LEVEL CONTACT CLOSED M Timer expires System waits for Level to close RUNNING RUNNING o Level Contact closes system starts running again 4 Modes and Behaviour 4 3 6 Low Pressure Input The Low Pressure Input is used to monitor fuel train pressure Insufficient fuel pressure may result in the flame burning back into the fuel train causing damage or improper operation A low pressure switch is installed on the fuel train and then connected to the Low Pressure Input Contact on the PF2100 If the fuel pressure drops below the switch s mechanically set pressure setting the switch opens and the PF2100 will close all valves and stop running The system can be setup to begin running again automatically after the pressure returns above the switch s pressure setting This is done by enabling the Auto Restart feature in Menu 4 The response to the contact opening is delayed by 2s to reject
41. T CLOSE EVENT Q HIGH PRS CONTACT PILOT DELAY MAIN SHUTDOWN CHART 1 EVENTS 1 System started by user with High Pressure Contact closed High Pressure Contact opens while the system is running with the mains open and starts counting down 2s Timer expires with High Pressure Contact still open system shuts down CHART 2 EVENTS 1 System started by user with High Pressure Contact open Main valve opens and timer starts counting down 2s Timer expires High Pressure Contact still open and the system shuts down 4 Modes and Behaviour 4 3 7 High Pressure Input Continued CHART 3 HIGH PRESSURE CONTACT OPEN ON START DOES CLOSE CHART 3 EVENTS o System started by user with High EVENT Q Pressure Contact open OPEN Main Valve opens and timer starts counting down 2s HIGH PRS CONTACT CLOSED i 3 High Pressure Contact closes with MN ee MMC in 2s of the main valves opening and the system continues to run PILOT DELAY 4 Modes and Behaviour 4 4 4 20mA Expansion Card Behaviour The 4 20mA Expansion Card provides an alternate method of monitoring tank level and fuel train pressure This is via 4 20mA loop transmitters These devices can be used in place of the switches attached to the level and pressure contacts on the PF2100 Using transmitters allows actual measurements of the level and pressure to be shown on the PF2100 s disp
42. TION Cal Process TC Zero al Proc TC alibrate Process Thermocouple zero 3 5 8 ae Dunt by shorting the Input Cal High Temp TC Zero Cal HiTemp TC Calibrate High Temp Thermocouple zero N A N A 958 Zero point by shorting the Input Cal Aux TC Zero Cal AUXTC Calibrate Aux Thermocouple zero point N A N A 3 5 8 Zero by shorting the Input Cal Process TC Span Cal Proc TC Calibrate Process Thermocouple span N A N A 8 58 Span xxC point by applying a calibrated reference then adjust the on screen value Cal High Temp TC Span Cal HiTemp TC Calibrate High Temp Thermocouple N A N A 91518 Span xxC span point by applying a calibrated ref erence then adjust the on screen value Cal Aux TC Span Cal AUX TC Calibrate Aux Thermocouple span point N A JA 95S Span xxC by applying a calibrated reference then adjust the on screen value Cal 4 20 Level Zero Calibrate 4 20 Calibrate 4 20mA Level Input zero point N A JA 3 58 LVL Zero by applying a calibrated 4mA reference Cal 4 20 Level Span Calibrate 4 20 Calibrate 4 20mA Level Input span N A 3 5 8 LVL Span point by applying a calibrated 20mA reference Cal 4 20 Pressure Zero Calibrate 4 20 Calibrate 4 20mA Pressure Input zero N A JA 3 58 PRS Zero point by applying a calibrated 4mA reference Cal 4 20 Pressure Span Calibrate 4 20 Calibrate 4 20mA Pressure Input span N A JA 3 5 8 PRS Span point by applying a calibrated 20mA reference Cal 4 20 Out Zero Cal 4 20 Out Calibrat
43. VENT Low to High Fire Delay elapses High Fire Valve opens Proc Temp increases even faster PILOT OFF SP The Proc Temp exceeds the Pilot Off Setpoint the Pilot Valve closes the Proc Temp begins to decrease PROCESS a B S amp o The Proc Temp drops below the Process Setpoint minus Deadband the pilot relights the Proc Temp begins to increase again The Pilot to Main Delay elapses the Main Valve opens and the Proc Temp begins to increase faster 4 Modes and Behaviour 4 2 5 Proportional Valve Control In this scenario a Proportional Valve is connected to the 4 20mA Output This is used as a second Main Valve downstream from a traditional safety solenoid valve connected to the Main Valve output Proportional Valve Control is always used with the Low Fire set to On at Proc Setpoint In this mode both the Process and Low Fire Setpoints are enabled If the temperature is below the Process Setpoint the 4 20 mA output slowly ramps up opening the control valve When the temperature exceeds the Process Setpoint but is below the Low Fire Setpoint the 4 20mA output decreases closing the Proportional Valve The burner should stabilize at the Process Setpoint The ringing swing on the graph is caused by the balancing of temperature throughout the bath CHART 9000 9 090090 LOWFIRESP PROCESSSP n E E e a 4 20 LEVEL LOW FIRE SETTING AmA 4
44. alve is open when the main turns on can also be specified In addition the speed at which adjustments are made can be adjusted to mitigate undershoot and overshoot This feature is always used with a traditional safety solenoid valve connected to the PF2100 s Main Valve output In addition the Low Fire setting must also be enabled by setting it to On at Proc Setpoint 4 20 LOW FIRE SETTING MENU 5 This setting is only available when the 4 20 Output Mode is set to Valve Control It is used to specify the minimum amount that the proportional valve will ever be open This is therefore also the starting position of the main valve each time it is turned on This can be set to any value from 096 to 7096 4 20 GAIN SETTING MENU 5 This setting is only available when the 4 20 Output Mode is set to Valve Control It is used to specify the speed at which valve adjust ments are made It can be set to any value from 0 1 s to 1 096 s 3 User Interface amp Settings 3 4 3 Alarm Status Contact Settings The Status Contact will always open if the system is shut down due to an alarm condition There are two settings that affect the behaviour of the Status Contact Alarm Mode and Low Temp Alarm Setpoint ALARM MODE MENU 4 The Alarm Mode is used to select whether the Status Contact will open when the unit is stopped remotely via the Start Contact It can be set to either of the following two values Alarm When Off In this case the St
45. ance from high voltage lines and shielded when necessary PROCESS THERMOCOUPLE This thermocouple is normally used on the primary temperature control device The system will shutdown if an open circuit is detected on this thermocouple It should be placed in the same thermowell as High Temperature Thermocouple This is com monly accomplished by using a dual element thermocouple HIGH TEMPERATURE THERMOCOUPLE This thermocouple is used for the high temp shutdown The system will shutdown if an open circuit short circuit or short to ground is detected on this thermocouple It should be placed in the same thermowell as Process Thermocouple This is com monly accomplished by using a dual element thermocouple AUX THERMOCOUPLE This thermocouple is optional and can be enabled in menu 5 It can be used to monitor stack temperature or to control a secondary process temperature System will shutdown if an open circuit is detected and AUX Thermocouple is enabled 2 Installation 2 6 4 Ignition Coil Flame Detection There are numerous ways to wire the ignition and flame detection circuits correctly but there are also a number of things that must be carefully considered before choosing an approach The sections after this one contain recommended instructions for wire vari ous configurations WIRE LENGTHS AND TYPE When wiring the ignition and flame detection circuits wire length must be carefully considered If the wire lengths are too
46. and to adjust some setpoint values REMOTE SETPOINT ADJUSTMENT This card can be used to remotely adjust some setpoints such as High Fire Low Fire and Pilot Off setpoints Refer to the Modbus Expansion Card Manual for further details on installation and operation of this card 2 Installation MODBUS EXPANSION CARD Some PF2100 models come with this card pre installed 2 7 5 4 20mA Expansion Card An optional 4 20mA Expansion Card can be installed in the PF2100 which provides two 4 20mA inputs as well as a pair of complementary dry contact outputs 4 20mA FUEL TRAIN PRESSURE MEASUREMENT This card can be used as an alternative to the High and Low Pressure Contacts which are built into the PF2100 This input can be wired to a 4 20mA Pressure Transmitter to obtain an actual reading of the fuel train pressure The transmitter range and units can be set along with low and high pressure thresholds The reading can be displayed on the PF2100 display or read remotely via Modbus if the optional Modbus Expansion Card is also installed 4 20mA TANK LEVEL MEASUREMENT This can be used as an alternative to the Level Contact which is built into the PF2100 This input can be wired to a 4 20mA Level Transmitter to obtain an actual reading of the tank level The transmitter range and units can be set along with low and high level thresholds The reading can be displayed on the PF2100 display or read remotely via Modbus if the optional Modb
47. attach to the PF2100 are not designed to accept both 12VDC and 24VDC They typically only work with one or the other If the valve voltage ratings are exceeded the valves may become damaged SYSTEM VOLTAGE SETTING MENU 4 The following options are available The purpose of this setting is to select voltage limits to protect and ensure the proper operation of the attached valves If the PF2100 VOLTAGE SETTING CHOOSE THIS OPTION WHEN detects that the input voltage is getting close to these limits it will 12V The Power Supply and all valves are 12VDC present a warning message on the display If the voltage exceeds 24V The Power Supply and all valves are 24VDC these limits it will shut down which cuts power to the valves to pre vent them from being damaged The exact limits used are shown in the following table Note that the high voltage limits also depend on the Pilot Valve Power Set ting and Main Valve Power Setting which can also be found in Menu 4 VOLTAGE SETTING PILOT MAIN VALVE PWM SETTING LOW VOLT ALARM LOW VOLT WARNING HIGH VOLT WARNING HIGH VOLT ALARM 12V At least one equal to 10096 lt 8 4V lt 9 9V gt 14 6V gt 15 6V ES EN PR MM E rite ee ert cip i enit E P _ E EY eet ere yv pnis B Dicen E 22 D Logan dud SH eave x EE Note that if the system has the Auto Restart
48. atus Contact will open when the unit is stopped turned off remotely via the Start Contact No Alarm When Off In this case the Status Contact will remain closed when the unit is stopped turned off remotely via the Start Contact LOW TEMP ALARM SETPOINT MENU 1 When enabled the Status Contact will remain open until the Process Temperature exceeds this setpoint See section 3 4 10 Process Set points for more detail 3 User Interface amp Settings 3 4 4 Auxiliary Temperature Settings There are two settings that affect the way that the Auxiliary Temperature signal is used by the system Process Control and Aux Temp Mode PROCESS CONTROL MENU 5 This setting is used to select the thermocouple input that is associ ated with the Auxiliary Temperature signal See section 3 4 9 Process Control Settings for more details AUX TEMP MODE MENU 5 Aux Temp mode can be set to any of the following Disabled The Aux Temp signal is ignored by the system Display Only The Aux Temp signal is only used for display purposes It can be read on the PF2100 display in manual mode via the Review Menu It can also be read remotely via the Modbus Expansion Card if it is installed and enabled Temp Main Ctl In this mode the Aux Temp signal is used as a secondary Process Control input This modifies the normal Process Control algorithm by adding the additional requirement that the signal be below the Aux Setpoint for the Main Valve s to
49. be set to Disabled In this case the Process Control Algorithm was disabled and the system would ensure the burner was always lit and running This was useful when it was desired to have an external device such as a PLC controlling the process In this scenario the PLC would turn the system on and off using the Start contacts This behaviour can still be achieved by simply setting all Process Setpoints to maximum 3 User Interface amp Settings LOW FIRE ENABLE MENU 5 This setting is used to enable disable use of the Low Fire Setpoint in the Primary Process Control Algorithm Low Fire can be enabled in two different modes On at Proc Setpoint and On at Low Fire Setpoint In the first case the Low Fire Valve will close when it ex ceeds the Low Fire Setpoint but will not reopen until it drops below the Process Setpoint minus Deadband In the second case the Low Fire Valve will close when it exceeds the Low Fire Setpoint and will reopen after it drops below the Low Fire Setpoint minus Deadband PILOT OFF ENABLE MENU 5 This setting is used to enable disable use of the Pilot Off Setpoint in the Primary Process Control Algorithm AUX TEMP MODE MENU 5 When this setting is set to Temp Main Ctl the Auxiliary Process Control Algorithm is enabled See section 3 4 4 Auxiliary Temperature Settings for more details 3 4 10 Process Setpoints There are seven Process Setpoints in total four of which may be disabled
50. before this feature can be used If the Pilot Off and or Low Fire Setpoints are enabled this feature will also adjust them In this case each press of the up or down key will adjust all of these setpoints by 1 degree up or down All other setpoints are not affected by this feature 3 2 5 System Menus The System Menus store all of the system settings in an organized fashion These menus are also used to show historical and system status information as well as to provide access to calibration features These menus cannot be accessed while the system is running in Auto Mode Some menus can only be accessed while the system is stopped Some menus require a Level 2 password and others require an optional Level 1 password 3 2 6 Review Menu The Review Menu provides a quick way for an operator to check key setpoints and system status accessible only in Manual Mode 3 2 7 Firmware Version Screen The Firmware Version Screen shows the firmware version of all cards in the system including the Door Card Terminal Card and any installed Expansion Cards 3 User Interface amp Settings 3 2 8 Warning Messages When the system detects a warning condition it will flash a warning message across the bottom line of the Home Screen Some messages can be dismissed by pressing the OK key eg Unit restarted from LVL event Others persist until the warning condi tion is resolved eg LO Volt Warning 3 2 9 Shutdown Screen When the system shuts dow
51. cation factor internal to the system Press OK and the message Parameter Saved will show on the display briefly Press the Menu Key to go to the next item Repeat steps 14 16 for the Cal HiTemp TC Span and Cal Aux TC Span menu items Press and hold the OK key for 3 seconds until the message Password Logout is displayed on the screen The Calibration Menu is now hidden again 3 User Interface amp Settings 3 5 8 Field Calibration Continued CALIBRATING THE 4 20MA OUTPUT For the 4 20mA Output the first calibration point is 4mA and the second calibration point is 20mA You will need a current meter capable of measuring current to 0 1 accuracy The calibration procedure is as follows 1 2 Ensure that the system is stopped Connect a current meter in series with the 4 20mA Output Set the current meter to a range setting that covers both 4mA and 20mA Press the UP and Down Keys simultaneously to unlock the Cali bration Menu Menu 7 which is normally hidden Press the Menu Key repeatedly until Menu 7 is shown Press OK enter the L2 Password if prompted A V A A V A ok Press the Menu Key repeatedly until Cal 4 20 Out Zero is shown on the display Use the Up and Down Keys to adjust the output current until the current meter reads 4 0mA Press OK and the message Parameter Saved will show on the display briefly 3 User Interface amp Settings 10 11 12 13 P
