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USER MANUAL REV 1.0.2 - Profire Energy, Inc.

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1. 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 40 2 Installation 2 3 B Mounting Instructions Metallic Enclosure 1 Remove and open the included bag of components taped to the mounting brackets 2 Determine the best location for conduit attachment on the bottom of the enclosure 3 Install grommits and conduit ports required 4 Securely mount the enclosure to either a pole structure or building which satisfies the location requirements previously listed in section 2 2 Mounting Locations CONDUIT AND CABLES AS REQUIRED 2 4 Terminal Card Diagram D 00009090 0 89999969 INTERNAL COIL SPARE MAIN FUSE ONE SPARE STATUS CONTACT FUSE EXPANSION CARD SLOT DOOR CARD CONNECTOR MAIN FUSE HW SERIAL VERSION LABEL IGNITION TER 4 20mA OUTPUT ALS FLAME DETECTION TERMINAL POWER TERMINALS 1 8 05 FW VERSION LABEL STATUS CONTACT FUSE 9 mna savas o Start ESD ESD Proof of Closure Proof of Clo STAT
2. Check if the solar panels are incorrectly wired in parallel rather than series Expected battery life is not achieved The PF2100F is not setup to use low power valves with a PWM setting of 20 The PF2100F is not setup to put the display to sleep when not being used The solar panel is undersized The solar panel is shaded or not located in full sun The battery is not being charged at all Check if the Solar Charger is damaged or defective Look for flashing error codes on the controller s LEDs The solar panel is undersized The solar panel is shaded or not located in full sun The battery is defective SOLAR POWER 1 a 2 a b C d 3 a b G d SOLENOIDS 1 Valves are not opening a b Check if the positive and negative wires are reversed 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 Check if 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 master 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
3. 2 Connect a single Type k thermocouple to the AUX TC input and place this thermocouple in the location of the pilot flame 3 Connect a single Type k thermocouple to the HighTemp TC input and place this thermocouple in a location where a high temperature should cause a system shutdown NOTES All Thermocouples must be 1 Isolated from ground 2 Isolated from power 3 Type K thermocouples 4 Connected with 20 AWG or larger Type K extension wire 5 Placed a safe distance from high voltage lines and shielded when necessary NET 2 Installation PILOT THERMOCOUPLES Process TC and AUX TC Two pilot thermocouples can be used for flame detection and pilot flame temperature measurement These thermocouples are independent and both can be optionally omitted if ionization is being used for flame detection HIGH TEMPERATURE THERMOCOUPLE This thermocouple is used for the high temp shutdown The system can shutdown if an open circuit short circuit or short to ground is detected on this thermocouple This thermocouple is optional and by default the PF2100F does not expect this input 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 This section provides some tips to help you achieve reliable ignition and flame detection and then concludes with specifi
4. Try replacing the pilot nozzle YES Set the system up to use separate rods for flame detection and ignition 5 6 Appendix A Main Valve The PF2100F supports the use of a main valve in addition to the pilot valve This configuration is NOT recommended and may violate local codes The main valve operation is simple The main valve is open when a flame is detected 5 Troubleshooting GENERAL FEATURES e Designed for use with flare applications e Meets or exceeds all relevant codes and standards e Easy installation with clearly marked component I O e Easily accessible removable terminal connections e Electronic spark ignition e Low power operating mode to accommodate solar panel or TEG applications e Transient protected and fail safe circuits e All solid state circuit components s CSA compliant for Class Division 2 locations e Certified for use on B 149 compliant valve trains e Optional internal or external ignition coil INPUTS 8 OUTPUTS 6 Digital inputs for safety interlock device connections 5 Digital outputs 1 4 20mA output 1 Flame rod input 3 Thermocouple inputs TECHNICAL SPECIFICATIONS Operating Range 40 C 40 F 55 C 130 F C n G erza S ies IS A EZ Controller only display ON 2 6W 2 9W Ignition Voltage Internal Coil up to 20 kV up to 40 kV TERMINAL BLOCKS VALUE Maximum Wire Gauge 12 AWG STATUS CONTACT VALUE mpedance When Closed 15Q Widt
