USER MANUAL REV 1.0.0 - Profire Energy, Inc.
Contents
1. wire where it connects to the coil Is it close to the same voltage that was measured across the ION and ION terminals Check the ION wire for shorts to ground or nicks YES Replace the coil 5 Troubleshooting 5 2 Flame Detection Troubleshooting Guide Continued PREVIOUS PAGE Is the there flame present NO Set the Multi Meter to measure DC voltage across ION and ION with the system in manual mode i Remove the wire from ION and eS Is the reading across ION and ION Se COTE o around 5VDC the ION and ION terminals again Is the voltage across the ION and It is possible that the ION terminals around 5VDC terminal card is faulty Check the ION wire for nicks or other faults 7 Press the ON button and turn on gas so that the flame is present Take note of the voltage after the sparking while the flame is present The system is not seeing the flame at all The circuit from the rod through the flame to the nozzle to ground is not being completed Did the voltage drop below 5V when the flame was present ES 8 The system is sensing flame just not enough The DC voltage should drop to 5VDC or lower 8VDC is better for stable flame detection Check the grounding to the pilot nozzle Check for cracked ceramic on the flame rod2. 9 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 Recheck the orifice size and increase the pilot pressure Did placing the grounded rod in the flame improve the DC voltage reading Try replacing the pilot nozzle YES Set the system up to use separate rods for flame detection and ignition 5 Troubleshooting GENERAL FEATURES e Single rod ignition and flame detection e User configurable spark intensity e User configurable spark interval e User configurable timeouts e Status contact for remote notification of flame failure e Flame Light provides a visual indication of flame presence e 3 user selectable operating modes e Manual e On Demand e Continuous e Test mode and Debug LEDs help fine tune flame rod positioning during installation e 12 24VDC operation e Weather proof NEMA 4X enclosure e Integrated battery and solar charge controller e Low power consumption for up to 2 weeks of battery life SCBOO MODEL ONLY SC000 MODEL ONLY TECHNICAL SPECIFICATIONS TEMPERATURE RATINGS MIN MAX Operating Range SC000 40 C 40 F 80 C 176 F Operating Range SCB00 40 C 40 F 50 C 122 F Storage Range SC000 40 C 40 F 85 C 185 F Storage Range SCB00 40 C 40 F 60 C 140
3. L SPARK FLAME FAULT em ON BUTTO OFF BUTTO DEBUG LEDs RESET BUTTO SPARE FUSE gt Fama o T FW VERSIO SUNSAVER 6 SOLAR CONTROLLER SS 6 12V BATTERY TYPE SELECT JUMPER LOAD OUTPUT Solar Charge Controller only included with SCB00 model 2 Installation 2 5 Circuit Board Terminal Descriptions This table provides a brief description of each terminal and references to further detail TERMINAL EXPECTED CONNECTIONS DESCRIPTION SECTION Status Connect to PLC negative input con tact or other alarm device Connect to PLC positive input con tact or other alarm device This is a dry contact output used to indicate system status to an exter nal device eg a PLC The contacts will be closed when the system is running and opened when the system is shutdown Note that the contacts are not internally connected to power or ground 200V Peak AC or DC 150mA 592 2 8 1 Ground return for the ignition coil Connect to ignition coil primary black Driver for the low voltage primary of the ignition coil Connect to ignition coil primary red wire The primary of the ignition coil should be connected to these terminals DC pulses will be applied while sparking This output is protected by a 250mA thermal fuse ZA ZI These terminals are used to power the system Apply input power in the range of 12 24VDC 4A MAX Should connect to the solar charge controll
4. 1 Overview 1 1 1 Available Models alana alaan ne e e es e eh non ee e es e e en enis 3 12 Included COMPONENTS retener aio 4 13 Optional Components est else Mania ego din Led ato aee taedas 5 1 4 ExternaliDiagrami suac en ee i 6 1 5 Internal Dada aerea 7 1 6 Installation TVpeSs a nennen nennen rise rris a rrr siii 8 1 7 Regulatory Requirements i 8 2 O A a tas 9 2 1 Installation Vanings ista la 12 22 Mounting Location iii id a 13 2 3 Mounting ISTE CUIOMS see een ee poto patina 14 2 4 Circuit Board amp Solar Charge Controller Diagram nern 15 25 Circuit Board Terminal Descriptiva es 16 2 6 Solar Charge Controller Terminal Descriptions 17 2 7 hequiredWitings psn nia ina ae aio ao 17 231 SC000 Systeimn Wining asia 18 19 2 72 SCBOO0 System Wiring nenne nnnen nennen 20 21 28 Optional WIN da a A eerta a ii 22 2 8 1 Status Contatti da 22 2 82 SC000 ESDS With irrita tete nine Ria 23 2 83 SCBOD ESD Mitin ua usa 24 3 User Interface amp Settings 25 3 1 User lintentaces HM M 27 3 1 1 Keypad Dia d 28 31 2 O E 29 3 1 3 Indicator Lightez enden Pee ret Co odd tr 30 314 Debug l EDS renee ae tain An Fem ce ep tabe pps eee do ob osais 31 3 2 Seli 32 33 3 3 Operating the System 34 3 3 1 Starting the System 34 3 32 Stopping the Syste misil Het EC e re ana 35 3 3 3 LED Indicator Light Test eee ie 36 3 3 4 Viewing Firmware VEersions ii 37 38
5. The system failed to ignite and or detect flame before the timeout elapsed Try the following a b Check wiring for shorts to power or ground Check pilot assembly ground wiring Check pilot gas flow Check rod positioning Consider increasing the timeout setting Try suggested solutions to issue 3 to verify that the system can properly detect flame STATUS CONTACT NOT WORKING a Check for errors in wiring It is a dry contact and does not source power Ensure that the max voltage and current ratings are not exceeded If so the circuit board may be damaged Contact Profire to arrange for a repair replacement 5 2 Flame Detection Troubleshooting Guide System is not detecting flame 1 Does the flame LED come on then go out when the main turns on TES Does the system stay running with the flame arrestor open YES Clean the arrestor and look for other air restrictions The draft from the main No 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 QUESTION ARE IN WHITE RECTANGLES 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 PF1300 Ensure that the ignition rod is fully immersed in the flame With the sys