52. contains various optional system settings It cannot be accessed while the PF2100 is running MENUMAP ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING SECTION Auto Restart Auto Enables system to restart from a power On Off Restart failure low pressure or high voltage event Purge Time Purge Time Adjusts the time from all valves closed 10 900 sec 30 sec 3413 to Pilot relight attempts Pilot to Main Delay Pilot to Main Adjusts the time from Pilot proven to 5 600 sec 15 sec GAS Delay Main Valve opening Restart Attempts Restart Adjusts the number of Restart At 0 3 3 Sure Attempts tempts after an unexpected flame failure before a shutdown 3 User Interface amp Settings 3 3 4 System Setup MENU 4 Continued MENUMPP ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING SECTION Enables recovery from a Low Level event Level Event Restart Level Event Restart Pressure Level Delay PRS LVL Delay Alarm Mode Alarm Mode Adjusts the behaviour of Status Contact relative to Start Contact Pilot Solenoid PWM Main Solenoid PWM System Voltage Setting System Voltage Temperature Display Units Temp Units Restore Factory Defaults Reset to Factory Defaults Configures the expected input voltage for the system Configures the temperature units displayed by the system he date that the system was commissioned he install location of the system 14 Characters Max Restore all settin
53. current of 4mA 0 Press the OK key and the message Calibrating Wait will appear for several seconds followed by the message Parameter Set after the calibration has successfully completed 10 Calibrate the Pressure Input s Span point a Press the Menu Key repeatedly until Calibrate 4 20 PRS Span is shown on the display Use the Up or Down key to select Yes and begin the calibration process The display will now read Apply 20mA then press Set the process calibrator to source a current of 20mA 10096 Press the OK key and the message Calibrating Wait will appear for several seconds followed by the message Parameter Set after the calibration has successfully completed Disconnect the process calibrator from the Pressure input and reconnect any wiring that was removed from it previ ously 11 Disconnect the process calibrator s negative lead from the ground pin on the 4 20mA Input Card 3 User Interface amp Settings 3 5 8 Field Calibration Continued RESETTING CALIBRATION DATA If you want to reset the calibration settings to default use the Cal Data option at the end of Menu 7 This process resets the following calibrations to defaults Calibration of the Thermocouples Calibration of the 4 20mA Output e Calibration of the 4 20mA Intput The procedure to do this is as follows 1 2 Ensure that the system is stopped Press the UP and Down Keys simultaneously t
54. d in 1 Line Heater 4 Tank Heater 7 Gas Production Unit 2 Dehyarator 5 Separator 8 Amine Reboiler 3 Combustor 6 Treater 9 Thermal Oxidizer 1 7 Regulatory Requirements The PF2100 is certified for use in Class Division 2 Group ABCD locations Certain modes of operation or wiring options may be against code in some locations or for burners exceeding a certain heat rating Profire makes no assertion as to the suitability of a particular component for a given application It is up to the customer to examine the local codes and safety requirements to determine if the PF2100 and any other associated components sold by Profire are suit able for use in a given application CANADA The PF2100 is designed to meet CSA B149 requirements which are becoming legislated in Canada The regulations are not yet finalized It is expected that compliance of all components of the fuel train will be required including the BMS the solenoids etc In addition field inspection and approval by an accredited inspections group is anticipated to be required USA The PF2100 currently exceeds the requirements for use in the United States Other Consult local codes and safety regulations to determine if the PF2100 can be used in your jurisdiction 1 Overview 2 Installation This section includes the steps that should typically be followed when wiring up a PF2100 system in the field If you are new to the PF2100 you should read this section in
55. ds should only be used as a last resort since normally another less costly solution can be found INTERNAL VS EXTERNAL COIL If less than 5m 15ft of ignition wire are required to connect the PF2100 to the burner housing the internal coil configuration can be used Otherwise the external coil configuration must be used The Internal Coil Configuration refers to an internal coil included inside the PF2100 while the External Coil Configuration refers to a coil not included with the PF2100 and located in a separate enclosure or inside the burner housing SINGLE ROD VS DUAL ROD A single Kanthal rod can be used for both ignition and flame detection to save cost if desired This often results in a performance trade off between ignition and flame detection This option is only available with external coils Using two Kanthal rods one for ignition and one for flame detection allows for greater flexibility in rod placement and often yields better performance WIRING OPTIONS There are three possible ways to wire the ignition coil and flame detection circuit with the PF2100 as illustrated in the table below Wiring instructions and diagrams are provided for each CONFIGURATION COIL TYPE SINGLE ROD DUAL ROD Internal Coil External Coil 2 Installation 2 6 5 Internal Coil Dual Rod Use this configuration when the PF2100 is bm 15ft from the burner and you want greater flexibility for rod placement WIRING STEPS 1 Con
56. e Connect the Kanthal Flame Detection Rod to the PF2100 s lon terminal Use the included Ferrule and Straight Silicone Boot to ensure that the connection is robust It is recommended to use 7mm Ignition Wire but 16 AWG may be acceptable for shorted runs Connect Coil terminal on the External Coil to the Coil terminal on the PF2100 using 16 AWG or thicker wire Connect Coil terminal on the External Coil to the Coil terminal on the PF2100 using 16 AWG or thicker wire Connect the Kanthal Ignition Rod to the free High Voltage terminal on the External Coil Use the included 90 degree Bakelite Connector to ensure that the connection is robust 7mm Ignition Wire must be used Connect the other High Voltage terminal on the External Coil to one of the mounting screws on another 90 degree Bakelite Connector and 7mm lgnition Wire Using a multimeter verify that the coil base plate and the Pilot Assembly are both securely connected to earth ground If not you may need to run a ground wire between them Adjust the Flame Rod positioning bend it if necessary so that 2 to 3 of the rod will be inside the pilot flame Adjust the Ignition Rod positioning bend it if necessary so that there is a 1 8 to 1 4 gap between the rod and the front of the pilot nozzle MAX WIRE LENGTHS ION 8m 25ft if using 16AWG Wire 15m if using 7mm Ignition Wire 2 Installation 2 6 7 External Coil Single Rod Use this configuration
57. e monitoring In addition to being an extremely useful tool it improves safety by preventing the flame from being lit under unsafe conditions 1 1 Available Models The PF2100 is available in two configurations BASE MODEL and INTERNAL COIL MODEL The Base Model is for use with externally mounted ignition coils This is useful when the controller must be mounted more than bm 15ft away from the burner An external ignition coil can be purchased separately from Profire for use with this model The Internal Coil model includes a built in ignition coil and can be used whenever the controller can be mounted less than 5m 15ft away from the burner Both of these models can be further enhanced by adding one of two optional expansion cards 4 20mA Expansion Card 1PS166 Modbus Expansion Card 1PS167 BASE MODELS E0000 Base Model E0400 Base Model with 4 20mA Expansion Card EOMOO Base Model with Modbus Expansion Card E04MO Base Model with 4 20mA Expansion Card and Modbus Expansion Card INTERNAL COIL MODELS ECOOO0 Internal Coil Model 400 Internal Coil Model with 4 20mA Expansion Card ECMOO Internal Coil Model with Modbus Expansion Card EC4M0 Internal Coil Model with 4 20mA Expansion Card and Modbus Expansion Card 1 Overview 1 2 Included Components The PF2100 comes packaged with the following varies across models If any components are missing contact Profire immediately ror s
58. e 4 20mA Output zero point by N A N A 8 578 Zero x adjusting until a multimeter reads 4mA 3 User Interface amp Settings 3 3 7 Calibration MENU 7 Continued MENUMAP O ON SCREEN DESCRIPTION RANGE DEFAULT SETTING SECTION Cal 4 20 Out Span Cal 4 20 Out Span x Calibrate 4 20mA Output zero point by adjusting until a multimeter reads 20mA Thermocouple zero point calibration factors for Debug Thermocouple span point calibration factors for Debug 4 20mA Pressure zero point and span point calibration factors for Debug 4 20mA Level zero point and span point calibration factors for Debug Display TC Zero Factors Cal Factors Zero wxyz Display TC Span Factors Cal Factors Span wxyz Display 4 20 PRS Factors 4 20 PRS Factors Z x S y Display 4 20 LVL Factors 4 20 LVL Factors Z x S y Clear Ca Clear All Cal Capital Data 3 3 8 Review Menu This read only menu allows various commonly needed system settings and status parameters to be reviewed while the system is runni Restore all calibration factors to 0 3 5 8 Ux queso m a ONE Y m e E 25 M ERU a M m 2 Yes No ng MENUMAP ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING SECTION Temp at which system will shutdown Temp at which High Fire Main Valve will turn off Temp at which Low Fire Valve will turn off
59. e Low Temp Alarm or Deadband whichever is larger PROCESS SETPOINT LOW TEMP ALARM 0C DEADBAND PROCESS SETPOINT LOW TEMP ALARM 0C DEADBAND LOW TEMP ALARM SETPOINT MENU 1 If the Process Temperature goes below this setting the Low Temp Alarm will be asserted and the status contact will open This setting can be set to a maximum of the Process Setpoint The minimum value is 1 C Set to 0 C to disable the Low Temp Alarm 3 User Interface amp Settings DEADBAND MENU 1 The deadband setting provides temperature hysteresis below the Process Setpoint For the main valve to open the temperature must be below Process Setpoint minus the deadband setting For the main valve to close the temperature must be above the Process Setpoint The deadband setting also provides provides temperature hysteresis below the Low Fire Setpoint when the Low Fire Enable setting is set to On At Low Fire Setpoint In this case the Low Fire valve will open when the Process Temperature is below the Low Fire Setpoint minus the Deadband setting and will close when it is above the Low Fire Setpoint The deadband setting also provides provides temperature hysteresis below the Aux Setpoint when the Aux Temp Mode setting is set to Temp Main Ctl In this case the main valve s will open when the Auxuliary Temperature is below the Aux Setpoint minus the Deadband setting and will close when it is above the Aux Setpoint This setting
60. e below the setpoint or the system will shutdown The process temperature is below the Low Temp Alarm Setpoint and the Status Contact is Open 5 4 Warning Messages Continued ON SCREEN DESCRIPTION Unit restarted from LVL event The system has recently restarted from a Level event Press OK to clear this message The system has recently restarted from a Low Pressure event Press OK to clear this message The system has recently restarted from a Low or High Voltage event Press OK to clear this message iting HiVolt ng LoVolt ill automatically restart once the Start Contact is closed iting STRT Inp 5 Troubleshooting 5 5 Flame Detection Troubleshooting Guide System is not detecting flame 1 Does the flame quality drop from 10096 Pilot when the main comes on YES Does the system stay running with the flame arrestor open Cr Clean the arrestor and look for other air restrictions 5 Troubleshooting The draft from the main could be pulling the pilot flame away from the flame rod Reposition the flame rod Ensure that the pilot orifice is correct for the gas used 54 for natural gas Ensure that there is a metal on metal connection from the pilot nozzle to the housing and a ground wire from the housing to the 2100 Ensure that the ignition rod is fully immersed in th
61. e difference between the Process and High Temp Thermocouple readings The acceptable difference varies with the HT ESD Setpoint ESD as follows 15C when ESD lt 200C 25C when 200C lt ESD lt 400C 35C when 400C lt ESD lt 800C 45C when 800C lt ESD TERM ERR Communications between the Terminal Card and the Door Card has been Terminal Card Errors interrupted 3 User Interface amp Settings 3 5 6 Viewing Firmware Versions From any point in the User Interface press the Up and Down Keys simultaneously The system will then show four different firm ware versions in sequence CARD CURRENT FW VERSION NOTE Door Card DC FW E1 8 115 puo r A EE Ka uu e PN Modbus Expansion Card MBUS FW v4 1 Will show if not installed or not enabled in Menu 6 The expansion card firmware versions are only shown if the cards are installed and enabled They can also be viewed in menu 6 3 5 7 Resetting to Defaults The system settings can all be reset to factory defaults by following these instructions 1 Ensure that the system is stopped 2 Navigate to the Reset to Factory Defaults menu item at the bottom of Menu 4 3 Use the Arrow Keys to change the setting to Yes and then press the OK Key 4 system will display Parameter Saved and will then reb
62. e flame With the system powered and in idle mode set a Multi Meter to read AC voltage and measure across the ION and ION terminals The voltage will fluctuate a bit due to the flame test Take note of the maximum voltage Is the voltage greater than 25VAC Measure the AC volatage from the flame rod to ground if the rod is accessible If it is not accesible remove the wire from the flame rod and measure on the connector QUESTION ARE IN WHITE RECTANGLES 17 gt lt NO ALWAYS MOVES TO THE RIGHT Remove the wire from ION and measure the AC voltage between the ION and ION terminals again Is the voltage above 35VAC YES Is the wire run length from the burner to the PF2100 longer than 25 29 The length loading the wire is too high Using ignition wire for ION will allow the signal to be run up to 50 Using separate rods for flame detection and ignition can also reduce the ION load by bypassing the coil M 27 YES ALWAYS MOVES DOWN It is possible that the terminal card is faulty Something is loading the signal Ensure that the wire type is not shielded Look for partial ground shorts or nicked wires NO THERE ARE TWO RODS Is the voltage measured at the rod close to the voltage measured across the ION and ION terminals Is the same rod being used for both flame detection and ignit
63. e nene nene KB e 68 3 5 Operating the System eese rete e naian NENEN EN ERNIE NEE KERE 68 Sn MEE CIE EYE JP 69 70 3 5 2 Stopping the System ainan eee ee hehehe ee eee eee nudes e ee edens 71 3 5 3 Adjusting Settings amp Reviewing Status eene eene 72 3 5 4 VIEWING EVENT COUNTERS m E 73 3 5 5 Viewing the Event Log aee eee III eee 74 76 3 5 6 Viewing Firmware VERSIONS ete re Pee eee be roe Doe Uni ete dem p npe PE NERO 77 3 5 7 Resetting to Defaults orco a e EA ER EUER UE bande dut ke DH RSEN 77 78 3 5 8 Field ined Pd 78 83 4 Modes and Behaviour sssessee mI aa aa aaa rne eere 85 Slate Dia Gia Sess bebes edes tete M LED mM 87 Power On Sedguenee ec ee e E EET Ra EE EUREN Rel 87 4 1 2 Starting in Auto Mode is e t EE EE E EE ERE ERE DE Ag 88 4 1 3 Starting in Manual 89 PROCESS COMMON 90 93 ALS Wating STATS Sa 94 4 1 6 agawa agi ernea n ga ee bang EEEE a re 95 4 2 Process Control Behaviour Lise ee eme baga aa sa a rere nene enn 96 4 2 1 Basic Process Cohittoll aa Ee teta 96 4 2 2 Low F