5. 7 1350 C HIGH TEMP ESD SETPOINT HIGH TEMP ESD SETPOINT MENU 1 LOW ALARM SETPOINT This setpoint is used to protect the flare and other equipment from overheating If the High Temp TC is enabled and its temperature goes above this setpoint the system will immediately shut down MINIMUM RUN TEMP MENU 1 This setpoint defines the Pilot Temperature that the PF2100F considers an indicator of flame If either Pilot Thermocouple measures a temperature higher than this setpoint the PF2100F operates assuming a detected flame This setting must be set to at least 1 C higher than the Low Alarm Setpoint PROCESS HIGH TEMP LOW ALARM SETPOINT MENU 1 If the Pilot Temperature falls below this setpoint the status contact will open and the Flame LED will remain off Between this setpoint and the Pilot TC Setpoint the Flame LED will blink 3 User Interface amp Settings O55 3 4 11 Restart Settings The PF2100F can be configured to automatically restart after certain alarm conditions clear When the system restarts it will continuously attempt to ignite until a flame is detected for the duration of the Flame Timeout period AUTO RESTART MENU 4 If this setting is enabled the system will restart automatically once all alarm conditions are cleared and if the reason that the system stopped running was any of the following 1 System Input Voltage too low including power cycle 2 System Input
6. Press the display Menu Key repeatedly until Menu 7 is shown enter the L2 Password if prompted AVA AVA Use the Up or Down keys to select Yes OK Menu Key repeatedly until Cal Data is shown on the Press OK and the message Parameter Saved will show on the display briefly Press and Password Logout is displayed on the screen The Calibration hold the OK key for 3 seconds until the message Menu is now hidden again 3 User Interface amp Settings 4 Modes amp Behaviour This section of the manual describes the behaviour of the PF2100F 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 behaviour 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 and Input Output Contacts 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 PF2100F goes through when the system is powered on when starting the system in Auto or Manual modes and once the Process Control algorithm takes over The current state is always shown on the display 4 1 1 Power On Se
7. Setpoint OR AND Flame Quality 100 Flame Quality 100 NO FLAME DETECTED OPEN OPEN Low Alarm Pilot Temp 1 gt Low Alarm Temp PilotTemp 1 lt Low Alarm Temp Setpoint OR AND etpoin PilotTemp 2 gt Low Alarm Temp PilotTemp 2 lt Low Alarm Temp LOW TEMP ALARM OPEN OPEN 4 1 5 Waiting States In all waiting states the system turns off the main and pilot valves and waits for some event to occur before restarting There is a group of waiting states which may be optionally enabled through the Auto Restart setting 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 system 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 START Low Pressure Contact Open WAITING Low Pressure Contact Closed ON LOW PRESSURE 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 PILOT TIMEOUT No
8. such that 2 to 3 of its length is positioned 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 in contact the flame is 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 flare USING EXTRA RODS TO IMPROVE FLAME DETECTION In some challenging installations 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 detecting flames that are not well anchored Use of additional rods should only be used as a last resort since normally another less costly solution can be found 2 Installation CHN 2 6 4 Ignition Coil Flame Detection Continued INTERNAL VS EXTERNAL COIL If less than 5m 15ft of ignition wire are required to connect the PF2100F to the flare housing the in