6. F POWER SUPPLY REQUIREMENTS VALUE Base Model SC000 12 24 VDC Battery Model SCB00 12V Solar Panel 40W MAX POWER CONSUMPTION 12VDC 24VDC Average Current When not Sparking 30mA 30 mA e LN E p iria 2 1 0 SA i i EE mi z EE Der Ded Li ci Maximum Wire Gauge 12 ANG Type a sest H ham A mass prora di Impedance When Closed PHYSICAL DIMENSIONS VALUE Width 30 9 cm 12 15 in Height 23 4 cm 9 23 in Depth 13 4 cm 5 28 in WEIGHT VALUE SC000 Model 3 2 kg 7 0 lbs SCB00 Model 6 0 kg 13 5 lbs 5 Troubleshooting TECHNICAL SPECIFICATIONS CONT BATTERY SPECS SCB00 VALUE Voltage 12V i on sas m RS a m RER EEA EEE NE FUHREN So TREES EN Ce e i anis a ai E RA centers dine een MORENA i pe i ia s ia AUTONOMY SCB00 VALUE Manual On Demand Mode Off State 112 days Rating 4A 125VDC Fast Blow rr dazio ci BROWN TAS Replacement Part Number On Semi SA24ARLG Down to 80 of Max Capacity Assumes operation O 25C Assumes interval 10s 5 Troubleshooting www profireenergy com 2013 PROFIRE
7. Ur TVS Zener Diode Optional External ESD Switch Not Included 2 Installation 3 User Interface amp Settings This section of the manual is organized into three sub sections The first deals with the user interface The next sub section contains detailed information about the settings that can be adjusted The final sub section contains instructions on how to operate the system 3 1 User Interface The user interface consists of three parts 1 A Keypad 2 Indicator lights 3 DIP Switches The following sub sections describe each of these in detail 3 User Interface amp Settings 3 1 1 Keypad Diagram SPARK LIGHT FLARE IGNITION SYSTEM FLAME LIGHT FAULT LIGHT ON KEY OFF KEY 3 User Interf X Settings 3 1 2 Keys There are two keys on the keypad that are used to operate the PF1300F ON e OFF For convenience during installation and debugging these keys PF1300F are also duplicated on the circuit board inside of the enclosure FLARE IGNITION SYSTEM ON KEY 1 The ON key is used to start or restart the system OFF KEY 2 The OFF key is used to stop the system PROFIRE ENERGY INC PF1300 v2 3 m dm mi SPARK FLAME FAULT 2 im LED Enable m u Da Unused m User Interface amp Settings wo 3 1 3 Indicator Lights There are three indicator lights on the keypad that are used to show the status of the PF1300F e SPARK e FLAME e FAULT For
8. and easily accessible The recommended mounting height is 1 5m 5ft 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 to adjust settings The system should not be mounted facing the sun to make it easier to observe the 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 close to the top of the flare stack 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 5 PRODUCT PROTECTION To protect the system from being damaged it should not be mounted a Where chemicals may splatter or bubble over from the flare onto the system Chemicals on the keypad may interfere with an operator s ability to control the product or view the LED indicators b Near the top of the flare 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 e
9. and may vary across systems and with temperature 4 1 Mode Descriptions There are three operational modes and one test mode that can be selected using the DIP switches The following chart describes the differences between these modes FEATURE MANUAL MODE ON DEMAND MODE CONTINUOUS MODE TEST MODE Auto Start User Selectable Yes No User Selectable Yes No Power 0 36W Typical 0 36W Typical 0 50W Typical 0 52W Typical 12V Power Supply Low Intensity Spark and a 10 second interval For On Demand Mode it is assumed that the flare blows out once every hour 4 2 State Diagrams The following diagrams illustrate the various states that the PF1300F goes through when the system is powered on or manually started There are diagrams provided for each mode 4 Modes amp Behaviour 4 2 1 Manual Mode POWER APPLIED OR RESET BUTTON PRESSED o ON Key Held BA DIP SWITCH SETTING In this mode the system will spark continuously as long as the On key continues to be held down and will not spark again after this When the On key is released the system will immediately close the Status Contact and begin checking for flame The timeout is fixed at 5 seconds in this mode If flame is not detected within 5 seconds the system will open the Status Contact turn on the Fault LED and stop running 4 Modes amp Behaviour ON Key Released Failed Self Test Flame Gone for 3s Flame Detected Flame Gone f
10. is a test CHART EVENTS mode The system will only spark while the ON Key is held and then never again The Flame Light and Status Contact will immediately follow the flame guality to allow the operator to adjust rod positioning grounding etc O ON Key pressed system starts sparking O ON Key released system stops sparking system does NOT detect flame Flame Light remains off HH mm 2 s Spark and Fault Lights begin blink BENT 9 9 l o 9 ing to indicate test mode CHART Operator adjusts flame and posi tion to be better positioned in the flame Flame Light turns on Status Contact closes Operator adjusts flame rod position to be out of flame Flame Light turns off and Status Contact opens Operator fixes flame rod position again Flame Light turns on Status Contact closes STATUS CONTACT SYSTEM STATE OFF 4 Modes amp Behaviour 4 4 Timing Accuracy The PF1300F does not use a precision clock source As such the accuracy of all timing parameters for the PF1300F are fairly loose The timing may vary from the nominal values as shown in the table below This variance may occur from unit to unit and also over temperature 20 C 68 F y 40 C 40 F q 80 C 176 F NOMINAL VALUE MIN MAX MIN MAX 5 sec Interval 4 7 sec 5 6 sec 3 8 sec 73 sec Ein REATO E de pus RAT i eo SERE En a RISE po rise n Alias E Mee kiere a Dm D see 5 Troub