64. e setpoint below it Depending on which settings are enabled this will be the Pilot Off Low Fire or Process Setpoint PILOT OFF SETPOINT MENU 1 If the Process Temperature goes above this setting the Pilot Valve will close and the system state will change to Waiting on Temp This is often done to conserve pilot gas when it is not needed This setting is hidden if Pilot Off in menu 5 is set to Disabled This setting can be set to a maximum of 1 C below the High Temp ESD Setpoint The minimum value is the same as the setpoint below it Depending on which settings are enabled this will be the Low Fire or Process Setpoint 3 User Interface amp Settings 3 4 10 Process Setpoints Continued LOW FIRE SETPOINT MENU 1 If the Process Temperature goes above this setting the Low Fire Valve will close and the system state will change to Pilot On This setting is hidden if Low Fire in menu 5 is set to Disabled This setting can be set to a maximum of 1 C below the High Temp ESD Setpoint or the Pilot Off Setpoint if it is enabled The minimum value is 1 C above the Process Setpoint PROCESS SETPOINT MENU 1 If the Process Temperature goes above this setting the Main Valve will close and the system state will change to Low Fire This setting can be set to a maximum of 1 C below the High Temp ESD Setpoint the Pilot Off Setpoint if it is enabled or 1 C below the Low Fire Setpoint if it is enabled The minimum value is th
65. e the system shuts down as a result of failing to ignite the pilot within the allocated number of attempts HIGH PRESSURE ESDs Increments each time the system shuts down as a result of the High Pressure Contact opening or the 4 20 Pressure reading exceeding the 4 20 High Pressure Setpoint LEVEL ESDs Increments each time the system shuts down as a result of the Level Contact opening or the 4 20 Level reading dropping below the 4 20 Low Level Setpoint LOW PRESSURE ESDs Increments each time the system shuts down as a result of the Low Pressure Contact opening or the 4 20 Pressure reading dropping below the 4 20 Low Pressure Setpoint THERMOCOUPLE ERRORS Increments each time the system shuts down as a result of a thermo couple issue such as a short circuit open circuit or ground short RELIGHTS Increments each time the system attempts to automatically re ignite the pilot The first ignition attempt after a manual start is not counted RESETS Increments each time the door card is reset by a power loss or by manually pressing the reset button SYSTEM ERRORS Increments each time the system shuts down as a result of an inter nal system error TERMINAL CARD ERRORS Increments each time the system shuts down as a result of a termi nal card error 3 User Interface amp Settings 3 5 5 Viewing the Event Log The Event Log can be accessed from the end of Menu 2 The log contains entries for various types of events s
66. ectly or that it is enabled when not present at all Expansi on Card Erro Card Fail he Modbus Expansion Card is not responding This may indicate that it is not installed correctly or that it is enabled when not present at all Flame was detected prior to the system igniting the pilot This may indicate a leaky valve inadequate purge time or a faulty Terminal Card Flame Fail The system failed to ignite the pilot within the allocated number of retry attempts 5 Troubleshooting 5 2 Shutdown Messages Continued ON SCREEN DESCRIPTION Flame Rod Test Error Adjust Flame The Flame Rod or associated wiring may be shorted to ground thus preventing it from properly detecting Rod Position flame he High Pressure Contact remained open for more than 2s after the main valve opened This error can also be triggered by the 4 20 Input Card if the Pressure reading remains above the 4 20 Pressure High Setpoint for 2s after the main valve opened High Temp Setpnt Mismatch The Door Card and Terminal Card do not agree on the value of the High Temp ESD Setpoint High Voltage xx x Volts The system voltage remained above the High Voltage Alarm point for 20s or more and Auto Restart is disabled xx x is the voltage reading at the point in time when the shutdown occurred See section 3 4 12 System Voltage for a description of these alarm points HT Thermocouple Error he High Temp Thermocouple is open or shorted Ignite
67. ed to access menus 1 3 and the Quick Setpoint Adjust feature 3 User Interface amp Settings 3 4 9 Process Control Settings For the PF2100 Process Control means controlling the temperature of a process The process usually involves heating fluid in a tank or pipe The Process Control algorithm requires a primary temperature control signal This is called the Process Temperature or Proc Temp The control algorithm can optionally accept an auxiliary temperature control signal This signal is called the Auxiliary Temperature or Aux Temp These two signal are not necessarily the same as Proc TC and Aux TC which are the names of the physical thermocouple inputs on the Terminal Card The Aux Temp signal is only compared to the Aux Setpoint if enabled There are four settings that affect the behaviour of the Process Control Algorithm Process Control Input Low Fire Enable Pilot Off Enable and Aux Temp Mode Note that changing any of these settings may cause the Process setpoints High Temp ESD Pilot Off Low Fire Process Low Temp Alarm Deadband and Aux to reset to factory defaults A warning message will display if this occurs PROCESS CONTROL INPUT MENU 5 This setting selects which thermocouple inputs will be used as the primary and auxiliary temperature control signals as shown in the following table SETTING PROC TEMP AUX TEMP Proc TC Proc TC Aux TC Aux TC Aux TC Proc TC In previous firmware versions this could also
68. em shuts down due to the incorrect valve state ok a 5 e CLOSED FLAME PILOT DELAY SHUTDOWN If this contact is not needed it must be shorted out with the provided jumper or a wire 4 Modes and Behaviour 4 3 5 Level Input The Level Input is generally used in tank heater applications A level switch is installed in the tank to determine when the tank fluid level drops below to position of the fire tube This Switch is then connected to the Level Input Contact on the PF2100 If the fluid level drops below the switch position the switch opens and the PF2100 will stop heating the tank This is to prevent damage to the tank and fire tube which may result from applying heat to the empty tank Generally this situation arises when a tanker truck arrives on site and empties the tank into the truck The system can be setup to begin heating the tank again automatically after the level of fluid rises back above the switch position This is done by enabling the Level Event Restart setting in Menu 4 The response to the contact opening is delayed by 2s to reject electrical noise that is common on some sites If long periods of severe noise are common on a particular site the delay can be increased to 20s by enabling the Pressure Level Delay feature in Menu 4 If this contact is not needed it must be shorted out with the provided jumper or a wire 4 Modes and Behaviour 4 3 5 Level Input Continued CHAR
69. emicals on the keypad may interfere with an operator s ability to control the product or view the display and LED indicators b Directly to a heated tank where excessive heat may damage the product Refer to the maximum operating temperature listed in this document c To anything that may tip over due to wind or snow For example a pole that is not set properly into the ground or a tripod that is not secured with anchor bolts or guy wires d In locations that may be prone to flooding 2 Installation 2 3 Mounting Instructions 1 Remove and open the included bag of components taped to the mounting brackets 2 Attach the two mounting brackets to the back of the PF2100 enclosure using the 4 screws 3 Determine the best location to drill holes in the product enclosure for the wires to enter It is recommended that these holes be drilled on the bottom of the enclosure as shown 4 Install grommets or conduit ports as required 5 Securely mount the enclosure to either a pole structure or building which satisfies the location requirements previously listed in section 2 2 Mounting Locations DETERMINE DRILL LOCATIONS CONDUIT AND CABLES AS REQUIRED 2 Installation 2 4 Terminal Card Diagram D 66666666 INTERNAL COIL OPTIONAL EXPANSION SPARE MAIN FUSE SPARE STATUS CONTACT FUSE EXPANSION CARD SLOT DOOR CARD CONNECTOR MAIN FUSE HW SE
70. estart and Level Event Restart Each of these states can be entered automatically from any other Process Control state if the associated condition is satisfied Once that condition is cleared the sys tem will automatically restart via the Relight procedure The following waiting states are enabled when the Auto Restart feature is enabled System Voltage below System Voltage above Low Alarm WAITING Low Alarm ON LOW VOLTAGE System Voltage above System Voltage below ANY PROCESS High Alarm WAITING High Alarm RELIGHT CONTROL STATE HIGH VOLTAGE Low Pressure Contact Low Pressure Contact open or 4 20 Pressure closed and 4 20 Pressure below Low Setpoint WAITING above Low Setpoint ON LOW PRESSURE The following waiting state is enabled when the Level Event Restart feature is enabled Level Contact closed and 4 20 Level WAITING below Low Setpoint ON LOW LEVEL Level Contact open or 4 20 Level PROCESS below Low Setpoint CONTROL STATE RELIGHT 4 Modes and Behaviour 4 1 6 Relight Procedure After the system has been initially started if it needs to be automatically relit the procedure below is followed Note that the number of retries varies depending on the mode and reason for pilot being off Flame went out unexpectedly SET RETRIES TO RELIGHT WHY IS THE PILOT OFF Process Control USER SETTING DECREMENT RETRIES 5s No Flame PROCES
71. feature enabled Menu 4 the system will automatically relight the burner after a high or low voltage alarm clears Otherwise the system will remain shut down 3 User Interface amp Settings 3 4 13 Timing Delay Settings There are four time delay settings that can be adjusted to match the needs of various applications These are as follows PURGE TIME MENU 4 This setting is used to set the minimum amount of time that must elapse between when all valves are known to be closed and the next time that the pilot is lit This will be the minimum elapsed time be tween relights and also the minimum amount of time before lighting the burner after a loss of power The purge time ensures that danger ous amounts of gas are not present in the fire tube before the pilot is lit thus reducing the risk of an explosion Generally the larger the burner the larger the purge time should be Local codes may dictate the amount of purge time required for a given application This setting can be set to a minimum of 10s and a maximum of 900s PILOT TO MAIN DELAY MENU 4 This setting is used to set the minimum amount of time that must elapse between the pilot successfully lighting and the main or low fire valve opening The Pilot to Main Delay is used to ensure that enough draft is established before opening the main valve If this is not done the volume of gas flowing through the main valve can snuff out the flame due to insufficient oxygen supply Generall
72. ght the pilot if it ever goes out unexpectedly It will only attempt the diagram is actually a collec to relight the pilot if it was turned off by the system as a result of normal process control ie tion of several states that will be Waiting on Temp Waiting for Level etc explained in more detail later POWER Pilot Key PILOT OPEN Pilot Ignite Key Pilot Key 5s Flame Main Key CONTROL START 4 Modes and Behaviour 4 1 4 Process Control The primary function of the PF2100 is to maintain a process at a user specified temperature It first monitors the temperature and then makes adjustments as required to increase or de crease the temperature This process of monitoring and controlling forms a closed loop control system that is referred to in this manual as Process Control The control is accomplished using a gas fired heater with an electronic ignition circuit and several electronic fuel valves also called solenoids The monitoring is accomplished using a flame detection circuit and up to three temperature measuring thermocouples The PF2100 implements Process Control using a software algorithm that takes three tempera ture signals as inputs High Temp Proc Temp and Aux Temp By default these signals correspond to the High Temp Thermocouple the Process Thermocouple and the Aux Thermo couple respectively The Process Control setting allows the Process and Aux thermocouples to be swapped This is usef
73. gs to the factory default On Off On Off Of Alarm when No Alm when 3 4 3 Off Of No Alm When Off Off 8096 6096 3 4 14 6096 4096 2096 Off 8096 6096 3 4 14 6096 4096 2096 12V 24V 12V SUM Fahrenheit Celsius 3 4 6 Celsius DD MMM 01 JUN 2012 3 4 5 YYYY A Z 0 9 3 4 5 saf Yes No No 93 5 3 User Interface amp Settings 3 3 5 Control Setup MENU 5 This menu contains various optional Process Control settings It cannot be accessed while the PF2100 is running MENUMAP ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING SECTION High Temp ESD Setpoint High Temp ESD Setpoint Adjusts the High Temperature shut down setpoint Configure the thermocouple used as the Process Temperature 2 to 1350 C 36 to 2462 F Process TC AUXTC 90 C Low Fire Enable Low Fire Enables Low Fire feature and setpoint Disabled on at Proc Setpnt on at Low Fire Setpnt Disabled Delay Adjusts the time from Low Fire Valve opening to High Fire Valve opening when Low Fire is enabled Disabled Enabled Configures how the Auxiliary Thermo couple is used Disabled Display Only Temp Main Ctl Temp 4 20 Output Mode 4 20 Out Mod 4 20 Low Fire Setting 4 20 Out Lo Fi Setting 4 20 Gain Setting 4 20 Out Cntr Valve Control Temperature Out Sets the minimum output for the 4 20mA Output when used for Valve Control Gain 3 User Interface amp Settings
74. his may lead to small rounding errors when operating in Fahrenheit 3 User Interface amp Settings 3 4 7 Modbus Expansion Card Settings This setting all applies to the Modbus Expansion Card which must be installed in the PF2100 s expansion slot MODBUS ENABLE ADDRESS MENU 6 The Modbus Card is disabled by setting the address to zero and enabled by setting the address to any non zero value The address is shown on the display as a decimal number which can be set to any value in the range of 1 to 254 This corresponds to hexadecimal values 0x01 to OxFE 3 4 8 Password Setting There are two levels of password protection Menus 1 3 and the Quick Setpoint Adjust feature may be optionally protected by the Level 1 Password Menus 4 7 are always protected by the Level 2 Password These passwords can not be modified Level 1 Password A V A ok Level 2 Password AVA A V A ok For convenience once a password has been entered it unlocks all menus that it protects for a period of time Therefore it does not need to be re entered again when returning to the menu later The menus will remain unlocked for 10 minutes or until the user manually locks the menus again To lock the menus manually press and hold the OK button for 3 or more seconds The display will briefly show Password Logout to indicate that the menus are now locked again PASSWORD ENABLE MENU 4 When enabled the Level 1 or Level 2 Password must be enter
75. if Low Fire is enabled ESD Setpoint ESD Setpnt Process Setpoint ProcSetpnt Low Fire Setpoint LF Setpnt Pilot Off Setpoint Pilot off Temp at which Pilot Valve will turn off if Pilot is enabled 3 User Interface amp Settings 3 3 8 Review Menu Continued MENUMAP O ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING SECTION TC Debug Screen Lists up to 3 simultaneous alarm codes 3 User Interface amp Settings 4 20 High Level Setpoint HLV DH ww TH xx TA zz will toggle Level below which shutdown or wait if is enabled Pressure above whi shutdown after Mai Pressure below whi shutdown or wait if enabled Level at which 4 20mA Output contacts he system will Level Event Restart Shows the current readings of all temperature sensors simultaneously always in degrees c the display unit sett elsius regardless of ing DH Door Card High Temp Thermo couple TH Termincal Card mocouple P Terminal Card P couple if any are present High Temp Ther rocess Thermo Terminal Card Ambient Thermo 3 4 Settings Grouped Alphabetically This section of the document contains detailed descriptions of all system settings organized alphabetically by topic Not all settings need to be modified for a given installation The settings that need to be modified for every installation are these 1 Valve Modulation Settings Pilot and Main