9. 5 5 Flame FLAME DETECTION Detection Troubleshooting Guide for further details on e Flame Detection 1 System Has Visible Flame But Cannot 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 5 Troubleshooting CH 5 1 Common Issues amp Solutions Continued SHUTDOWN 1 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 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 Refer section 2 6 1 Power for details 2 System shuts down on High Temperature ESD a Check that the HT ESD setpoint is not set too close to the operating temperature of the system Measurement accuracy and process control overshoot can cause the system to shutdown if they are too close 3 System shuts down on an Open TC Error a Check if one of the thermocouples is not connected inside of the PF2100F b Check that there are no breaks in the thermocouple wiring MED 5 Troubleshooting Solar output voltage is 12V when 24V is expected
10. Flame RELIGHT PROCESS Flame CONTROL START 5 Troubleshooting This section of the manual is designed to aid you in troubleshooting the PF2100F It begins with a list of Common Issues and Solutions 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 PF2100F System please consult the following resources in this order N Consult this section for solutions to see if one matches your needs N Consult the support section of our website at www profireenergy com N 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 s y recommended maximum length 1 Cannot Write Setpoints via Modbus S c Check that the lon wire is securely connected as per the a Check that the system has the latest firmware appropriate wiring diagram b Check that the Modbus Card has the latest firmware d s 9 Check that the ground connection between the PF2100F Firmware older than v4 0 did not support this feature and the pilot assembly is present and secure e Consult the instructions in the section
11. Voltage too high 3 Low Pressure Contact open HEN 3 User Interface amp Settings 3 4 12 System Voltage The PF2100F 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 attach to the PF2100F 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 PF2100F 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 prevent 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 Setting and Main Valve Power Setting which can also be found in Menu 4 VOLTAGE SETTING PILOT PWM SETTING LOW VOLT ALARM LOW VOLT WARNING HIGH VOLT WARNING HIGH VOLT ALARM 12V 100 lt 8 4V lt 9 9V gt 14 6V gt 15 6V a A A E EENE ZH E a di ins
12. 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 BVDC 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 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 Did placing the grounded rod in the flame improve the DC voltage reading NO pressure Recheck the orifice size and increase the pilot YES
13. keys was stuck at System Startup This may indicate a defective keypad This error must be resolved in order to continue using the system The particular key stuck will be displayed in place of XXXX and will be one of the following DOWN IGN MAIN MODE OK PLT MENU STOP UP The Level Contact is open and Level Event Restart is set to Off The Low Pressure Contact is open and Auto Restart is set to Off Low Voltage xx x Volts 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 Sys tem 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 system shut down because a remote shutdown command was recieved via Modbus Modbus Card Shutdown Remote Cmd Error 5 Troubleshooting The system recieved an undefined command from the Modbus Expansion Card 5 2 Shutdown Messages Continued ON SCREEN DESCRIPTION POSSIBLE SOLUTIONS Pilot Key Stuck The Pilot Key was held for more than 30s while in manual mode 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 Door Card and Terminal Card do not agree on the value
14. o dana S S aragon Cn en ial aan naan E ias tc init a it S S iia oe crono S SEETHA S STE ate E ds e iaa Note that if the system has the Auto Restart feature enabled Menu 4 the system will automatically relight the flare after a high or low voltage alarm clears Otherwise the system will remain shut down 3 User Interface amp Settings 3 4 14 Valve Modulation Settings The valve outputs can be modulated with a pulsed DC signal to conserve power through a technique known as Pulse Width Modulation PVVM The duty cycle of the modulation can be adjusted independently for each valve Each can be set to 100 60 40 or 20 The 100 setting applies continuous DC voltage ie no modulation to the valve and is the highest power option The 20 setting applies DC voltage only 20 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 100 These valves are sometimes called Low Power or Peak and Hold valves since they require only short periodic voltage pulses to hold the valve open Do not use a duty cycle of 100 with low power valves as this can damage them Likewise do not use a duty cycle of 20 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