11. 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 grounded Never leave the PF1300F running unattended without the door screws securely tightened down This is to prevent moisture from penetrating inside of the enclosure and damaging the product Moisture damage to the internal circuitry is not covered by the product warranty if the door has been left open 2 Installation BATTERY MODELS Never store or ship the unit with the battery connected Dis connect the battery s negative wire from the charge controller and cover the fork connector with electrical tape or some other insulator that will prevent it from shorting to other components Failure to observe this warning may result in accidental electrocu tion fire product damage or simply a dead battery Never operate the unit with the zener diode removed from across the load terminals of the charge controller as this may lead to failure Never power these from any DC power supply or from a solar panel rated for more than 12V nominal 40W This may lead to failure of the charge controller Be careful not to damage the temperature sensor on the charge controller It is delicate and if damaged the charge controller will not function 2 2 Mounting Locations The PF1300F should be mounted at the base of the Flare Stack or in another location that is both safe
12. section of the document is optional This includes the status contact and ESD switch Note that the wiring of the ESD switch differs depending on model 2 8 1 Status Contact The status contact is a solid state relay wired as a dry contact which means that it does not source any power A maximum of 200V Peak AC or DC at 150MA can be run through the contact safely The status contact can be used to control a remote alarm The status contact is initially open when the system is unpowered or not running When the system is running the behavior of the contact varies depending on the mode selected In general it is closed when flame is detected and open after flame has been absent for the duration of the timeout For detailed behaviour refer to the charts in section 4 3 To wire the status contact follow these steps EXAMPLE 2 DC LOAD ON POSITIVE TERMINAL 1 Feedapairof wires in through the conduit port and connect them to the Status and terminals on the pluggable header 12 to ar Alarm 2 Outside of the enclosure connect the status wires to a PLC or Device an alarm as shown in one of the examples below ale EXAMPLE 1 DC LOAD ON NEGATIVE TERMINAL EXAMPLE 3 AC 12 to 200VDC 120VAC e LA Alarm Device 2 Installation 2 8 2 SC000 ESD Switch If desired an Emergency Shutdown Switch can be attached to the PF1300F The wiring for this switch will vary slightly dependi
13. system detects flame Flame Light turns on Spark Light will blink once per second to indi cate that the system is running 3 Flare blows out Timeout Timer begins counting down 5 seconds o Flare has been out for 3 seconds Flame Light turns off O Flare has been out for 5 seconds timeout Timer expires Fault Light turns on Status Contact opens system stops running eS EE ES O CLOSED 4 Modes amp Behaviour 4 3 2 On Demand Mode In this mode the system will spark on the specified interval whenever the flame is out It will CHART EVENTS shut down if the flame remains out for the entire timeout period In this example the timeout N ON Key pressed system starts period is 5 minutes and the interval is 5 seconds 9 ida sparking CHART O ON Key released system stops sparking system detects flame Flame Light turns on Spark Light will blink once per second to indi cate that the system is running EVENT O Flare blows out 4 Flare has been out for 3 seconds Flame Light turns off system sparks Timeout Timer begins counting down 5 minutes and In terval Timer begins counting down 5 seconds O Interval Timer expires system sparks and then the Interval Timer begins counting down 5 seconds again OPEN STATUS CONTACT CLOSED Q Timeout Timer expires the flare is still out system shuts down with the Fault Light on and the Status Con
14. system to restart f a Pressing the On key while the system is already running will cause the system to restart When it restarts it will immediately begin to spark The timout counter will also be reset 3 User Interface amp Settings 3 3 2 Stopping the System If there is an external ESD switch installed on the system it can be used to stop the system by cutting its power There are two Off keys which perform the same function Keypad outside of enclosure E sl PF1300F Circuit Board inside of enclosure FLARE IGNITION SYSTEM Pressing one of the Off keys will also stop the system When an Off key is pressed all LEDs will turn off and the system will enter a low power state This is true whether the system was previously running or stopped with the Fault LED on PROFIRE ENERGY INC PF1300 v2 3 SPARK FLAME FAULT O ON OFF 2 DEBUG LEDs Flame Errors 3 User Interface amp Settings 3 3 3 LED Indicator Light Test If you become concerned that one of the LED indicator lights on the keypad or circuit board is no longer functioning you can verify if this is the case by following this procedure Note that this will turn the system off momentarily an tacts will open 1 Set the LED Enable DIP Switch on the ci position 2 Press and release the reset button D on d the status con rcuit board to the ON he circuit board 3 All LEDs on the circuit board will flash brie ly in
15. the ON key if this occurs S1 SWITCH ORIENTATION Auto Start O Intensity O Interval C Timeout O AUTO START 1 If this DIP switch is set to ON the system will automatically start running when power is applied Auto Start will not work in Manual or Test mode E nm OFF INTENSITY 2 Spark intensity can be selected between low and high Auto Start is enabled Auto Start is disabled With low intensity selected the system will generate a cooler spark for 1 second during ignition This mode provides the lowest possible power consumption This mode is preferred for the SCBOO model where battery life is a concern 3 User Interface amp Settings LED Enable C Default setting s With high intensity selected the system will generate a hotter spark for 2 seconds during ignition This mode can be used if the pilot gas is wet the flame rod is dirty the spark gap is too large or the ignition wire is too long This mode is not recommended on 24V systems as it may prematurely wear the circuit components High Intensity Power 2 seconds Low Intensity Power 1 second IB OFF INTERVAL 3 The Interval is the time between ignition attempts when running in On Demand or Continuous mode There are two options 5 seconds 10 seconds n OFF TIMEOUT 4 The timeout determines when the fault LED will turn on and the sta tus contacts will open The behaviour varies between modes