76. ignition rod should be positioned by bending it if necessary so that there is a 1 8 to 4 gap between it and the front of the pilot nozzle The flame rod should be positioned by bending it if necessary such that 2 to 3 of its length is posi tioned within the pilot flame Care should be taken to ensure that the ignition rod and flame rod are not directly in line with each other Otherwise the ignition rod may cast a shadow on the flame rod such that there is no flame present at the flame rod and therefore no flame is detected FLAME ANCHORING The term Flame Anchoring refers to how much the flame is in con tact with the pilot nozzle Poor flame anchoring causes poor flame detection Poor flame anchoring can be caused when there is too much gas pressure resulting in the flame burning primarily outside of the nozzle as opposed to along the inside and outside surfaces of the nozzle It can also be caused by wind or draft from the main burner USING EXTRA RODS TO IMPROVE FLAME DETECTION In some challenging installations such as non enclosed or high veloc ity burners adding one or two additional rods may be required A second flame detection rod can help in cases where the flame may blow away from the primary rod from time to time The addition of a ground rod positioned further away from the nozzle tip can assist with 2 6 4 Ignition Coil Flame Detection Continued detecting flames that are not well anchored Use of additional ro
77. int minus Deadband crease slowly CHART Pilot to Main Delay elapses Low Fire Valve opens Proc Temp in creases faster EVENT 000 090600 0 3 Low to High Fire Delay elapses HIPH TEM 0 SR High Fire Valve opens Proc Temp increases even faster LOW FIRE SP i Proc Temp exceeds Proc Setpoint High Fire Valve closes Proc Temp begins to drop HIGH FIRE SP i E K Q a ProcTemp drops below Proc Setpoint minus Deadband High Fire Valve opens again Proc Temp begins to increase again Decreased Heat Demand The demand for heat decreases and the Proc Temp begins to rise The Proc Temp exceeds the Low Fire Setpoint Low Fire Valve closes and Proc Temp begins to drop The Proc Temp drops below Low Fire Setpoint minus Deadband the Low Fire Valve opens and Proc Temp begins to rise again 4 Modes and Behaviour 4 2 4 Pilot Off This scenario is the same as the basic scenario except that the Pilot Off feature has now CHART EVENTS been enabled In this case when the Proc Temp rises above the Pilot Off Setpoint the Pilot 7 System is started Pilot Valve Valve will close and will not re light until the temperature is below the Process Setpoint minus gt opens Proc Temp beings to in Deadband crease slowly CHART Pilot to Main Delay elapses Low Fire Valve opens Proc Temp in creases faster E
78. ion ESX Measure the AC voltage on the ION wire where it connects to the coil Check the ION wire for shorts to ground or nicks Is it close to the same voltage that was measured across the ION and ION terminals a Replace the coil Check the ION wire for shorts to ground or nicks PREVIOUS PAGE Set the Multi Meter to measure DC voltage across ION and ION with the system in manual mode Is the reading across ION and ION around 5VDC Put the system into Auto Mode and monitor the voltage on the Multi Meter While sparking the voltage will jump around ignore this Take note of the voltage after the sparking while the flame is present Remove the wire from ION and measure the DC voltage between the ION and ION terminals again Is the voltage across the ION and ION terminals around 5VDC Did the voltage drop below 5V when the flame was present The system is sensing flame just not enough The DC voltage should drop to 5VDC or lower 8VDC is better for stable flame detection Adjust the flame rod positioning to try to decrease the voltage while the flame is present The problem could be related to flame anchoring To verify this place a grounded rod in the flame The system is not seeing the flame at all
79. ire On at Proc Setpoint kaba aa naak aa mener e ne esee 97 4 2 3 Low Fire On at Low Fire Setpoint ccc cc ccc ccc esa ee nene ne nemen ene neni 98 42A PIOR AAS KANE E KA KERA 99 42 5 Proportional Valve Control eti tra ret peter Rt DA eit OE Serb PE eR E ERE cadres 100 4 2 6 Aux Temp Mode Temp Main Ctl erreira IH me n eene nnns 101 4 2 7 High c eiecti ote emet iter KA ag ga Da a Ki 102 4 2 8 AuxTemp ESD issssssssesssee I IH Hee nenne nennen ee ee ee e ee ee ee iere ee re enne 103 4 3 Contact BellaviOUf css aaa a ak ret Do ect tod ket exe Fen Sade e cog ges Oba Pado EE HE E RI puc ee 104 p Status 104 106 43 2 Start oec see oe vies E 107 4 3 3 gg a 108 4 34 Prootot Closure Inpede kd Peel 109 4 3 5 Level Input 110 111 4 3 6 Low Pressure Triput us eoo e ERE EBENE OD S OD EET iet iere stre 112 113 4 3 7 HighiPressure Input aaa aa decet ail e ce ved peste eigen E Qiu 114 116 4 4 Expansion Card Behavi0ur sarean naa na aab an ag aaa ga nagan ene enne ren ga ka aa a ine ness nee nnns 117 4 4 1 4 20mA
80. isplay State System Error Terminal Card Terminal Card Terminal Card he Term he Termi he Termi Door Card failed to detect this he Termi d to detect this Card faile he Term inal Card detec ncal Card is no inal Card recieved a valid command from the Door Card but the command was refused because it would result in an invalid or unsafe state The Door Card failed to detect this communicating with the Door Card This may indicate a faulty ribbon cable or incom mware The Door Card failed to detect this nal Card detec nal Card detec ed that the High Temp Thermocouple exceeded the High Temp ESD Setpoint The ed that the system voltage was outside of allowable limits The Door Card failed to is See section 3 4 12 System Voltage for a description of these alarm points Thermocouples Not Equal Check Wiring he High Temp and Process Thermocouples are reading temperatures that are too far apart This may indicate a failed thermocouple or improper wiring User Stop 5 Troubleshooting The user pressed the Stop key on the keypad 5 3 Alarm Codes The following is a list of alarm codes that may show on the Alarm screen of the PF2100 display These codes indicate a persistent problem that must be cleared before the system can be restarted Use the table below to determine the meaning of these codes ON SCREEN DESCRIPTION 4 20Lvl The 4
81. ive lead in its place Turn on the process calibrator and set it to source a current of 4mA 0 Press the OK key and the message Calibrating Wait will appear for several seconds followed by the message Parameter Set after the calibration has successfully completed Calibrate the Level Input s Span point a Press the Menu Key repeatedly until Calibrate 4 20 LVL Span is shown on the display Use the Up or Down key to select Yes and begin the calibration process The display will now read Apply 20mA then press OK Set the process calibrator to source a current of 20mA 100 Press the OK key and the message Calibrating Wait will appear for several seconds followed by the message Parameter Set after the calibration has successfully completed Disconnect the process calibrator from the Level input and reconnect any wiring that was removed from it previously Calibrate the Pressure Input s Zero point a Press the Menu Key repeatedly until Calibrate 4 20 PRS Zero is shown on the display Use the Up or Down key to select Yes and begin the calibration process The display will now read Apply 4mA then press OK Disconnect any wiring that is connected to the Pressure input and instead attach the process calibrator s positive lead in its place 3 User Interface amp Settings 3 5 8 Field Calibration Continued d Turn on the process calibrator and set it to source a
82. lay or read remotely via Modbus if the Modbus Card is installed 4 4 1 4 20mA Level Input amp Output Contacts The 4 20mA Level Input is used to monitor tank level in the same way that the Level Contact is The behaviour and features are identical to those described in the previous Level Contact section The difference is that a Level Transmitter is used instead of a Level Switch and the Low Level setpoint is set via a menu instead of the physical position of the switch on the tank When the 4 20mA signal is below the Low Level setpoint the system will stop When it is above the setpoint it will run The 4 20mA expansion card also has a pair of High Level Output Contacts which toggle when the Level Input exceeds the Level High Setpoint One contact is normally open and the other is normally closed Normally in this case means when the level is below the high setpoint The normally closed contact could be used to turn off the pump that is filling the tank and the normally open contact could be used to sound a remote alarm to signal that the tank is full To use the 4 20mA Level Input it must be setup as follows gt Attach a properly calibrated Level Transmitter to the 4 20 Level Input Enable the Level DIP Switch on the 4 20 Card Enable the 4 20 Card in Menu 6 Set the Level Low Setpoint High Setpoint Range and Units in Menu 6 oF Disable the Level Contact by installing jumper it 4 Modes and Behaviour
83. le is placed in a separate thermowell inside of the outlet pipe Process Control is set to Aux TC and Aux Temp Mode is set to Temp Main Ctl This allows the system to apply as much heat as is necessary to maintain the desired outlet tempera ture up to the maximum allowable bath temperature as specified using the Aux Setpoint Recommended Settings SETTING USER SETTING Process Control AuxTC Aux Setpoint Maximum Bath Temperature THERMOCOUPLE LOCATION Process High Temp Bath Q Aux Outlet 4 Modes and Behaviour 4 5 4 Remote Temperature Monitor For any application where it is desired to remotely monitor a temperature other than the process two thermowells are required One for the process and one for the temperature that you want to remotely monitor The illustration below portrays a Dehydrator as an example In this case the operator wants to remotely monitor the inlet temperature for information purposes The Process and High Temp Thermocouples are both placed inside of the thermowell in the bath The Aux Thermocouple is placed in a separate thermowell inside of the inlet pipe Process Control is set to Process and Aux Temp Mode is set to Display Only This allows the system to run process control using the Process Ther mocouple while using the Aux Thermocouple only for display only purposes The Aux Thermocouple reading can be displayed on the PF2100 s display in Manual Mode or read remotely via the Modbus Card if
84. me from burning back into the fuel train 4 20 HIGH PRESSURE SETPOINT MENU 6 If the 4 20mA PRS input exceeds this setpoint the system will shut down 3 User Interface amp Settings 4 20 PRESSURE RANGE MENU 6 Specifies the maximum capacity of the tank s 4 20mA Pressure transmitter 4 20 PRESSURE UNITS MENU 6 Specifies the units of measurement Note that this may have an impact on measurement accuracy 3 4 2 4 20mA Output Settings The 4 20mA Output is built into the Terminal Card ie not part of the 4 20mA Expansion Card It can be used for either of two dif ferent purposes To echo the process temperature to a PLC or to control a proportional valve 4 20 OUTPUT MODE MENU 5 Set to either Process Temperature or Valve Control to specify the mode of the 4 20mA Output Process Temperature In this mode the 4 20mA Output will encode the Proc Temp signal as a 4 20mA signal Note that the Proc Temp may correspond to either the Process Thermocouple or the AUX Thermocouple input depending on the Process Control setting The signal is scaled such that 4mA OC and 20mA the High Temp ESD Setpoint Valve Control In this mode the 4 20mA Output is intended to drive a proportional valve The signal is scaled such that 4mA Valve Closed and 20mA Valve Fully Open A temperature feedback system is used to determine how much the valve should be opened at any given point in time The amount that the proportional v
85. n as a result of an alarm condition it will flash the word SHUTDOWN in large text on the display alternately with a more detailed message explaining the reason that the system shut down The Shutdown Screen can always be dismissed by pressing OK toggling the Start Contact or sending the Start Command via Modbus 3 User Interface amp Settings 3 3 Menu The following sections include brief descriptions of each PF2100 Menu including the valid settings range default setting and the location in this document where more detailed information can be found 3 User Interface amp Settings 3 3 Menu Map Continued HOMESCREEN SYSTEM MENUS 1 4 oe ee o System State Proc SP Process Temperature Ed REVIEW MENU ESD Setpoint Process Setpoint Low Fire Setpoint Pilot Off Setpoint 4 20 High Level Setpoint 4 20 Low Level Setpoint Y Pilot Off Setpoint Low Fire Setpoint Y Relights Flame Fails a Y High Temp TC Reading Process TC Reading q uve AMOO PRAESES rasswor may BE REGUIRED L a G G Y Auto Restart Purge Time Process Setpoint Low Temp Alarm Setpoint Resets ESDs 4 20mA Output Percent Pilot to Main Delay Door Card Ambient Temp Tenn Restart Attempts Deadband 4 20 High Pressure Setpoint 4 20 Low Pressure Setpoint Flame Aux Temp 4 20 Level Reading 4 20 Pressu
86. nabled and the Process Temp is above the Pilot Off Setpoint 4 Modes and Behaviour 4 1 4 Process Control Continued AUX TEMPERATURE PROCESS TEMPERATURE PROCESS CONTROL STATES VALVE OUTPUT STATUS amp ASSOCIATED SETPOINTS amp ASSOCIATED SETPOINTS WAITING High Fire CLOSED Low Fire CLOSED GET Pilot CLOSED Pilot Off Setpoint ProcTemp Pilot Off SP Proc Temp lt Pilot Off SP Low CLOSED Aux Setpoint CONTROL ow START Pilot CLOSED ProcTemp Low Fire SP ProcTemp Low Fire SP Low Fire Setpoint of and AuxTemp Aux SP AuxTemp lt Aux SP High Fire OPEN Low Fire OPEN Pilot CLOSED ProcTemp Proc SP ProcTemp Proc SP Process Setpoint or and AuxTemp Aux SP AuxTemp lt Aux SP High Fire OPEN Low Fire OPEN Pilot OPEN Used when Aux Temp Mode is set to Temp Main Ctl The Pilot to Main Delay must elapse before this transition will occur The Low to High Fire Delay must elapse before this transition will occur These setpoints may be diabled in menu 5 4 Modes and Behaviour 4 1 5 Waiting States In all waiting states the system turns off the burner and pilot and waits for some event to occur before restarting The Waiting on Temp state shown in the Process Control state diagram is one example of this There are two other groups of waiting states which may be optionally enabled Auto R
87. nect the Pilot Assembly ground screw to the PF2100 s lon terminal using a 16 AWG or thicker ground wire Connect the Kanthal Flame Detection Rod to the PF2100 s lon terminal Use the included Ferrule and Straight Silicone Boot to ensure that the connection is robust It is recommended to use 7mm Ignition Wire but 16 AWG may be acceptable for shorter runs Connect the Kanthal Ignition Rod to the PF2100 s Internal Coil Output Terminal using the included ignition wire Use the included Ferrule and Straight Silicone Boot to ensure that the connection is robust Adjust the Flame Rod positioning bend it if necessary so that 2 to 3 of the rod will be inside the pilot flame Adjust the Ignition Rod positioning bend it if necessary so that there is a 1 8 to 1 4 gap between the rod and the front of the pilot nozzle Verify that the Coil terminal is connected to the black pigtail on the ignition coil Verify that the Coil terminal is connected to the white pigtail on the ignition coil 2 Installation MAX WIRE LENGTHS ION 8m 25ft if using 16AWG Wire 15m 50ft if using 7mm Ignition Wire Ignition Rod Wire 5m 15ft must use 7mm Ignition Wire 2 6 6 External Coil Dual Rod Use this configuration when the PF2100 is gt 5m 15ft from the burner and you want greater flexibility for rod placement WIRING STEPS 1 Connect Pilot Assembly ground screw to the PF2100 s lon terminal using a 16 AWG or thicker ground wir