15. of the Purge Time Setting Solenoid Feedback Error Check Solenoid Wiring The solenoids were observed to have a state opposite to the one being driven by the PF2100F Check that the wiring is correct and not shorted to power or ground Terminal Card Ambient Fail Terminal Card Command Refused Terminal Card igh Temp Alarm he Terminal Card could not measure the ambient tem perature The Door Card failed to detect this he Terminal 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 he Termincal Card is not communicating with the Door Card This may indicate a faulty ribbon cable or incom patible firmware The Door Card failed to detect this he Terminal Card detected that the High Temp Thermo couple was shorted to ground The Door Card failed to detect this he Terminal Card detected that the High Temp Thermo couple exceeded the High Temp ESD Setpoint The Door Card failed to detect this Troubleshooting CH 5 2 Shutdown Messages Continued ON SCREEN DESCRIPTION POSSIBLE SOLUTIONS Terminal Card he Terminal Card detected that the Door Card status or Reciprocal Comp High Temp ESD Setpoint did not match The Door Card failed to detect this Terminal Card he Terminal Card detected an alarm condition The Sh
16. ok Level 2 Password AVA AV 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 entered to access menus 1 3 and the Quick Setpoint Adjust feature 3 User Interface amp Settings Ign 3 4 9 Flare Control Settings For the PF2100F Flare Control refers to controlling the temperature of the flare The Flare Control algorithm requires a Pilot Temperature control signal for this control There are four settings that affect the behavior of the Flare Control Algorithm 1 Pilot Off 2 Flame Fail Timeout 3 Spark Mode 4 Spark Interval PILOT OFF MENU 5 By default when the Pilot Temperature reaches the Minimum Run Temp the pilot valve remains open When the Pilot Off setting is enabled and the Minimum Run Temp setpoint is reached the pilot valve closes after a 5 second delay If the Pilot Temperature drops below the setpoint the pilot valve will immediately re open SPARK MODE MENU 5 The PF2100F supports two sparking mod
17. temperature should be at least 20C above the ambient temperature and preferably close to the maximum planned operating temperature Cal High Temp TC Span will show on the display Use the Up and Down Keys to adjust the temperature displayed on the PF2100F 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 because each key press is adjusting a fractional multiplication 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 Pilot TC 1 Span and Cal Pilot TC 2Span 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 CS 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 1mA 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 th
18. 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 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 CS 2 3 A Mounting Instructions Non Metallic Enclosure 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 PF2100F enclosure using the 4 screws
19. to save cost by using a single rod WIRING STEPS 1 Connect the Pilot Assembly ground screw to the PF2100F s lon terminal using a 16 AWG or thicker ground wire Connect the lon terminal on the External Coil to the lon terminal on the PF2100F 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 PF2100F using 16 AWG or thicker wire Connect the Coil terminal on the External Coil to the Coil terminal on the PF2100F using 16 AWG or thicker wire Connect the single Kanthal 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 Use a 90 Bakelite connector and 7mm Ignition 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 2 7 Optional Wiring The wiring in this section of the document is optional 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 PF2100F controls Neither contact is internally con
20. 100F 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 Terminal Card m a N 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 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 PF2100F 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 PF2100F in various application and jurisdictions These include recommended 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 CLOS 2 1 Installation Warnings Before inst