16. the following sequence Debug LEDs D20 D21 D22 D23 D24 Spark Flame Fault 4 Pressandrelease the reset button 1 on the circuit board again 5 Quickly close the door and observe the keypad 6 AI LEDs on the keypad will flash briefly in the following se quence Spark Flame Fault If an LED fails to flash on as described or if more than one LED turns on simultaneously the keypad or circuit board may need to be replaced 3 User Interface amp Settings PF1300F FLARE IGNITION SYSTEM PROFIRE ENERGY INC PF1300 v2 3 Imi nudo mi SPARK FLAME FAULT DEBUG LEDs Flame Errors 3 3 4 Viewing Firmware Versions The firmware version is printed on a label 1 on the circuit board If this label is missing or illegible the firmware version can also be checked using the LEDs The procedure to do this is as follows Note that this will turn the system off momentarily and the status contact will open 1 Setthe LED Enable DIP Switch to the ON position 2 Withyourright hand press and hold the reset button 2 on the circuit board At the same time use your left hand to also press and hold the On 3 and the Off O buttons 3 Release the reset button but continue to hold the On and Off buttons 4 The LED s on the circuit board will begin to blink a sequence of patterns on the LED s When you are done determining the firm ware version let go of the buttons and the system will resume normal operati
17. 0F is available in two configurations BASE MODEL and BATTERY MODEL The Base model is designed for 12 24VDC operation whenever power is available on site The Battery model includes a 12V 9Ah battery and solar charge controller intended for use with a 12V solar panel sold sepa rately BASE MODEL SC000 Base Model BATTERY MODEL SCB00 Battery Model 1 Overview 1 2 Included Components The PF1300F comes packaged with the following If any components varies across models are missing contact Profire immediately CODE DESCRIPTION SC000 SCB00 A o o PF1300F J Solar Charge Controller Manual 1 Overview 1 3 Optional Components The following components may be required to install the PF1300F 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 O Channel Bar o Conduit Port Liquid Tight Port Rubber Grommet 2 WIRE lgnition Wire 3 RODS AND CONNECTORS Kanthal Ignition Rods Various Lengths 4 PILOT ASSEMBLY O Nozzle O Brackets 5 POWER amp AUTONOMY e Power Supply Solar Panel 1 Overview 1 4 External Diagram DOOR amp KEYPAD ENCLOSURE SERIAL MODEL LABEL 1 Overview 1 5 Internal Diagram WIRING DIAGRAM DIP SWITCH DIAGRAM PLUGGABLE HEADER IGNITION COIL KEYPAD FLEX CABLE CI
18. Modes amp Behaviour 39 4 1 Mode DescriptionS He ene nemen naakka aa nene en e e eee s een n RENEA 41 4 2 State Diagrams nen nenne hn nis essaie riae ndisse sane eiie ede esa ee ree nen 41 421 Manua Mode oia ctt ia elemen 42 4 2 2 On Demand Mode noniin alakaan naa e EE AAEE rens ss ss ESEE ANEA 43 4 2 3 Continuous Mi ia 44 424 TEME lili teria dd 45 4 3 Process Control Behaviour coe ciere eser dc did 46 431 MantalMode rusia As e ie meri 46 4 3 2 On Demand Mode 47 43 3 Continuous Mode ini 48 4 8 4 Test MODE a eaa ae a nnen eee esses e e ener teer n sess s e eterne 49 4 4 Timing ACCUACY A nectit cred vas te docte Suis deesse ter dede bd tum epe eaten 50 Troubleshooting 112 ii e 51 5 1 Common Issues amp SOlUtions e ee eene hehehe A ERT ese esee sellis 53 54 5 2 Flame Detection Troubleshooting Guide 55 56 NUI IHE 57 1 Overview The PF1300F FIS Flare Ignition System is an electronic control and monitoring system designed for use with Flare Stacks It s pur pose is to ensure that the flare is always lit which facilitates compliance with the latest environmental regulations This eliminates the need to manually light the flare providing convenience and improving operator safety The system also includes a dry status contact which enables remote monitoring of the flare status reducing the number of times a person must physically visit a site 1 1 Available Models The PF130
19. PF1300F USER MANUAL 120 FLARE IGNITION SYSTEM O WARNINGS WARNING EXPLOSION HAZARD DO NOT INSTALL ON ENCLOSED BURNERS OR FIRETUBES DO NOT DISCONNECT WHILE CIRCUIT IS LIVE UNLESS AREA IS KNOWN TO BE NON HAZARDOUS BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE NON HAZARDOUS SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS 1 DIVISION 2 REPLACEMENT FUSES MUST BE CERAMIC AVERTISSEMENT RISOUE D EXPLOSION NE PAS INSTALLER DE BR LEURS FERM S OU TUBES D INCENDIE NE PAS DEBRANCHERTANT OUE LE CIRCUIT EST SOUS TENSION A MOUNS OU IL NE SAGISSE D UN EMPLACEMENT NON DANGEREUX BATTERIES NE DOIT ETRE CHANGE DANS UNE REGION CON NUE COMME NON DANGEREUX SUBSTITUTION DE COMPOSANTS PEUT PORTER ATTEINTE LES QUALIFICATIONS POUR CLASSE 1 DIVISION 2 FUSIBLES DE REMPLACEMENT DOIVENT ETRE CERAMIOUES HW amp FW VERSIONING This version of the manual was written for use with PF1300F systems that have the following hardware and firmware versions e HW v2 3 0 e FW v2 3 0 System hardware and firmware versions can be found printed on separate labels inside of the enclosure on the circuit board Section 2 4 Please refer to the Profire Energy website for the latest documentation APPROVALS SC000 Class I Div 2 Grp ABCD TAA CSA Type 4 SCB00 Class Div 2 Grp ABCD T5 CSA Type 4 G MC 248705 FOR ANY QUESTIONS PLEASE CALL 1855 PRO FIRE 1 855 776 3473 OR VISIT WWW PROFIREENERGY COM
20. RCUIT BOARD SOLAR CHARGE CONTROLLER SCB00 ONLY BATTERY BRACKET BATTERY SCB00 ONLY 1 Overview 1 6 Installation Types The PF1300F is designed for use only on Flare stacks It should not be used to control an enclosed burner or fire tube as this is usu ally against code and would pose a safety risk 1 7 Regulatory Reguirements The PF1300F 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 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 PF1300F and any other associated components sold by Profire are suit able for use in a given application NORTH AMERICA The PF1300F is certified for use in Canada USA and Mexico OTHER Consult local codes and safety regulations to determine if the PF1300F can be used in your jurisdiction 1 Overview 2 Installation This section includes the steps that should typically be followed when installing a PF1300F system in the field If you are new to the PF1300F you should read this section in its entirety and follow these instructions closely STEPS 1 Review Installation Warnings Choose a Mounting Location Mount the System Get Familiar with the Circuit Board o P amp N Connect the Reguired Wiring includin