88. nterface amp Settings 3 3 2 History MENU 2 Continued MENUMAP ON SCREEN BRIEF DESRIPTION RANGE DEFAULT SETTING SECTION Resets Resets umber of power failures or manual 3 5 4 resets ESDs ESDs umber of system shutdowns caused to 1000 JA 3 54 by faults Clear History Clear History Clears all History and logged events Yes No 35191515 3 3 3 System Info MENU 3 This menu contains read only information about the system ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING SECTION High Temp TC Reading Hi Temp TC Current High Temp Thermocouple 50 C to 4 9 3 4 10 4 2 reading 1350 C Process Temp TC Reading Proc TC Current Process Thermocouple reading 50 C to N A Su 9 sa 10242 1350 C 4 20mA Output Percent 4 20 Current status of the 4 20mA Output 10096 N A GADA D Output 3 User Interface amp Settings 3 3 3 System Info MENU 3 Continued MENUMPP ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING SECTION Ambient Temp Ambient Temp Current ambient temperature Used for 55 C to 65 C 2 6 3 thermocouple cold junction compensa 70 F to 150 tion Commission Date Date that the system was commis sioned if entered by user YYYY Location Location The install location of the system if N A JA entered by user Terminal Card State Term Card Debug Information N A idden 3 3 4 System Setup MENU 4 This menu
89. o unlock the Cali bration Menu Menu 7 which is normally hidden Press the Press OK Press the display Menu Key repeatedly until Menu 7 is shown enter the L2 Password if prompted A V A A V A Menu Key repeatedly until Cal Data is shown on the Use the Up or Down keys to select Yes Press OK and the message Parameter Saved will show on the display briefly Press and hold the OK key for 3 seconds until the message Password Logout is displayed on the screen The Calibration Menu is now hidden again 3 User Interface amp Settings 4 Modes amp Behaviour This section of the manual describes the behaviour of the PF2100 when various features are enabled vs disabled Simplified state diagrams are provided and discussed to give a high level understanding of how the system works Following this detailed behav iour descriptions are provided including process charts to illustrate the behaviour of the system when various features are enabled and in response to various external events These are provided for the Process Control Algorithm Input Output Contacts and Ex pansion Cards Finally examples of common applications are provided including process charts and recommended Process Control settings 4 1 State Diagrams The following diagrams illustrate the various states that the PF2100 goes through when the system is powered on when starting the system in Auto or Manual modes and once the Process
90. olved in order to continue using the system Up Key Stuck at System Startup This may indicate a defective keypad This error must be resolved in order to continue using the system The Level Contact is open and Level Event Restart is set to Off This error can also be triggered by the 4 20 Input Card if the Level reading is below the 4 20 Level Low Setpoint and Level Event Restart is set to Off he Low Pressure Contact is open and Auto Restart is set to Off This error can also be triggered by the 4 20 Input Card if the Pressure reading is below the 4 20 Pressure Low Setpoint and Auto Restart is set to Off The system voltage remained below the Low Voltage Alarm point for 20s or more and Auto Restart is set to Off xx x is the voltage reading at the point in time when the shutdown occurred See section 3 4 12 System Voltage for a description of these alarm points The Master Power switch to the powered valve outputs was in the wrong state This may indicate a Terminal Cards hardware failure The Proof of Closure Contact was detected to be Open when it was not expected to be This may indicate a faulty valve or wiring The solenoids were observed to have a state opposite to the one being driven by the PF2100 Check that the wiring is correct and not shorted to power or ground 5 Troubleshooting 5 2 Shutdown Messages Continued ON SCREEN DESCRIPTION Illegal Process Control or D
91. om line of the display The top line differs depending on mode In Manual Mode the top line shows the system state In Auto Mode it shows the Process Setpoint instead The accessibility of other features from the Home Screen also differs depending on mode For example the System Menus and Re view Menu are only accessible in Manual Mode whereas the Quick Setpoint Adjust feature is only available in Auto Mode For more information on which features are available in which modes refer to Sections 3 5 3 Adjusting Settings amp Reviewing Status AVAILABLE FEATURES WITHIN OPERATIONAL MODES MODE DISPLAY MENUS REVIEW SETPOINT ADJUST Manual System State Yes Yes No Process Temperature Auto Process Setpoint No No Yes Process Temperature 3 2 3 System State The System State is the Process Control State of the system It is shown on the display for a few seconds before and after a state change In Manual Mode the top line of the Home Screen always shows the System State For a complete list of the Process Con trol States refer to section 4 2 3 User Interface amp Settings 3 2 4 Quick Setpoint Adjustment The Quick Setpoint Adjust feature is only available on the Home Screen while running in Auto Mode It allows the user to quickly adjust the Process Setpoint using the up and down keys The change takes effect immediately and does not need to be saved by pressing ok If password protection is enabled a password will need to be entered
92. on the Aux Temp Mode setting Some settings enable an Aux Setpoint which this signal is compared to 4 Modes and Behaviour 4 1 4 Process Control Continued The following diagram illustrates the Process Control states for two different cases In the one case only the Process Temperature signal is used In the other case both the Process Tem perature and Auxiliary Temperature signals are used The system will automatically transition between these states in response to the temperature signals When the system transistions from the Pilot On state to the Low Fire state the Pilot Main Delay must first elapse If Low Fire is disabled this Delay must elapse between the Pilot On state and the High Fire state Similarily when the system transitions from the Low Fire state to the High Fire state the Low to High Fire Delay must first elapse Between all other state transitions a minimum 30 second delay must elapse to prevent oscillation The Low Fire setpoint and Low Fire state are only used when Low Fire is enabled in menu 5 The Pilot Off setpoint and Waiting on Temp state are only used when Pilot Off is enabled in menu 5 When Aux Temp Mode is set to Temp Main Control the Auxiliary Temperature signal is en abled as a control input as described previously When the Aux Temp signal is above the Aux Setpoint the Process Control state is forced to be either Pilot On or Waiting on Temp The latter occurs only if Pilot Off is e
93. onnecting it to an output relay on a PLC or even to a switch located elsewhere on the site Generally speaking the system will begin running when the contact is closed and will stop running when the contact is open The exception to this is when the system shuts down as a result of an alarm condition In this case the contact must be closed to acknowledge the shut down condition and must then be opened and closed again to restart the system The status contact can give some idea as to whether the system is shutdown However it is not always possible to do so under all circumstances and settings Therefore it is recommended to al ways start the system using the close open close sequence described above This will always work even if the system is not waiting for a shutdown message to be acknowleged Once the start sequence has been entered the system will start after the purge time has elapsed When the start contact is opened the system will always stop immediately CHART var 000090 coso RUNNING SHUTDOWN o a x n If this contact is not needed it must be shorted out with the provided jumper or a wire CHART EVENTS o System already in a shutdown state due to some previous alarm User opens Start Contact Shutdown message on display is aknowledged and cleared System is now waiting for Start Contact to close User closes Start Contact System is now ready to be star
94. oot After rebooting the system will display the message CONFIGU RATION RESET TO DEFAULT alternating with Check Settings and Setpoints 5 Press the OK Key to acknowledge this warning 3 User Interface amp Settings 3 5 7 Resetting to Defaults Continued This process only resets the user settings back to factory defaults and does not affect the calibration settings To reset the calibra tion settings to defaults refer to the Field Calibration section below Note that older versions of firmware did reset both the user settings and the calibration settings to defaults Also note that all settings are stored on the Door Card If the Door Card is replaced for any reason the settings will need to be re entered and calibration may need to be performed 3 5 8 Field Calibration It is possible to field calibrate the thermocouples the 4 20mA Output and the two 4 20mA Inputs on the 4 20mA Expansion Card In general it should not be necessary to do this in the field because the system has already been calibrated at the factory How ever there are circumstances where this may be necessary such as if the door or terminal card was replaced in the field or if the system is very old and has drifted out of calibration Before recalibrating the system it is strongly recommended that you explore all other possible solutions first For example verify that system settings are correct and that the devices attached to the system are calibrated cor
95. or 3 levels which are possible using normal valves Typically the 4 20mA Output is used in conjunction with a normal valve The 4 20mA Output also supports low fire HIGH FIRE MAIN VALVE The High Fire valve is required and must be wired up for all installations This valve is sometimes called the Main Valve especially when Low Fire is not used 2 6 3 Thermocouples The High Temp and Process thermocouple inputs are mandatory and must be connected to a Dual Element thermocouple The Auxiliary thermocouple is only required when a second process temperature such as the outlet temperature on a line heater must be monitored Otherwise the Auxiliary thermocouple is optional All thermocouples are cold junction compensated For this reason it is important to ensure that Type k thermocouple wire and con nectors are used exclusively The temperature compensation is done using an ambient temperature sensor located on the terminal card near the thermocouple terminals WIRING STEPS 1 Connect a Dual Element Type k Thermocouple to the Process and High Temp Thermocouple inputs 2 If desired connect a single Type k Thermocouple to the AUX Thermocouple input 3 sure that all connections are made using Type k thermo couple wire and connectors NOTES All thermocouples must be 1 2 Isolated from ground Isolated from power Type K thermocouples Connected with 20 AWG or larger Type K extension wire Placed a safe dist
96. or Card and Te Comparison he Door Comparison The Door MAN DC xxx TC xxx Xxx wi Comparison The Door PLT DC xxx TC xxx W Comparison The Door Comparison The Door Comparison do not agree on the sta he Ambient Temperature read by the Door Card does not match the one reported by the Terminal Card PRL DC xxx TC xxx Wi 5 Troubleshooting do not agree on the sta he Low Pressure Contact 5 2 Shutdown Messages Continued ON SCREEN Comparison STRT D TC xxx DESCRIPTION The Door Card and Terminal Card do not agree on the state of the Start Contact xxx will be either ON or OFF Expansi 4 20 Le Expansi 4 20 Le Expansi 4 20 PRS High Expansi 4 20 PRS Low Expansi 4 20 PRS Open Expansi Card Fail on Card Erro vel Low on Card Erro vel Open on Card Erro on Card Erro on Card Erro on Card Erro The 4 20mA Level Input was below the Level Low Setpoint while the system was running with the Level Event Restart feature disabled The 4 20mA Pressure Input was above the Pressure High Setpoint while the system was running with the Main Valve open The 4 20mA Pressure Input was below the Pressure Low Setpoint while the system was running with the Auto Restart feature disabled The 4 20mA Expansion Card is not responding This may indicate that it is not installed corr
97. or burner housi Driver for the low voltage primary of the ignition coil Ground return for the ignition coil Ground return for flame detection e primary of the ignition coil should be connected to this terminal Ihe 12 24VDC input power will be applied for 1 ms and turned off for 50 ms while sparking This output is protected by a 250mA thermal fuse 2 Installation 2 5 Terminal Description Continued TERMINAL EXPECTED CONNECTIONS DESCRIPTION SECTION Status Connect to PLC positive input con The status and contacts will be closed when the system is run 2 71 tact or other alarm device ning and opened when the system is shutdown Dry contact output to Gtatus Connect to PLC negative input con indicate d id to an ie ion Note that the m taerorotheralafmidevico tacts are only and are not internally connected to power or ground 40VDC 250mA 150 Start 4 Remote start input from an external Dry contact switch is expected The input is internally pulled up to 292 device ie PLC ESD External Shutdown input typically plant ESD loop ESD Ground Proof of Proof of Closure from main valve s Closure 4 Proof of Ground Closure igh Input from a mechanical High Pres Pressure sure switch igh Ground Pressure Low Input from a mechanical Low Pres Pressure 4 sure switch Low Pressure Ground Level Input from a float switch mounted in the bath Level Ground
98. ose to the operating temperature of the system Measurement accuracy and process control overshoot can cause the system to shutdown if they are too close System shuts down on an Open TC Error a Checkif one of the thermocouples is not connected inside of the PF2100 Note that both the Process and High Temp thermocouples are required b Check that there are no breaks in the thermocouple wiring 5 Troubleshooting SOLAR POWER 1 Solar output voltage is 12V when 24V is expected a Check if the solar panels are incorrectly wired in parallel rather than series 2 Expected battery life is not achieved a he PF2100 is not setup to use low power valves with a PWM setting of 20 b The PF2100 is not setup to put the display to sleep when not being used c The solar panel is undersized d The solar panel is shaded or not located in full sun 3 The battery is not being charged at all a Checkif the Solar Charger is damaged or defective Look for flashing error codes on the controller s LEDs b The solar panel is undersized c The solar panel is shaded or not located in full sun d The battery is defective SOLENOIDS 1 Valves are not opening a Check if the positive and negative wires are reversed b Ensure that each valve has a separate negative return wire connected to the correct terminal A common ground wire 5 1 Common Issues amp Solutions Continued cannot be used and will not work c Checkif
99. ounded 2 Installation CSA NEMA Type 4 rated and have seals poured in them in order to maintain the Type 4 rating 2 2 Mounting Locations The PF2100 should typically be mounted near the burner it s controlling or in another location that is both safe and easily accessible The recommended mounting height is 1 5m bft above the ground or platform that the operator will be standing on Please consider the following when choosing an install location 1 ACCESSIBILITY The operator should be able to easily access the system to observe its operation and change settings The system should not be mounted facing the sun to make it easier to observe the display and LED indicators on the front panel 2 SECURITY In some situations it may be desirable to mount the system in a location that is not accessible to the general public to prevent accidental and intentional tampering 3 OPERATOR SAFETY The system should not be mounted in a dangerous location such as in the path of an open flame or next to a tank that might over flow or in any other location where an operator might be placed in undue danger 4 PERFORMANCE Choose a mounting location that will allow ground and ignition wires to be kept as short as possible This will ensure the best ignition and flame detection PRODUCT PROTECTION To protect the system from being damaged it should not be mounted a Where chemicals may splatter or bubble over from a tank onto the system Ch