21. 2100F checks three conditions to determine if a flame is detected If any of these conditions are met the PF2100F considers a flame present e Pilot 1 Thermocouple gt Minimum Run Temperature e Pilot 2 Thermocouple gt Minimum Run Temperature e lonization Flame Quality 100 The PF2100F does not need to be configured for specific flame detection behavior At least one of the inputs from the conditions above must be connected in order for the PF2100F to perform its Flare Control Algorithm but it does not matter which condition is met or if any combination of them are met As long as at least one condition is satisfied a flame is detected The Flare Control Algorithm does not make any distinction between flames detected by these three conditions The PF2100F does not support any other combination of conditions for flame detection As an example the PF2100F cannot be configured to require the Pilot 1 Thermocouple and Pilot 2 Thermocouple to agree that a flame is detected The diagram below shows how the Flare Control Algorithm makes flare control decisions based on the status of flame detection 4 Modes and Behaviour 4 1 4 Process Control Continued FLAME QUALITY OR PILOT TEMPERATURE PROCESS CONTROL STATES PILOT VALVE STATUS A Pilot Off Disabled Pilot Off Enabled FLAME DETECTED OPEN CLOSED Pilot Temp 1 gt Min Run Temp Pilot Temp 1 lt Min Run Temp OR D 100 PilotTC PilotTemp 2 gt Min Run Temp PilotTemp 2 lt Min RunTemp
22. A E60079 15 2005 UL 508 17th Edition ee ANSI ISA 12 12 01 2007 248705 UL 60079 0 2005 UL 60079 15 2002 FOR ANY QUESTIONS PLEASE CALL 1855 PRO FIRE 1855 776 3473 OR VISIT WWW PROFIREENERGY COM 1 2 O en ee E 1 11 Available Models van A iO aaa 3 12 Included CompGnents rc a n E beta dao 4 1 3 Optional COMPONENES emitida id a dades 5 14 Extra Diane odo meee TN 6 15 JIT al GO aora rcis rta 7 aE Wristallation TES ti aia decadente cad 8 1 7 Regulatory Requirements 0 0 ccc cececcec eee ecesececseeueseeeseueeeaeseeesseeesaeseeaesesaeeneneasneenes 8 SE ee 9 2 1 Installation Warnings isis sac Zra asic saeads sag iia 12 22 Mounting Locations ii A a ad 13 23 Mounting He e eT 14 15 ZA Terminal Cara Diagrama in 16 2 5 Terminal DescriptiONS oocccooccnnnccnnnccnnnononocnonccnonccnnnononcnnnacnnnronnnrannncannnononrcnanccnnnnass 17 19 26 RequircaWiihd ci ii tica 20 BGA PoWerricararaa iia iii 20 262 T ips 22 263 TMETMOCOUDIES ri aa 22 2 6 4 Ignition Coil Flame Detection 23 24 2 6 5 Internal Coil Dual Rom ba 25 26 6 a Tae lt e HT lt iden 26 2 6 7 External Coil Single Rod serna daa cta init 27 2 7 Optoma UO A A a di 28 271 Status Contact tds bie 28 2 72 Dry Contact lps da 29 30 2 73 4 20mA Temperature OUIOT 31 2 74 Modbus Expansion Card annan nanang anana aeaa eana aana anana 31 3 User Interface 8 SettingS ooooo connnnnnccnnnnoncccconononc cnc nnnn nono conan o
23. DOOR amp KEYPAD SERIAL MODEL LABEL ENCLOSURE 1 5 Internal Diagram HW SERIAL VERSION LABEL FW VERSION LABEL KEYPAD FLEX CABLE RIBBON CABLE MODBUS CARD 4 20mA CARD INTERNAL COIL TERMINAL CARD 1 6 Installation Types Below are examples of some of the applications that the PF2100F can be used in 1 Flare Stack 2 Flare Pit 1 7 Regulatory Requirements The PF2100F 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 flares 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 PF2100F and any other associated components sold by Profire are suitable for use in a given application CANADA The PF2100F is not designed to meet CSA B149 requirements which are becoming legislated in Canada therefore it is not suitable for use on enclosed burners USA The PF2100F currently meets the requirements for use in the United States Other Consult local codes and safety regulations to determine if the PF2100F can be used in your jurisdiction 2 Installation This section includes the steps that should typically be followed when wiring up a PF2100F system in the field If you are new to the PF2