21. closure will be enabled This includes the Spark Flame Fault and Debug LEDs The LEDs on the keypad are always enabled regardless of this setting E IB OFF UNUSED This switch is ignored by the current firmware version and should be left in the OFF position EI o E OFF Circuit Board Keypad LEDs enabled Keypad LEDs enabled Unused Unused 3 User Interface amp Settings 3 3 Operating the System This section of the manual describes how to operate the system including how to start and stop it in various ways test the LEDs and how to check the system firmware version 3 3 1 Starting the System If there is an external ESD switch installed on the system it must be turned on so that power will be applied to the PF1300F If the Auto Start DIP switch is set to the OFF position when power is first applied to the PF1300F it will enter the low power OFF state In PF1300F this state all LEDs are off MEN EIE UEM LJ o o MES Press one of the On keys to start the system running There are two On keys which perform the same function Keypad outside of enclosure Circuit Board inside of enclosure If the Auto Start DIP switch is set to the ON position On Demand or Contiuous Mode only the system will begin running immediately without the need to press one of the On keys PROFIRE ENERGY INC PF1300 v2 3 If the system is stopped with the Fault LED on pressing either On Es hs m key will cause the
22. convenience during installation and debugging these LEDs are also duplicated on the circuit board inside of the enclosure These duplicate LEDs are disabled by default to conserve power To turn them on use the LED Enable DIP switch SPARK LED 1 The Spark LED will pulse approximately once per second to indicate that the system is running When the system is sparking the Spark LED will pulse rapidly FLAME LED 2 The Flame LED will turn on when the system has detected that flame is present In the normal operating modes the Flame LED is time averaged over a few seconds to prevent the LED from flickering when wind is present In the test mode the Flame LED is not averaged FAULT LED 3 The Fault LED will turn on when the flame has been continuously absent for the entire timeout period It will also turn on if a problem with the flame detection circuit is discovered 3 User Interface amp Settings PF1300F FLARE IGNITION SYSTEM 0 8 0 Mik i im Intensity ma n ma Interval mn ma Timeout WI Auto Start WI W PROFIRE ax 3 1 4 Debug LEDs The debug LEDs are located on the circuit board inside the enclosure They only function when the LED Enable DIP switch O is in the ON position This is done to conserve power when they are not needed e When the system is off the Debug LEDs will be too e When the system is on the Debug LEDs are used to indicate one of two things lis
23. e In Manual and On Demand mode the system will stop running when the timeout expires n Manual and Test mode the timeout DIP switch is ignored The setting is fixed at 5 seconds and 0 seconds respectively e n On Demand and Continuous mode the timeout is user selectable between 5 minutes and 60 minutes Bl o A OFF MODE 5 6 There are three operational modes and one test mode that can be selected using the DIP switches This is the only setting that reguires two DIP switches to adjust 60 minutes 5 minutes Further detail on these modes can be found in section 4 The selectable modes are E BA OFF OFF Manual Mode The system will only spark while the ON button is being held down This mode will NOT automatically relight the flare On Demand Mode The system will spark periodically whenever flame is not detected It will stop sparking after the selected timeout expires EB on OFF Continuous Mode The system will spark periodically regardless of whether flame is being detected The status contacts will open after the selected timeout expires but the system will not stop running and sparking Test Mode Similar to the manual mode except that after the ON button is released the system will enter a continuous flame detection mode which is useful for debugging the flame detection circuit wiring DI LED ENABLE 7 When this switch is set ON the LEDs on the circuit board inside the PF1300F en
24. er is disconnected 4 2 4 Test Mode POWER APPLIED OR RESET BUTTON PRESSED T o ON Key Held HH DIP SWITCH SETTING In this mode the system will spark cont inuously as long as the On key continues to be held down When the On key is released the system will immediately enter a test mode The Spark and Fault LEDs will both flash sim ultaneously on a 1 sec ond interval to emphasize that this is a test mode The Flame LED will turn on when flame Status Contact will close is present and the ON Key Released Flame Gone Flame Detected If flame goes away the Flame LED will immediately turn off and the Status Contact will immediately open The system will never shutdown unless the OFF key is pressed or power is discon nected Refer to section 5 Troubleshooting for further details on how to use Test mode for Flame Detection Troubleshooting 4 Modes amp Behaviour 4 3 Process Control Behaviour This section illustrates the behaviour of the process control algorithm in response to real world situations Timing is approximate 4 3 1 Manual Mode In this mode the system only sparks once when the ON key is pressed If the flare blows out CHART EVENTS h m will sh n after nds an ill not automatically relight the system will shutdown after 5 seconds and will not automatically relight Ole pressed System alin sparking CHART DON key released system stops EVENT 1 2 e 5 sparking