100. our application do one of the following a Wire the Low Fire valve to the Low Fire terminals b Ifyou want to use a proportional valve wire the valve to the 4 20mA Out terminals 4 Ensure that each valve has a separate return wire Multiple valves sharing common return wires will not function properly 5 Connect valve EGND wires to Earth Ground NOTES 1 Itis possible to connect multiple valves to the same control out put in parallel or series If you do this ensure that the configura tion you are using meets local codes and also does not exceed the total current rating of the PF2100 2 The negative valve control wires are NOT connected directly to ground Therefore you cannot use a common return wire for all valves 2 Installation PILOT VALVE The Pilot valve is required and must be wired up for all installa tions LOW FIRE VALVE The Low Fire valve may also be required by local code or for proper operation of your particular application Low Fire is often used on high Btuh burners such as those that exceed 5 MM Btuh to establish a draft before opening the High Fire valve Failure to do this on high Btuh burners can cause the burner to starve itself of oxygen and snuff out the flame 4 20mA OUTPUT The 4 20mA Output can be used to control a proportional valve that is designed for a 4 20mA current loop Using a proportional valve allows for finer control of the burner s temperature as opposed to the 2
101. pendent of the High Temp ESD previosuly described However it is possible for the High Temp ESD Setpoint and the Aux ESD Setpoint to both be applied to the same thermocouple This happens when Process Control is set to Aux TC and Aux Temp Mode is set to Temp ESD In this case whichever Heat demand decreases suddenly setpoint is lower will be used and substantialy Aux Temp begins to rise above normal levels 1 System is started Process Control begins Aux Temp begins to rise In this case the Aux Setpoint is used as another ESD setpoint It is always compared against Q AuxTemp rises above the Aux the Auxiliary Temperature signal which depends on the Process Control setting The system Setpoint the system shuts down will immediately shut down if this signal exceeds this setpoint the Aux Temp begins to decrease slowly This particular graph is a representation of an Aux Temp ESD Process Control is set to Proc TC and Aux Temp Mode is set to Temp ESD Once the Auxiliary Temperature exceeds the Aux Setpoint the system will shut down and require user input to acknowledge the error CHART EVENT 1 a 5 x Decreased Heat Demand 4 Modes and Behaviour 4 3 Contact Behaviour This section discusses the behaviour of the PF2100 s input and output contacts and its response to external signals 4 3 1 Status Output The Status Output Contact is generally used to provide a
102. ptional 2 7 1 Status Contact The status contact is a dry contact output comprised of a solid state relay It can be thought of as a switch which the PF2100 controls Neither contact is internally connected to power or ground so these connections must be provided externally as required When the system is run ning the contacts are internally connected together and when the system is not running the contacts are open circuited These contacts are typically used for remote monitoring of the PF2100 s status An alarm siren trouble lamp or PLC are examples of devices that might be con nected to this contact The status contacts are rated for DC only so it is important to observe the correct polarity when attaching an external device The positive sta tus contact terminal should always be at a voltage potential that is greater than or equal to the negative terminal Be careful not to exceed the voltage and current ratings which are 40VDC 250mA The impedance when closed 15150 There is a fuse on the status contact to protect it A spare fuse is also included 2 Installation 2 1 2 Dry Contact Inputs There are 6 dry contact inputs on the PF2100 The expected connection to each of these is a switch These contacts must all be closed shorted in order for the system to start Jumpers are provided for each of these by default If you need to use a particular contact for your application simply remove the associated jumper and connect a switch in it
103. re Reading TC Debug Screen Alarms AUX Setpoint 3 User Interface amp Settings High Pressure ESDs Low Pressure ESDs Door Card Voltage Reading VETERES Level Event Restart Commission Date Pressure Level Delay Level ESDs Thermocouple Errors Location Control State Terminal Card Errors System Errors View Event Log Clear History Terminal Card State EVENT LOG Event 1 Event 2 e Event 31 Event 32 Alarm Mode Password Enable menus 1 3 Display Sleep Pilot Valve Power Setting Main Valve Power Setting System Voltage Setting Temperature Display Units Commission Date Entry Commission Location Entry Reset to Factory Defaults SYSTEM MENUS 5 7 SCREEN NAVIGATION ADJUSTMENTS HOME N A ADJUST PROCESS gt 5 CONTROL SETUP Eg 6 EKPANSION carps 3 7 CALIBRATION SETPOINT IN REAL TIME q HOME LEVEL 2 PASSWORD MAY BE REQUIRED SCREEN TO ENTER REVIEW e v a e M a H MANUAL E a E REVIEW cycLE N A 0 RETURN HOME High Temp ESD Setpoint 4 20 Expansion Card Enable Cal Process TC Zero T X EVENT N A Process Control Input 4 20 Level Low Setpoint Cal High Temp TC Zero LOG E RETURN HOME Low Fire Enable 4 20 Level High Setpoin
104. re as follows 1 Open the Start Contact and leave it open The system will stop immediately VIA A SHUTDOWN CONDITION Whenever any shutdown condition is present the system will stop and will not automatically restart after the condition is removed Examples of conditions that cause a Shutdown include the Process Temperature rising above the High Temp ESD Setpoint the High Pressure Contact Opening or the ESD Contact Opening Many other conditions can cause shutdowns Some are dependent on system settings REMOTELY VIA THE MODBUS CARD IF INSTALLED This method can be used to stop the system via a remote device over a Modbus RTU network The steps to do this are as follows 1 remote device should write 4321 to the 40100 register to stop the system 2 The remote device should poll the 40100 register and wait for it to clear to zero which indicates that the system has processed the command The remote device should poll the 10001 register and wait for it to become set to zero which indicates that the system is stopped 3 User Interface amp Settings 3 5 3 Adjusting Settings amp Reviewing Status There are four ways to check and adjust system settings and to view system status HOME SCREEN REVIEW MENU In Manual Mode the Home Screen displays the System State and The Review Menu is used to check key setpoints and to view various the Process Temperature In Auto Mode the Home Screen displays real time system mea
105. rectly If it is deemed necessary to proceed with recalibrating the PF2100 follow the procedures below carefully Failure to perform the calibration correctly may result in worse performance than if the system had been left alone The PF2100 uses a two point calibration system to provide readings with greater accuracy than a single point offset calibration The first point compensates for any fixed offset in the system and the second point defines the slope If the calibration fails for any reason there is an option in the calibration menu to clear all calibration data 3 User Interface amp Settings 3 5 8 Field Calibration Continued CALIBRATING THE THERMOCOUPLES For thermocouples the first calibration point is zero volts which corresponds to the ambient temperature of the terminal block where the thermocouple plugs into the Terminal Card The second calibration point is referenced to a known temperature that is well above the ambient temperature This temperature is typically the hottest temperature at which the system will operate but should not be higher than 1350 C and should not be lower than ambient 20 C The calibration procedure is as follows 1 2 10 11 Ensure that the system is stopped Remove the 3 pairs of thermocouple wires High Temp Process and Aux from the P8 Pluggable Header on the Terminal Card Short each pair of thermocouple inputs individually using a jumper or short piece of copper wire ie
106. remote indication of whether the system is operating normally It can be connected to a PLC and used to trigger a remote alarm so that a service technician can be sent to the site in the event of trouble In general the contact will be closed when the system is running and it will be open when the system is not running Five exceptions to this are as follows 1 ON START When the system is first started the status contact will remain open until after the pilot has been successfully lit 2 ALARM MODE If the Alarm Mode setting in Menu 4 is No Alarm When Off the contact will remain closed if the system is stopped because the Start Contact is open 3 LOWTEMP ALARM If the Low Temp Alarm feature is enabled in Menu 1 and the Process Temperature is currently below the Low Temp Alarm Setpoint the Status Contact will be open The contact will close again as soon as the temperature rises above the Low Temp Alarm Setpoint 4 WHILE WAITING If the system is in a waiting state the status contact will remain closed 5 WHILE RESTARTING If the flame blows out and the system is in the process of relighting the pilot the status contact will remain closed If the pilot fails to relight within the specified number of Restart Attempts then the contact will open 4 Modes and Behaviour 4 3 1 Status Output Continued CHART 1 LOW TEMP ALARM DISABLED ALARM MODE ALARM WHEN OFF CHART 1 EVENTS CU OO oO A 3 09 Start Con
107. ress the Menu Key repeatedly until Cal 4 20 Out Span is shown on the display Use the Up and Down Keys to adjust the output current until the current meter reads 20 0mA Press OK and the message Parameter Saved will show on the display briefly Press and hold the OK key for 3 seconds until the message Password Logout is displayed on the screen The Calibration Menu is now hidden again 3 5 8 Field Calibration Continued CALIBRATING THE 4 20MA INPUTS For the 4 20mA Output the first calibration point is 4mA and the second calibration point is 20mA You will need a handheld pro cess calibrator such as the Fluke 725 The calibration procedure is as follows 1 2 Ensure that the system is stopped Ensure card is installed and enabled in menu 6 The LVL and PRS DIP switches must also be enabled on the card Press the UP and DOWN Keys Press the Menu Key repeatedly until Menu 7 is shown Press OK enter the L2 Password if prompted A V A A V A Connect the process calibrator s negative lead to the ground pin on the 4 20mA Input Card Calibrate the Level Zero a Press the Menu Key repeatedly until 4 20 Level Zero Calibration 2 No is shown on the display Use the Up or Down key to select Yes and begin the calibration process The display will now read Apply 4mA then press Disconnect any wiring that is connected to the Level input and instead attach the process calibrator s posit
108. ress the OK Key to confirm that you want to start the system From this point onward the system s process control algorithm will take over to turn the valves on and off as required by the systems settings and the current Process Temperature The system will also be in Auto Mode which will allow the system to automatically restart from faults specified in the system settings MANUALLY VIA THE PILOT IGNITE AND MAIN KEYS This method of starting the system is useful primarily during com missioning when it may be desired to test the pilot valve main valve ignition circuit and flame detection circuitry in a slow sequence The steps to do this are as follows 1 Ensure that the system is stopped in Manual Mode with all alarms clear so that the Home Screen displays Ready 2 Press and hold the Pilot Key to open the Pilot Valve Listen to ensure that you can hear the Pilot Valve click open and that you can hear the hiss of gas flowing through it 3 While continuing to hold the Pilot Key press and hold the Ignite Key to being sparking Visually check the Pilot Nozzle for spark and flame If you cannot see the Pilot Nozzle listen for the sound of sparking and try to determine if it is coming from the ignition rod or from some other unintended location 4 Release the Ignite Key and check that the display shows a Flame Quality of 10096 5 After about 5 seconds the display will show Pilot On if the Pilot was successfully lit
109. roc Temp drops below Process Setpoint Main Valve opens and Proc Temp begins to increase Heat demand increases because the rate of flow in the pipeline increases or the inlet temp increases The Aux Temp bath temp begins to increase while the Proc Temp outlet temp stays low AUX TEMP ux Temp rises above the Aux Setpoint and Main Valve closes to protect the bath and fire tube i uxTemp drops below Aux LOW FIRE i d di l L i oSpgg MM M Setpoint minus Deadband and Main PROCESS Valves turn on again m Q Increased Heat Demand 4 Modes and Behaviour 4 2 7 High Temp ESD The High Temp ESD Setpoint is always compared against the High Temp Thermocouple regard less of the Process Control setting The system will immediately shut down if this thermocou ple exceeds this setpoint Becasue the High Temp Thermocouple and Process Thermocouple must always be in the same thermowell these two thermocouples can be thought of as being the same Note that the internal signal to which the Process Thermocouple is associated Proc Temp or Aux Temp will change depending on the Process Control setting This particular graph is a representation of a high temperature shutdown As shown the Pilot Off Setpoint is enabled This means that there is no heat being applied to the fire tube after the Process Tempera
110. s place START CONTACT The Start Contact can be used to attach a remote start stop switch This is typically connected to a PLC dry contact output When the contact is open the system is stopped For safety reasons a double action is required to start the system remotely via this con tact This is accomplished by closing the switch opening it and then closing it again Once the system is running simply open the switch again to stop it ESD CONTACT The ESD Contact can be used to attach an emergency shutdown switch This is typically connected to a mushroom switch mounted on a remote panel or to a PLC dry contact output When the contact is open the system is stopped The system cannot be started via this contact but this contact must be closed in order to start the system 2 Installation PROOF OF CLOSURE CONTACT The Proof of Closure Contact can be used to receive the feedback sig nal from a Main Valve that has a Proof of Closure output If multiple main valves with Proof of Closure outputs are used these can be wired together in series Before the system attempts to light the pilot it will check that the Proof of Closure Contact is closed If it is open it will not light the pilot HIGH PRESSURE CONTACT The High Pressure Contact can be connected to a High Pressure Switch installed in the fuel train Typically this switch is placed imme diately after the Main valve in the fuel train When the system initially