24. 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 Volt Warning The system voltage is getting close to the High Voltage Alarm threshold and may stop or shutdown soon igh Prs Warning The High Pressure Contact is open or the 4 20 Pressure Input is above the 4 20 Pressure High Setpoint The contact must be closed shortly after the main valve opens and the 4 20 Pressure is below the setpoint or the system will shutdown LO Volt Warning The system voltage is getting close to the Low Voltage Alarm threshold and may stop or shutdown soon Unit restarted from LVL event The system has recently restarted from a Level event Press OK to clear this message Unit restarted from PRS event The system has recently restarted from a Low Pressure Press OK to clear this message Unit restarted from VLT event The system has recently restarted from a Low or High Voltage event Press OK to clear this message 5 Troubleshooting CE 5 4 Warning Messages Continued ON SCREEN DESCRIPTION POSSIBLE SOLUTIONS Waiting HiVolt The system will automatically restart once the system voltage falls below the High Voltage Alarm Threshold Waiting LoVolt The system will automatically restart once the system voltage rises above the Low Volt
25. NG SECTION Auto Restart Auto Enables system to restart from a power On Off Off 3 4 Restart failure low pressure or high voltage event Password Enable Password Enables Password Protection Menu On Off Off 1 3 Sleep Mode for the Display Display Sleep Enable Sleep Mode for the Display Never After Never 3 4 10 Min Pilot Valve Power Setting Pilot Solenoid Adjusts the Pilot Valve PWM duty cycle 20 40 60 3 4 PWM 60 100 Main Valve Power Setting ain Solenoid Adjusts the Main Valve PWM duty cycle 20 40 60 3 4 PWM 60 100 System Voltage Setting System Configures the expected input voltage 12V 24V 12V 34 Voltage for the system Temperature Display Units Temp Units Configures the temperature units Fahrenheit Celsius 3 4 displayed by the system Celsius Commission Date Entry Commission Date Set the date that the system was DD MMM 01 JUN 2012 3 4 commissioned YYYY Commission Location Entry Commission Loc Set the install location of the system A Z 0 9 3 4 14 Characters Max Reset to Factory Defaults Restore Factory Restore all settings to the factory Yes No No SED Defaults default ay 3 User Interface l Settings 3 3 5 Control Setup MENU 5 This menu contains various settings for con ode Spark Mode Spark Interval with Detected Flame Spark Spark Interval rolling flare behaviour BRIEF DESCRIPTION RANGE DEFAULT SETTING SECTION Adjusts the system s behavior for sparking its ignition c
26. PF2100F USER MANUAL 102 FLARE IGNITION SYSTEM O WARNINGS HW 8 FW VERSIONING THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS 1 DIVISION 2 This version of the manual was written for use with PF2100F 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 A es ee ees CO eee Terminal Card v1 7 F1 7038 WARNING EXPLOSION HAZARD a aaa vasos S a is ETE SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR oO CLASS 1 DIVISION 2 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 Class 1 Division 2 CSA 22 2 No 199 2007 CERTAIN ELECTRICAL STANDARDS AND BEWITHIN VOLTAGE LIMITS Grp ABCD CSA C22 2 No 0 M91 IP54 CSA C22 2 No 0 4 04 REPLACEMENT FUSES MUST BE CERAMIC AND OF CORRECT RATING CSA Type 4x CSA C22 2 No 94 91 CSA C22 2 No 142 M1987 CSA C22 2 No 213 M1987 CSA E60079 0 2007 GR CS
27. Pressure Contact is Open and the Auto Re start is set to Off Lvl_Inp The Low Level Contact is Open and the Level Event Restart is set to Off 5 3 Alarm Codes Continued ON SCREEN DESCRIPTION POSSIBLE SOLUTIONS MbusErr The Modbus Card is not responding This may indicate that it is not installed correctly or that it is enabled when not present at all ProcTC The Process Thermocouple is open or otherwise wired incorrectly RemShut Modbus Shutdown Command Received Sys_Err System Error The Terminal Card is not communicating with the Door Card This may indicate a faulty ribbon cable or incompatible firmware TC_MM The High Temp and Process Thermocouples are reading temperatures that are too far apart This may indicate a failed thermocouple improper wir ing or a damaged Door or Terminal Card Val_MM The Door and Terminal Card s setpoints do not match 5 4 Warning Messages The following is a list of warning messages that may flash periodically on the PF2100F 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 POSSIBLE SOLUTIONS Check all settings Other settings A major process control setting was changed and the have changed process control setpoints were reset to factory defaults This includes the