25. er s load output terminals on the SCB00 model VBatt 2 Installation Flame Detection negative input Connect to ground screw on the PF1300F and also to the ground screw on the pilot assembly Flame Detection positive input Connect to ignition coil s left high voltage terminal Input power from a DC source These terminals are used for flame detection Place a Kanthal rod directly in the pilot flame and connect it to the ignition coil s right high voltage terminal The PF1300F will apply a 65VAC signal to the flame rod These inputs are protected from high voltage allowing them to be connected in series with the high voltage terminals of the ignition coil This enables a single flame rod to be used for both ignition and flame detection The pilot assembly must be grounded for the flame detection to function properly This input is protected by a 4A fuse DAE PIN PHP 2 6 Solar Charge Controller Terminal Descriptions This table provides a brief description of each terminal and references to further detail This is only applicable to the SCB00 model TERMINAL EXPECTED CONNECTIONS DESCRIPTION SECTION Solar 12V Solar Panel Lu terminal Only a 12V nominal Solar Panel 40W MAX should be used 257 hese terminals are used to draw power from and to charge the inte 272 grated battery These terminals are used to supply power to the PF1300F circuit board 2 72 RAIN eeu ee ee A cion diode must lso be installed across
26. g Power and lgnition Coil Flame Detection wiring 6 Connect the optional wiring including the Status Contact and the ESD switch The steps provided here are general and will help you to identify guestions that need to be answered to complete the installation properly You should also consult your local electrical and gas code before attempting any installation 2 Installation 2 1 Installation Warnings Before installing the PF1300F please review the following list of warnings Failure to observe these may result in death electrocu tion property damage product damage and or government fines ALL MODELS 1 The PF1300F is NOT intended for use on enclosed burners or fire tubes as it may pose a safety risk and may be against code in some jurisdictions For these applications please consider using our PF2100 system The PF1300F is NOT designed to control a pilot or main solenoid The PF1300F is NOT CSA B149 compliant If you require auto matic electronic control of a valve train please consider using our PF2100 system Failure to properly ground the pilot assembly back to the PF1300F s EGND screw may result in accidental electrocution product damage or simply failure to ignite the pilot The PF1300F generates 20kV 40kV 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
27. gh the grommet and 11 into the PF1300F enclosure Attach the included 90 degree bakelite connector to the end of the ignition wire that is inside of the enclosure 12 Connect the bakelite connector to the right terminal of the ignition coil Slide a straight silicone boot over the other end of the ignition 13 wire and then connect the ferrule to it Attach the ferrule to the Kanthal ignition flame detection rod Slide the silicone boot over the ferrule Feed two ground wires up through the grommet next to the ignition wire Crimp fork connectors to both ground wires and attach them to the EGND screw below the ignition coll Outside of the enclosure connect one ground wire to the pilot assembly and the other to earth ground Feed a pair of power wires into the enclosure through the con duit port and attach them to the Solar and terminals on the solar charge controller Outside of the enclosure attach the power wires to a 12V 40W Max solar panel Note that the charge controller is not designed to be used with DC power supplies or with solar panels larger than 12V nominal Locate the black wire attached to the negative terminal of the battery and remove the insulating cover from the fork connector It is taped to the top of the solar charge controller at the factory Attach the negative battery wire to the Battery terminal on the solar charge controller 2 Installation 2 8 Optional Wiring The wiring in this
28. ition wire and then connect the ferrule to it Attach the ferrule to the Kanthal ignition flame detection rod Slide the silicone boot over the ferrule Feed two ground wires up through the grommet next to the ignition wire Crimp fork connectors to both ground wires and attach them to the EGND screw below the ignition coil Outside of the enclosure connect one ground wire to the pilot assembly and the other to earth ground Feed a pair of power wires into the enclosure through the conduit port and attach them to the VBatt and terminals on the pluggable header 11 Outside of the enclosure attach the power wires to a 12VDC or 24VDC power source For more info see the technical specifica tions at the back of this document 2 Installation 2 7 2 SCB00 System Wiring This wiring diagram can also be found printed on the inside of the PF1300F door panel SCB00 KEYPAD STATUS LEDS BUTTONS PF1300F Control Board BATTERY v DIP SWITCHES SPARE FUSE SOLAR CHARGE CONTROLLER AD EGND SCREW SOLAR BATTERY LOAD GROUND TO PILOT BRACKET To 12 22VDC Source EGND 2 Installation 2 72 SCB00 System Wiring Continued These instructions detail the correct wiring of a PF1300F system with an integrated battery and solar charge controller Use 16 AWG or larger diameter wire for all connections unless otherwise noted 10 Feed the 7mm diameter ignition wire throu
29. leshooting 5 Troubleshooting This section of the manual is designed to aid you in troubleshooting the PF1300F It begins with a list of Common Issues and Solu tions This section concludes with a step by step guide for troubleshooting issues with Flame Detection If you are having trouble with your PF1300F 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 is a list of issues with corresponding possible solutions 1 2 SYSTEM SPARKS IN THE ENCLOSURE INSTEAD OF ON THE PILOT ASSEMBLY Check that the ignition wire is properly connected to the ignition coil and to the ignition rod Check that the spark gap between the Kanthal ignition rod and the pilot assembly is no bigger than 4 Check that the pilot assembly is properly grounded back to the system s EGND screw SYSTEM DOES NOT SPARK AT ALL a If no lights turn on when the ON key is pressed check the fuse and install the spare if necessary Check that the system is getting enough power Anything below 12V may not be sufficient to generate a spark Check mode settings You may be in On Demand mode when you want Continuous mode Check that the pluggable header is seated correctly Check that the Coil wires a