111. se the Level Contact was opened or the 4 20mA Low Level Level ESDs Setpoint was dropped below LO PRS ESD The system shut down because the Low Pressure Contact was opened or the 4 20mA Low Low Pressure ESDs Pressure Setpoint was dropped below 3 User Interface amp Settings 3 5 5 Viewing Event Log Continued DESCRIPTION ASSOCIATED COUNTER LO VOLT The system input voltage dropped below the Low Voltage Alarm threshold ESDs pu a mE M M aoe Ds a m E mm E nc n Mu T Ke IET I cu m iu ah TA EC SS UE M Pc ien o n uu mum shutdown 5 EET pc cu ar annui AI MEI 6 KA AN mx PEE mS ton mcum p aka na Pan SA AN KN EE AOE A PTT SET D ET E o d s i TM M M TA Eo eee ee te EC 0 Vu UAM NUR T r RUE estive EN Ae EE a E ER pue p uU viu 3 User Interface amp Settings 3 5 5 Viewing Event Log Continued ENTRY DESCRIPTION ASSOCIATED COUNTER TC NOT EQ The system detected an unacceptabl
112. short HT to HT short Proc to Proc and short Aux to Aux Press the UP and Down Keys simultaneously to unlock the Cali bration Menu Menu 7 which is normally hidden Press the Menu Key repeatedly until Menu 7 is shown Press OK enter the L2 Password if prompted AV A A A Cal Proc TC Zero will show on the display Press OK and the message Calibrating Wait will appear on the display for about 5 seconds Afterwards the message Pa rameter Saved will show on the display briefly Press the Menu Key to go to the next item Repeat steps 8 and 9 for the Cal HiTemp TC Zero and Cal Aux TC Zero menu items Reconnect the 3 pairs of thermocouple wires High Temp Pro cess and Aux to the P8 Pluggable Header on the Terminal Card 12 13 14 15 16 17 18 Set the High Temp Process and Aux thermocouples to a known reference temperature using a dry block or other calibrated refer ence The reference temperature should be at least 20C above the ambient temperature and preferably close to the maximum planned operating temperature Cal Proc TC Span will show on the display Use the Up and Down Keys to adjust the temperature displayed on the PF2100 to match the temperature being applied to the thermocouple Note that multiple key presses may be required before the temperature value on the display changes This is be cause each key press is adjusting a fractional multipli
113. ss Control and Aux Temp Mode are used Recommended Settings SETTING USER SETTING Process Control Process TC AuxTemp Mode Disabled THERMOCOUPLE LOCATION Process High Temp Bath 4 Modes and Behaviour 4 5 2 Stack Protection For any application where it is desired to monitor and protect the stack from overheating two ther mowells are required One for the process being controlled and one for the stack The illustration below portrays a Tank Heater as an example The Process and High Temp Thermocouples are both placed inside of the thermowell in the tank The Aux Thermocouple is placed in a separate thermow ell inside of the stack The default setting for Process Control is used and Aux Temp Mode is set to Temp ESD This allows the system to shutdown the burner if the stack temperature rises above the Aux Setpoint Recommended Settings SETTING USER SETTING Process Control Process TC Aux Setpoint Maximum Tolerable Stack Temperature THERMOCOUPLE LOCATION Process High Temp Bath Q Aux Stack 4 Modes and Behaviour 4 5 3 Outlet Temperature Control For any application where it is desired to control the outlet temperature indirectly via the temperature of a bath two thermowells are required One for the bath and one for the outlet The illustration be low portrays a Line Heater as an example The Process and High Temp Thermocouples are both placed inside of the thermowell in the bath The Aux Thermocoup
114. stem begins running again 4 Modes and Behaviour 4 4 2 4 20mA Pressure Input Continued CHART 5 LEVEL EVENT RESTART DISABLED CAUSE amp EFFECT EVENT Q 00 System already running with pressure between High and Low UMEN MEN setpoints 20 i PRESSURE HIGH SP id o9 Hand valve on fuel train closed PRESSURE LOW SP peser Moo oM DE a Pressure begins to drop 4 20 PRESSURE Pressure falls below the low set mmm Sanepan agan akak anana ng anga adan Aak NUES point Delay timer starts counting poa down max valve depends on the Level Pressure Delay setting Delay timer expires and system RUNNING SHUTDOWN shuts down Hand valve is opened and pressure increases quickly Q Pressure rises above low setpoint but system does not restart and remains shut down 4 Modes and Behaviour 4 5 Example Applications The following section gives examples of common applications The recommended process control settings for that application are provided as well as instructions on the placement of the thermocouples 4 5 1 Simple Heater For a simple heater such as a tank heater the process being controlled is the temperature of the liquid in the tank Only a single thermowell is required to measure this The Process and High Temp Thermocouples are both placed inside of this thermowell The Aux Thermocouple is not needed and is therefore not connected The default settings for both Proce
115. surements such as temperature pressure and the Process Setpoint and the Process Temperature The information level All information in this menu is read only The Review Menu is displayed on the Home Screen is read only except as noted below only accessible when the system is in Manual Mode To access it The Home Screen is accessible at any time by pressing and holding press the Up or Down Key while on the Home Screen the OK Key for 3 seconds SYSTEM MENUS QUICK SETPOINT ADJUST Menus 1 4 5 and 6 are used for checking and adjusting settings In Auto Mode the process setpoints can be adjusted directly from Menus 2 and 3 are used for read only values Menu 7 is used for the Home Screen using the Up and Down Keys This feature allows calibration and is usually hidden The System Menus are accessed several setpoints to be adjusted simultaneously by moving them all by pressing the Menu Key from the Home Screen while in Manual up or down together as a group The setpoints that are affected are Mode Some menus are not accessible while the system is running the Low Fire Setpoint if enabled the Process Setpoint and the Pilot Off Setpoint if enabled The adjustments are limited on the high Menu 3 contains some system status information that is not found and low side as described in section 3 4 10 Process Setpoints Any elsewhere in the menu system Refer to section 3 3 3 System Info changes made take effect immediately This feature is protected b
116. t Cal Aux TC Zero SYSTEM n CYCLE mE DE TO ADJUST RETURN HOME Low to High Fire Delay 4 20 Level Range Cal Process TC Span MENUS g El ro ACCEPT a TO CANCEL ANY E TOGGLES MODES AUX Temp Mode 4 20 Pressure Low Setpoint Cal Aux TC Span AUTO MANUAL 7 ecc FIRMWARE VERSIONS 4 20 Output Mode 4 20 Pressure High Setpoint Cal 4 20 Level Zero amp ENTER DEBUG MODE i i E a PRESS AND HOLD FOR 3s TO 4 20 Low Fire Setting 4 20 Pressure Range Cal 4 20 Level Span EXIT DEBUG MODE LOCK MENUS AND RETURN HOME 4 20 Gain Setting 4 20 Pressure Units Cal 4 20 Pressure Zero Will also adjust Pilot Off and Low Fire Setpoints if enabled MODBUS Enable Address Cal 4 20 Pressure Span 4 20 Card FW Version Cal 4 20 Out Zero FOOTNOTES MODBUS Card FW Version Cal 4 20 Out Span Hidden when Aux Thermocouple is disabled in Menu 5 Hidden when 4 20 Input Card is disabled in Menu 6 or LVL DIP Switch disabled on card Hidden when 4 20 Input Card is disabled in Menu 6 or PRS DIP Switch disabled on card Display TC Zero Factors 1 2 3 4 Hidden when No Alarms are present Display TC Span Factors 5 Hidden when Low Fire is disabled in Menu 5 6 7 8 9 Hidden when Pilot Off is disabled in Menu 5 Display 4 20 PRS Factors Hidden when 4 20 Output Mode in Menu 5 Temperature Out Edit fields using arrow keys Advance fields using OK Display 4 20 LVL Factors d 3 Required if enabled in Menu 4
117. tact toggled twice to start system System begins running Flame is detected by the system Status contact closes Start Contact opens START CONTACT STATUS CONTACT CHART 2 LOWTEMP ALARM DISABLED ALARM MODE NO ALM WHEN OFF CHART 2 EVENTS QUE n nO Start Contact toggled twice to start system System begins running Flame is detected by the system Status contact closes Start Contact remains closed START CONTACT STATUS CONTACT 4 Modes and Behaviour 4 3 1 Status Output Continued CHART 3 LOWTEMP ALARM ENABLED CHART 3 EVENTS EVENT 1 O 6 7 User starts system in Auto Mode _ _ Ignition sequence begins PROCESSSP idi EE EE System ignites pilot Proc Temp LOW TEMP ALARM begins to increase slowly PROC TEMP Flame was detected Status Contact remains open 0 Pilot to Main Delay elapses Main turns on Proc Temp begins to increase rapidly FLAME Proc Temp exceeds Low Temp Alarm Setpoint Status Contact CLOSED ee closes STATUS CONTACT Heat demand increases due to the sun going down or a cold front blowing in Proc Temp begins to drop Increased Heat Demand 9 Proc Temp drops below Low Temp Alarm Setpoint Status Contact opens 4 Modes and Behaviour 4 3 2 Start Input The Start Input Contact is used to remotely stop and start the PF2100 This can be done by c
118. tains instructions on how to operate the system 3 1 Hardware User Interface The hardware user interface consists of three parts 1 Indicator lights 2 A Keypad 3 An illuminated display 3 User Interface amp Settings 3 1 1 Keypad Diagram DISPLAY MENU KEY UP KEY MODE KEY PILOT LIGHT PILOT KEY IGNITE LIGHT 3 User Interface amp Settings STOP KEY FLAME LIGHT OK KEY DOWN KEY AUTO LIGHT IGNITE MANUAL LIGHT MAIN LIGHT MAIN KEY IGNITE KEY 3 1 2 Indicator Lights FLAME LIGHT Indicates that the system is detecting the pilot flame AUTO LIGHT Indicates that the system is running in auto mode 3 1 3 Keys STOP KEY Used to stop the system immediately or in other words turn off the burner MENU KEY Used to navigate through the menu UP KEY Used to adjust a setting upwards and to scroll up through lists MANUAL LIGHT Indicates that the system is running in manual mode PILOT LIGHT Indicates that the pilot valve is open DOWN KEY Used to adjust a setting downwards and to scroll down through lists OK KEY Used to enter a menu acknowledge a prompt save an edited setting or return to the home screen MODE KEY Used to toggle between Manual and Auto modes of operation IGNITE LIGHT Indicates that the system is sparking to ignite the pilot MAIN LIGHT Indicates that he main valve is open PILOT
119. ted Q User opens Start Contact again System is now waiting for Start Contact to close again User closes Start Contact again System begins running Q User opens Start Contact System shuts down immediately 4 Modes and Behaviour 4 3 3 ESD Input The ESD Input Contact is used to stop the PF2100 in the event of an emergency This is CHART EVENTS normally done by connecting the contact to the site s ESD Loop The PF2100 will shutdown immediately when the contact is opened and cannot be restarted until the contact is closed The PF2100 will not restart automatically if the ESD contact is subsequently reclosed but must ESD Contact opens instead be restarted via the start contact the keypad or the Modbus card system shuts down 1 System already running ESD Contact closes CHART system does not restart ESL i ooo automatically and remains shut EVENT Q down EB af AE us e CLOSED RUNNING SHUTDOWN If this contact is not needed it must be shorted out with the provided jumper or a wire 4 Modes and Behaviour 4 3 4 Proof of Closure Input When the PF2100 is started it drives the Main Valves to the closed position If for some CHART EVENTS reason the valves do not close a dangerous situation can result This condition might arise if a The system begins in the Alarm valve is mechanically damaged frozen open or has been wired incorrectly If undetected the 9 9
120. teps to do this are as follows 1 The remote device should write 1234 to the 40100 register to place the system into Auto Mode The remote device should poll the 40100 register and wait for it to clear to zero which indicates that the system has processed the command The remote device should poll the 10001 register and wait for it to become set to one which indicates that process control is running 3 User Interface amp Settings 3 52 Stopping the System There are five different ways to stop the system MANUALLY VIA THE STOP KEY This is the most common way to stop the system The steps to do this are as follows 1 Press the Stop key The system will stop immediately MANUALLY VIA THE AUTO KEY This method of stopping the system is useful primarily during com missioning when it may be desired to test the pilot valve main valve ignition circuit and flame detection circuitry in a slow sequence The steps to do this are as follows 1 Press the Mode Key to switch the system into Manual Mode which will prevent the system from automatically restarting from faults specified in the system settings 2 Press the Main Key to close the Main Valve and disable process control 3 Press the Pilot Key to close the Pilot Valve and stop the system REMOTELY VIA THE START CONTACT This method can be used to stop the system from a remote switch mounted elsewhere on the site or via a PLC output relay The steps to do this a
121. the PF2100 and the pilot assembly is present and secure b Check that the Modbus Card has the latest firmware Firmware older than v4 0 did not support this feature e Put the PF2100 into Manual Mode and use the Review FLAME DETECTION Menu to check the flame quality level 1 System Has Visible Flame But Cannot Detect It f Consult the instructions in the section 5 5 Flame Detection Troubleshooting Guide for further details on a The flame rod pilot assembly and the gap between them Flame Detection should be fully engulfed in flame If not adjust the rod positioning 5 Troubleshooting 5 1 Common Issues amp Solutions Continued SHUTDOWN 1 2 3 System shuts down with a High Low Voltage message shutdown a Ensure that the system voltage setting is set to match the power supply s nominal voltage b Check that the system has the latest firmware Firmware older than v1 8 005 was prone to shutdown on transient voltage spikes and dips c Ensure that some other load is not causing the supply to droop periodically This can be done by simply removing other devices from the supply or if that is not an option monitor the supply voltage with a data logger d Ensure that the power supply is rated appropriately for the valves and other peripheral devices attached to the PF2100 Refer section 2 6 1 Power for details System shuts down on High Temperature ESD a Check that the HT ESD setpoint is not set too cl
122. the proper PWM setting is used for each valve d Check if the valve voltage ratings match the system voltage 12V or 24V 2 System shuts down with terminal card command refused mas ter power solenoid feedback a Check solenoid wiring to ensure that no wires are crossed and separate return wires are used for each valve STATUS CONTACT 1 Status Contact Opens But System Continues to Run a Check that the system has the latest firmware Some firmware versions older than v1 8 005 had a bug that might lead to this under certain circumstances If you can t update your firmware immediately repositioning the flame rod so that it is more fully immersed in the flame can lessen the occurrence of this issue 2 Status Contact Never Closes a current or voltage ratings on the status contact may have been exceeded Verify that you are not exceeding these ratings If the ratings were exceeded check the terminal Card HW version to determine the appropriate solution i v1 6 Replace the Terminal Card ii v1 7 Replace the Status Contact Fuse on the Terminal Card THERMOCOUPLES 1 Thermocouple Readings are Bouncing a Verify that the Valve PWM Settings are correct for the valves that are being used Using incorrect settings for a valve can result in more noise than necessary The lowest noise will result when the PWM setting is set to 20 for low power valves and 10096 for regular valves b Verify that proper system gro