28. RE VERSIONS 4 20mA Output Cal Zero amp ENTER DEBUG MODE B PRESS AND HOLD FOR 3s TO EXIT DEBUG MODE LOCK MENUS AND RETURN HOME 4 20mA Output Cal Span Display TC Zero Factors Display TC Span Factors Clear Calibration Settings FOOTNOTES 1 Required if enabled in Menu 4 and password has timed out 2 Viewable in Debug Mode 3 Required if password has timed out 4 Hidden if Spark Mode is set to Until Flame 5 Edit fields using arrow keys Advance fields using OK 6 Visible if High Temp TC is enabled 3 User Interface amp Settings CES 3 3 1 Setpoints MENU 1 This menu is used to adjust the Process Control Setpoints MENUMAP ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING SECTION Low Temp Alarm Setpoint Low Alarm The Status Contact will close if the o 1349 C 200 C Temp system is running and either Pilot Tem lo to 2460 F 392 F perature exceeds this value inimum Run Temperature Minimum Run If either Pilot Temperature is greater 1 Temp than this setpoint a flame is detected 34 to 2460 F 1112 F High Temp Shutdown Tempera High Temp If enabled the system will immediately 1 to 1350 C 1350 C 3 4 ure Shutdown shut down if the High Temp reading 34 to 2462 F 2462 F exceeds this value 3 3 2 History MENU 2 This menu contains read only event counters and the event log Ce ON SCREEN BRIEF DESRIPTION RANGE DEFAULT SETTING SECTION Flame Fails Flame Fails umber of Shutdown
29. S Ean T ae T oA E A G ii A o S o ei O E pe eres tii Os TR Habis E ia a A E o A oo pineal cas E is A O S a C REO a S THE oo Tn aan E a 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 System Voltage Setting Process Control Settings Aa ww N Process Setpoints High Temp ESD Minimum Run Temp Low Temp Alarm 3 4 2 4 20mA Output Settings The 4 20mA Output is built into the Terminal Card and can be used to echo the Pilot temperature to the PLC The 4 20mA Output encodes the pilot thermocouple signal as a 4 20mA signal The signal is scaled so that 4mA 0 C and 20mA 1350 C 3 User Interface amp Settings CEN 3 4 5 Commissioning Settings The date and location of commissioning can be stored in the PF2100F 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 PF2100F 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 PF2100F was installed Use the Up and Down keys to edit each char
30. US CONTACT OUTPUT THERMOCOUPLE INPUTS MISC DRY CONTACT INPUTS VALVE OUTPUTS PRESSURE DRY CONTACT INPUTS Low Fire Low Fire Pilot Pilot OJO O DIO OOOO O LEVEL DRY CONTACT INPUT O ab saa Daa cc Q O e O PROFIRE COMBUSTION INC 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 20 EGND Earth Ground 2 6 1 4 20mA Out PLC 4 20mA positive input This output can be used to echo the Pilot Temperature to a PLC DQ A PS sssssssssesscssesessssssssossee sesessoossosssessesssesssosssesssssssssesssscssssssssssesssssescssses A resistance of 1200 to 2500 is expected 4 20mA Out Ground return for the 4 20mA output ighTemp_TC igh Temp Thermocouple positive TYPE K thermocouple must be connected between EI YELLOW ead the and terminals and must not be electrically inter ASIS AAA CARR ERS OPENERS ER H RAG NAAA connected to ground ighTemp_TC igh Temp Thermocouple negative Da riada An uninterrupted connection using TYPE K thermocouple Process_TC Pilot Thermocouple 1 positive lead wire is required for an accurate reading AUX_TC Pilot Thermocou
31. a Ae 80 5 Troubleshooting A A AA ace 81 51 Common Issues TTT 83 85 52 Shutdown Messages AA A A A A AN 86 90 53 Alarm T on e 91 92 5 4 Warning Messages errrertrerecnnnnnnonornnnnnnnnnnnnnnnnnnrnnnnnnnnnnnnnnnnnnrnenenenenennnnnnnrinennnnnnnananennnros 93 94 5 5 Flame Detection Troubleshooting Guide errrrncnnnonononononononononnnanonanenononennenenenennnnnnnnos 95 96 5 6 Appendix A Main Valve DAA AE E SANA EET TEER 97 1 Overview The PF2100F FIS Flare Ignition System is an electronic control and monitoring system designed for use on a wide array open flares and unenclosed incinerators It provides electronic pilot ignition flame detection temperature control and remote monitoring Safety is improved by providing the means to light the pilot electronically This eliminates the need for the old rag on a stick method which could be quite dangerous 1 1 Available Models The PF2100F 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 5m 15ft away from the flare 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 flare Both of these models can be further enhanced by adding an option