30. ng on model These instructions describe how to correctly wire an ESD switch to a PF1300F model SC000 1 Cutthe negative power wire outside of the enclosure and install an ESD Emergency Shutdown switch Note that if it is desired to connect the PF1300F to a plant ESD loop a relay must be used STATUS STATUS LEDS BUTTONS PF1300F Control Board DIP SWITCHES DEBUG LEDs 4A FUSE SPARE FUSE Optional External ESD Switch Not Included To 12 24VDC Source 2 Installation 2 8 3 SCB00 ESD Switch These instructions describe how to correctly wire an ESD switch to a PF1300F model SCB00 1 Remove the wire connected between the solar charge control er s Load terminal and the VBatt terminal of the pluggable KEYPAD header STATUS STATUS LEDS T x BUTTONS 2 Ensure that the zener diode remains connected across the load terminals of the solar charge controller PF1300F 3 Run two more wires into the enclosure through the conduit port Control Board 4 Attachoneof the new wires to the VBatt terminal of the plug gable header and the other to the Load wire of the solar charge controller SEE BELOW DEBUG LEDs 4A FUSE 5 Outside the enclosure attach the ESD wires to an ESD switch SOLAR CHARGE CONTROLLER Note that if it is desired to connect the PF1300F to a plant ESD loop a relay must be used SOLAR BATTERY LOAD
31. on PF1300F FLARE IGNITION SYSTEM PROFIRE ENERGY INC PF1300 v2 3 II SPARK FLAME FAULT O ON OFF 3 4 DEBUG LEDs Flame Errors 3 User Interface amp Settings 3 3 4 Viewing Firmware Versions Continued The LED pattern can be decoded into a firmware version The digits are encoded in binary on the debug LED s The Spark Flame and Fault LED s are used to indicate which part of the firmware version number is being shown When written out the three parts are separated by periods Eg 2 3 0 where the first part is 27 the second part is 3 and the third part is 0 Note that multiple digits may be shown per part If this is the case they will be separated by a brief pause with all LED s off 3 User Interface amp Settings PART AND DIGIT DECODING FIRST PART SECOND PART THIRD PART EXAMPLE FIRMWARE VERSION DECODING This table shows how firmware version v2 3 0 would be encoded LED PATTERN 1 PATTERN 2 PATTERN 3 DIGIT Firmware Version 2 2 3 0 4 Modes amp Behaviour This section of the manual describes the behaviour of the PF1300F 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 Detailed behaviour descriptions are also provided including process charts to illustrate the behaviour These are provided for each of the four available modes Note that all timing is nominal
32. or 5s Failed Self Test 4 If flame is detected the Flame LED will turn on If flame is subsequently lost for a period greater than or equal to 3s the Flame LED will turn OFF If flame continues to be lost for a total of 5s the system will stop running In other words manual mode will not automatically try to relight the flame It must be manually relit by pressing the On key again The system can be used in this mode to monitor the flame and sound a remote alarm when it goes out This mode is the default setting 4 2 2 On Demand Mode POWER APPLIED OR RESET BUTTON PRESSED Auto Mode ON amp Flame Detected Auto Mode On amp No Flame Detected Flame Gone for 3s Failed Self Test Auto Mode Off Flame Detected Flame Gone for ON Key Released Timeout Setting ON Key Held Failed Self Test 4 A Interval Elapsed PH DIP SWITCH SETTING In this mode the system will spark only if flame is not detected If flame is not detected again before the timeout expires the When the ON key is released the system will check for flame system will open the Status Contact turn on the Fault LED and not closing the Status Contact until flame is detected stop running After this the system must be manually restarted by pressing the ON key again or cycling the power if Auto Start The Flame LED will only turn off if flame is absent for 3s or is enabled more When the Flame LED turn
33. re attached correctly to the pluggable header and also to the bottom of the ignition coil The ignition coil or circuit board may be damaged Contact Profire to arrange for a repair replacement 5 Troubleshooting 5 1 Common Issues amp Solutions Continued 3 SYSTEM HASVISIBLE FLAME BUT CAN T DETECT IT a The flame rod pilot assembly and the gap between them should be fully engulfed in flame If not adjust the rod positioning and or decrease pilot gas pressure Check that the lon wire is securely attached from the pluggable header to the left terminal on the ignition coil Check the ground connection to the pilot assembly Flip up the LED Enable DIP switch and check the Debug LEDs to determine the flame quality level Consult the instructions in the section 5 2 Flame Detection Troubleshooting Guide for further details on Flame Detection 4 FAULT LIGHT IS ON The Fault Light will turn on for one of two reasons The flame is absent for the timeout period or the system failed its self test To determine which reason is the case set the LED Enable DIP switch to ON and observe the status of the Debug LEDs For more details please consult section 3 1 4 Debug LEDs FLAME CIRCUIT DEBUG LIGHT IS ON The flame detection circuit failed its self test Try the following a b Check wiring for shorts to power or ground Check for faulty circuit board 5 Troubleshooting TIMEOUT DEBUG LIGHT IS ON
34. s off the system will begin sparking at the selected intensity and selected interval The timeout counter will also begin counting down from the selected setting 4 Modes amp Behaviour 4 2 3 Continuous Mode POWER APPLIED OR RESET BUTTON PRESSED Interval Elapsed Auto Mode On ON Key Released amp Flame Detected Failed Self Test Auto Mode Off o ON Key Held Flame Gone for 3s ON Key Released amp No Flame Detected A Interval Elapsed Flame Detected Flame Gone for Timeout Setting Failed Self Test HJH DIP SWITCH SETTING In this mode the system will spark continuously on the inter val selected by the user regardless of whether flame is being detected Once flame has been detected the system will close the Status Contact and turn on the Flame LED The Flame LED will only turn off if flame is absent for 3s or more When the Flame LED turns off the system will begin counting down from the timeout setting that was selected by the user 4 Modes amp Behaviour Interval Elapsed If flame is not detected again before the timeout expires the system will open the Status Contact and turn on the Fault LED It will not however shutdown If flame is subseguently detected again the Flame LED will come back on and the Status Contact will close again In other words this mode will spark and detect flame continuously until the Off key is pressed or pow