123. the valve open Do not use a duty cycle of 10096 with low power valves as this can damage them Likewise do not use a duty cycle of 2096 with a High Power valve as it will not work properly If a multimeter is used to measure the valve power the measured voltage will be reduced proportionally with the PWM setting There are two valve power settings that can be adjusted to match the needs of various applications These are as follows PILOT VALVE POWER SETTING MENU 4 Adjusts the PWM Duty Cycle of the Pilot Valve output MAIN VALVE POWER SETTING MENU 4 Adjusts the PWM Duty Cycle of both the Low Fire and High Fire Valve outputs 3 5 Operating the System This section of the manual describes how to operate the system including how to start and stop it in various ways how to review key system settings how to adjust setpoints while the system is running how to check the system firmware versions how to reset the system settings to defaults and how to manually calibrate the various inputs and outputs 3 User Interface amp Settings 3 5 1 Starting the System There are five different ways to start the system MANUALLY VIA THE MODE amp OK KEYS This is the most common way to start the system The steps to do this are as follows 1 Ensure that the system is stopped in Manual Mode with all alarms clear so that the Home Screen displays Ready 2 Press the Mode Key and a confirmation prompt will show on the Display 3 P
124. ture exceeds the Pilot Off Setpoint yet the temperature continues to in crease Once the Process Temperature exceeds the High Temp ESD Setpoint the system will shut down and require user input to acknowledge the error CHART EVENT oe HIGH TEMP ESD SP PROCESSSP S S s amp E n Decreased Heat Demand 4 Modes and Behaviour CHART EVENTS System is started Pilot Valve opens High Temp Thermocouple temperature begins to increase slowly Pilot to Main Delay elapses Main Valve opens High Temp Thermo couple temperature begins to increase faster High Temp Thermocouple tem perature exceeds Process Setpoint Main Valve closes High Temp Thermocouple temperature begins to drop High Temp Thermocouple tempera ture drops below Process Setpoint minus Deadband Main Valve opens High Temp Thermocouple temperature begins to increase again Heat demand suddenly and substantialy decreases This could be caused by a rapid decrease in flow by the line heater or a sudden emptying of a tank heater The High Temp Thermocouple temperature rises above the High Temp ESD Setpoint system imme diately shuts down the High Temp Thermocouple temperature begins to decrease slowly 4 2 8 Aux Temp ESD If the Aux Temp Mode is set to Temp ESD then the Aux Temp signal must be below the Aux CHART EVENTS Setpoint or the system will shut down Normally this happens inde
125. uch as System Starts Stops Shutdowns Menu Accesses etc The log holds a maximum of 32 events The first event 1 is the most recent and the last event 32 is the oldest When the log is full the oldest event is removed from the list to make room for the next newest event Navigate through the log using the up and down arrow keys Press OK to return to the Home Screen The log can be cleared using the item at the end of Menu 2 Clearing the log also resets all event counters to zero The following is an alphabetical list of all possible Event Log entries including a brief description of their meaning and the associated counter which will increment when that event occurs ENTRY DESCRIPTION ASSOCIATED COUNTER AUTO The system switched to Auto Mode because the user pressed the MODE and OK button See oe nau t Muss E tenni ctu Aux Setpoint pa lt ndun d RHEINE NOIRE E Pa ied A A 3 attempts on initial start user defined for other cases HI PRS ESD The system shut down because the High Pressure Contact was opened or the 4 20mA High High Pressure ESDs Pressure Setpoint was exceeded HI VOLT The system input voltage exceeded the High Voltage Alarm threshold ESDs HT ESD The High Temp ESD Setpoint was exceeded by either Proc Temp or Aux Temp if en ESDs abled and caused the system to shutdown LEVEL ESD The system shut down becau
126. ul in circumstances that will be explained later INTERNAL SOFTWARE SIGNALS i EXTERNAL PHYSICAL CONNECTIONS High Temp High Temp Thermocouple f Thermowel 1 Process Thermocouple PROCESS CONTROL ProcTemp ALGORITHM Aux Temp Process Control Setting Acts like a DPDT Switch Aux Thermocouple Q Q O00 0 4 Modes and Behaviour 4 1 4 Process Control Continued In all circumstances the High Temp Thermocouple and the Process Thermocouple are expected to be mounted in a common thermowell This is usually accomplished by using a duel ele ment thermocouple The software uses these two thermocouples as a check for each other to ensure that one or the other is not defective If the readings from these two thermocouples do not agree within a specified amount of error the system will shutdown The High Temp signal is used to protect the burner and other process equipment from be ing damaged from excessive heat It cannot be disabled through any combination of process control settings The Proc Temp signal is the primary control signal for the process control algorithm This signal is compared to the Deadband Low Temp Alarm Setpoint Process Setpoint Low Fire Setpoint and the Pilot Off Setpoints in order to control the temperature of the process The Aux Temp signal can be used as a secondary control signal within the process control al gorithm The way that this signal is used will vary depending
127. unding is being observed Especially check that all solenoids are properly connected to earth ground 2 Thermocouple Readings are Incorrect a Check if the thermocouple wiring polarity is reversed Yellow should be connected to positive and red to negative b Check that no thermocouple pairs are crossed ie positive from one TC paired with negative from another TC c Ensure that only type k thermocouple wire and connectors are used Even small sections of other types of wire can significantly disrupt the measurement d Ifa head connection is used verify that none of the above wiring issues exist there either e Check if the thermocouple is defective by trying a different thermocouple that is known to be good or by connecting the suspect thermocouple to a process calibrator f Check that the PF2100 is in proper calibration using a process calibrator If not recalibrate the system 5 Troubleshooting 5 2 Shutdown Messages The following is a list of messages that may flash on the PF2100 display after the system has shutdown Typically the word SHUTDOWN in large text will flash alternately with one of the messages below These messages indicate the reason that the system last shutdown and can be cleared by pressing the OK key except where noted Use the table below to determine the meaning of these messages This table is organized alphabetically ON SCREEN DESCRIPTION Ambient Temps Not Equal Comparison The Do
128. ure FW VERSION WARNING SCREEN MESSAGES SHUTDOWN FW VERSION WARNING SCREEN MESSAGES SCREEN 3 User Interface amp Settings 3 2 1 Manual vs Auto Mode When the system first powers on it will normally be in Manual Mode If the Auto Restart feature is enabled and no alarm conditions are present it may switch automatically to Auto Mode after power up Otherwise the user must manually put the system into Auto Mode by using the Keypad the Start Contact or the Modbus Expansion Card For further details on how to start the system refer to section 3 5 1 Starting the System The main difference between these two modes is that all settings can be adjusted in Manual Mode whereas they cannot in Auto Mode The following table illustrates further differences ITEM MANUAL MODE AUTO MODE User Can View and Adjust Menu Settings Yes via Quick Setpoint Adjust Auto Indicator Light On No Yes Menus 1 3 only when process control is running all menus when stopped 3 User Interface amp Settings 3 2 2 The Home Screen is shown on the display after power up after waking the display from sleep and after the user acknowledges a shutdown message It is the starting point for most user interaction with the menu system To return to the Home Screen from any point in the user interface the user can press and hold the OK key for three seconds On the Home Screen the Process Temperature is always shown on the bott
129. us Low Pressure Contact and High Pressure Contact sections The difference is that a Pressure Transmitter is used instead of a pair of Pressure Switches and the setpoints are set via a menu instead of mechanically on the switches When the 4 20 signal is below the low setpoint or above the high setpoint the system will stop When it is between the two setpoints it will run It can be setup to restart from a low event but not from a high event To use the 4 20 Pressure Input it must be setup as follows 1 Attach a properly calibrated Pressure Transmitter to the 4 20 Pressure Input Enable the Pressure DIP Switch on the 4 20 Card Enable the 4 20 Card in Menu 6 Set the Pressure Low Setpoint High Setpoint Range and Units in Menu 6 gu a wN Disable the Low Pressure and High Pressure Contacts by installing a jumper in each of them CHART 1 PRESSURE INCREASES WHILE RUNNING EVENT 4 20 PRESSURE 4mA PILOT DELAY SHUTDOWN SYSTEM STATE CHART 1 EVENTS 1 System started by user with pressure between low and high setpoints Pressure regulator fails while the mains are turned on Pressure begins increasing Pressure exceeds High Setpoint and system shuts down 4 Modes and Behaviour 4 4 2 4 20mA Pressure Input Continued CHART 2 PRESSURE HIGH FROM START EVENT 4 20 PRESSURE 20mA PRESSURE HIGH SP PRESSURE LOW SP 4mA PILOT DELAY MAIN SHUTDOWN CHART 3 PRESSURE H
130. us Expansion Card is also installed TANK HIGH LEVEL DRY CONTACTS Both Normally Open NO and Normally Closed NC contacts are pro vided When the Level reading is above the High Level Setpoint the NO contact will close and the NC contact will open The opposite is true whenever the Level reading is below the High Level Setpoint This can be used to control auxiliary equipment such as a warning light an alarm or the pump that is filling the tank Refer to the 4 20mA Expansion Card Manual for further details on installation and operation of this card 4 20mA EXPANSION CARD Some PF2100 models come with this card pre installed 2 Installation 3 User Interface amp Settings The user interface is comprised of two parts a physical interface including things such as keys and indicator lights a software interface including things such as menus and status screens This section of the manual is organized into four sub sections The first two deal with the physical and software interfaces At the end of the software interface sub section is a menu map which is useful for quick reference Following this is a table that provides summary information about each item in the menu map along with the location in the manual where more detailed information can be found The next sub section contains detailed information about all of the settings that can be adjusted and is organized alpha betically by topic The final sub section con
131. vto cen toe aan bebo eed eese oe oe Boo e edge edu 36 2312 e creer ag Bn a a Rp OR UE cir ER NS ELEM CE heey 37 313 EEUU NUM na aga aa 37 EE MSIE ec 38 3 2 Software User Interface iccsece eee E ere e sacrae Fen redo Ee d eaa E dg edo aen 38 3 21 Manual VS Auto MB toot ree asana ae a ia pa tee desee ias 39 322 GME SCM Iken asana baa A aga aaa aaa ga a ad BAE ag 40 3 2 8 System State eem 40 3 2 4 Quick SetpointAdjustment eaaa eee aaa eaaa em e emere eee esee eren neis 41 325 41 326 CUI MucUm 41 3 2 7 Firmware Version Screen aaa eee h rokr err arrra EEA EE tese arie eaaa 41 3 2 8 Warning Messages aee eee ere rer nier tre ii iiri e rere ers peris siia 42 3 2 9 Shutdown Screen vss ee baee ag gan apaa oon 42 ank 43 45 3 3 1 Setpoint MENU M A A 46 3 23 2 History Men 2 Erin o aa aa D SEO ev On 46 47 3 3 3 System Info Menu 3 He eme nhe hene e ree ree re eer sere e KA 47 48 39 3 4 System Setup MENA 2 E b a ge pa DA EE pae 48 49 3 3 5 Control Setup Menu D ana saga saga aga e
132. y the larger the burner the larger the delay should be This setting can be set to a minimum of 5s and a maximum of 6005 LOW TO HIGH FIRE DELAY MENU 5 This setting is used to set the minimum amount of time that must elapse between the low fire valve opening and the high fire valve opening This setting is only available if Low Fire is enabled in Menu 5 The Low to High Fire Delay is used to ensure that enough draft is established before switching to high fire If this is not done the vol ume of gas flowing through the high fire valve can snuff out the flame due to insufficient oxygen supply Generally the larger the burner the larger the delay should be This setting can be set to a minimum of 30s and a maximum of 600s PRESSURE LEVEL DELAY MENU 4 This setting is used to reject spurious electrical noise that may be present on the Low Pressure Contact Level Contact and the 4 20mA Expansion Card if installed This noise can come from electrical inter ference mechanical vibration or small oscillations in gas pressure and tank level The rejection is accomplished by requiring these contacts to remain open for a continuous period of time called the delay before shutting down In the case of the 4 20mA Expansion Card the Pressure and Level readings must remain below their respective low setpoints for the delay time before shutting down If Auto Restart or Level Event Restart are enabled the delays are applied before enter ing a
133. y for more details the L1 Password when password protection is enabled in Menu 4 When the system is stopped all settings can be checked and adjusted When the system is running only some settings may be checked or adjusted The following table illustrates the circumstances under which various settings can be checked and adjusted For more information about the menu system and the user interface refer to section 3 2 Software User Interface MODE HOME SCREEN QUICK SETPOINT CHANGE AVAILABLE REVIEW MENU AVAILABLE SYSTEM MENUS AVAILABLE Manual Mode System State No Yes 1 6 and sometimes 7 System Stopped Process Temperature Manual Mode System State No Yes 1 3 System Running Process Temperature Auto Mode Process Setpoint Yes No None System Running Process Temperature 3 User Interface amp Settings 3 5 4 Viewing Event Counters Menu 2 contains a series of counters that increment automatically in response to various events These counters can be used to troubleshoot issues with a particular installation Each counter will count to a maximum of 1000 and then will stop incrementing At the bottom of Menu 2 is an option to clear these counters Clearing the counters also clears the event log ESDs Increments each time the system shuts down as a result of the ESD Contact opening the High Temp ESD Setpoint being exceeded by either Process Temp or Aux Temp if enabled or a high or low voltage alarm FLAME FAILS Increments each tim
134. y tank can damage both the fire tube and the tank The Level Contact is time averaged to help reject brief fluctuations in tank level which might be a result of vibration The contact must be open continuously for 2 or 20 seconds depending on the Pressure Level Delay setting before the system will shutdown If Level Re start is enabled the system will restart automatically when the Level Contact recloses See section 2 75 4 20mA Expansion Card section for details 2 Installation 2 1 3 4 20mA Temperature Output If the 4 20mA Output is not being used to control a proportional valve it can be configured to output the process temperature encoded as a 4 20mA signal This is useful if a PLC on site needs to know the process temperature In this case wire the PF2100 s 4 20mA Output to a PLC s 4 20mA Input Note that the PF2100 provides the loop power The PLC resistance is expected to be in the range of 120 Ohms and 250 Ohms The 4 20mA output signal will be scaled such that 4mA represents OC and 20mA represents HT ESD Setpoint 2 7 4 Modbus Expansion Card An optional Modbus Expansion Card can be installed in the PF2100 which provides the following additional features REMOTE MONITORING This card allows for remote monitoring of the PF2100 status including process temperature auxiliary temperature and 4 20mA Input Card status if installed REMOTE START STOP This card can also be used to remotely start and stop the system

USER MANUAL REV 1.8.1 - Profire Energy, Inc.

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