35. tact open 278 SECONDS LATER 4 Modes amp Behaviour 4 3 3 Continuous Mode In this mode the system will always spark on the specified interval even when flame is pres ent It will NOT shutdown if the flame remains out for the entire timeout period but it will open the Status Contact and turn on the Fault LED In this example the timeout period is 5 minutes and the interval is 5 seconds CHART EVENT 00 09 SPARK LIGHT FLAME LIGHT FAULT LIGHT OPEN STATUS CONTACT CLOSED 4 Modes amp Behaviour 278 SECOND CHART EVENTS O ON Key pressed system starts sparking O ON Key released system stops sparking system detects flame Flame Light turns on Interrval timer begins counting down 5 seconds Spark Light will blink once per second to indicate that the system is running O Interval Timer expires system sparks and then the Interval Timer begins counting down 5 seconds again This repeats continuously while the system is running are blows out are has been out for 3 seconds ame Light turns off Timeout imer begins counting down 5 minutes mm QO Timeout Timer expires the flare is still out Fault Light turns on and the Status Contact opens System continues running 7 Flame returns Fault Light turns off and Status Contact closes 4 3 4 Test Mode In this mode the Spark and Fault Lights will blink simultaneously to indicate that this
36. ted below e Flame Quality e Error FLAME QUALITY 2 When the PF1300F is on and running the Debug LEDs will show the flame quality as a bar graph The more LEDs lit the better m m m m A the quality The Flame LEDs on the keypad and the circuit board 1 3 4 een will both turn on when the quality is above 50 3 bars or more al lal lal odd st ro070 e 5LEDson 100 5753 s 25 e 4LEDson 75 99 OLEI EB perse o us e 3LEDson 50 74 SETE a e 2LEDson 25 49 s u e 1 LED on 1 24 e NoLEDson 0 ERBOR QD DEBUG LEDs When the PF1300F is in the Fault state the Debug LEDs will Flame Errors show the reason for the fault using one of the error LEDs The nh reasons are listed below 75 99 Timeout O 50 74 The flame went out and could not be relit before the timeout GO ot O expired 1 24 ii Il Flame Circuit O 0 ALL OFF Flame Circuit 5 The system detected a problem with the flame detection circuit This usually indicates a faulty circuit board 3 User Interface amp Settings 3 2 Settings The PF1300F can be configured by using the DIP switches on the circuit board inside of the enclosure Listed below are the fea tures configured by these DIP switches For your convenience a summary of the DIP switch settings is also provided on the inside of the PF1300F door panel Changing DIP switch settings while the system is running may cause it to enter the OFF state Simply restart the system by pressing
37. tem powered and in test mode both mode switches up set a Multi Meter to read AC voltage and measure across the ION and ION terminals Take note of the maximum voltage T NO ALWAYS MOVES TO THE RIGHT YES ALWAYS MOVES DOWN Is the voltage greater than 25VAC NO Remove the wire from ION and measure the AC voltage between the 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 ION and ION terminals again Is the voltage above 35VAC It is possible that the PF1300 is faulty YES Is the wire run length from the burner to the PF1300 longer than 25 Something is loading the signal Ensure that the wire type is not shielded TES Look for partial ground The length loading on 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 shorts or nicked wires 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 ignition lg Check the ION wire for shorts to ground or nicks Measure the AC voltage on the ION
38. these terminals 40 protect the controller from back EMF from the load Sealed or Jumper to load negative terminal This jumper is used to select the battery type and should always be 29 Flooded Select installed because the included battery is sealed 2 Required Wiring The wiring in this section of the document is required for all PF1300F installations Skipping or performing any steps in this section incorrectly will likely result in the PF1300F not functioning properly Choose the wiring steps that apply to your model 2 Installation 2 7 1 SC000 System Wiring This wiring diagram can also be found printed on the inside of the PF1300F door panel SC000 STATUS LEDS BUTTONS PF1300F Control Board DIP SWITCHES SPARE FUSE Y EGND SCREW 7 GROUND TO PILOT BRACKET To 12 24VDC lt Source 1 EGND 2 Installation 2 7 1 SC000 System Wiring Continued These instructions detail the correct wiring of a PF1300F base model Use 16 AWG or larger diameter wire for all connections unless otherwise noted 10 Feed the 7mm diameter ignition wire through the grommet and into the PF1300F enclosure Attach the included 90 degree bakelite connector to the end of the ignition wire that is inside of the enclosure Connect the bakelite connector to the right terminal of the igni tion coil Slide a straight silicone boot over the other end of the ign
39. xample 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 Removeand open the included bag of components taped to the mounting brackets 2 Attach the two mounting brackets to the back of the PF1300F enclosure using the 4 screws 3 Determine the best location to drill holes in the product enclosure for the wires to enter At least two holes are recommended for the following e Wiring that will go to the pilot assembly e Wiring that will go to the power source and status contacts 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 reguirements previously listed in section 2 2 Mounting Locations 2 Installation DETERMINE DRILL LOCATIONS PILOT ASSEMBLY POWER SOURCE SOLAR PANEL REMOTE MONITORING 2 4 Circuit Board amp Solar Charge Controller Diagram PLUG GABLE HEADER STATUS TERMINALS COIL TERMINALS ION TERMINALS VBA TERMINALS HWV ERSION FUSE S DIP SWITCHES TEMPERATURE SENSOR SOLAR INPUT BATTERY I O SPARK LED FLAME LED FAULT LED O mi M
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