32. a physical interface including things such as keys and indicator lights and 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 alphabetically by topic The final sub section contains 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 MED 3 User Interface amp Settings 3 1 1 Keypad Diagram DISPLAY MENU KEY UP KEY START KEY PILOT LIGHT PF2100F O FLAME O RUNNING START STOPPED STOP KEY FLAME LIGHT OK KEY DOWN KEY RUNNING LIGHT MANUAL LIGHT SPARK LIGHT 3 1 2 Indicator Lights FLAME LIGHT Indicate s that the system is detecting the pilot flame RUNNING 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
33. acter 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 PF2100F 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 This may lead to small rounding errors when operating in Fahrenheit HET 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 PF2100F 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 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 AVA A
34. age Alarm Threshold Waiting Low PRS The system will automatically restart once the Low Pressure Contact is closed Waiting LVL The system will automatically restart once the Level Contact is closed Waiting STRT Inp The system will automatically restart once the Start Contact is closed 5 5 Flame Detection Troubleshooting Guide System is not detecting flame 1 Does the flame quality drop from 100 Pilot when the main comes on oe 2 Ensure that the pilot orifice is correct for the gas used 54 for natural gas YES Does the system stay running with the flame arrestor open The draft from the main could be pulling the pilot NO Y flame away from the YES Clean the arrestor and look for other air restrictions 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 flame rod Reposition the flame rod Ensure that the ignition rod is fully immersed in the 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 wir
35. al Modbus Expansion card Note The 4 20mA Expansion Card is not supported by the PF2100F at this time MODELS F0000 Base Model FC000 Internal Coil Model 1 2 Included Components The PF2100F comes packaged with the following varies across models If any components are missing contact Profire immediately F e g E asiani E AA n pdas aiee o Eorann E E E E e S Sns 7 ties E nni pcia re eee en es id a ssosipeveudadiawsasadssassaseaybancescasesdegessatssesebedunescoivevasisesesesasessieveasueveide ssvasevsabesieaiedves rns 1 3 Optional Components The following components may be required to install the PF2100F 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 N Liquid Tight Ports Rubber Grommets 2 WIRE Ignition Wire N Thermocouple Wire 3 RODS AND CONNECTORS N Kanthal Ignition Rods Various Lengths 4 VALVES N DC Solenoids Safety Valves with Proof of Closure Proportional Valves 5 THERMOCOUPLES Single Type K PILOT ASSEMBLY Nozzles Brackets Mixers Orifices AUTONOMY e Batteries Solar Chargers Solar Panels ACCESSORIES N Modbus Expansion Cards External Ignition Coils External Ignition Coils with Enclosure 1 Overview 1 4 External Diagram
36. al on the PF2100F This terminal can be left unconnected if a pilot thermocouple is being used The primary of the ignition coil should be connected to this terminal 2 6 4 2 6 7 The 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 5 Terminal Description Continued TERMINAL EXPECTED CONNECTIONS DESCRIPTION SECTION on Status Connect to PLC positive input con The status and contacts will be closed when the system is run 2 71 act or other alarm device ning and opened when the system is shutdown Dry contact output to O dicate systems tosmendemaldedeede PLC Neto that thie con Status Connect to PLC negative input con DC onl d il d d actoriotheralarmidevica tacts are only and are not internally connected to power or ground 40VDC 250mA 1522 Start Remote start input from an external Dry contact switch is expected The input is internally pulled up to 22 device ie PLC 9VDC via a 3 75kQ resistance Jumper and if not used All input contacts can use a single common ground return if desired ESD External Shutdown input typically plant ESD loop ESD Ground Proof of Unused in PF2100F Closure Proof of Ground Closure igh Input from a mechanical High Pres Pressure sure switch gh Ground Pressure Low Input from a mechanical Low Pres Pressure sure switch Lo
37. al when the level drops below a certain minimum 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 seconds before the system will shutdown MED 2 Installation 2 7 3 4 20mA Temperature Output The 4 20mA Output can provide the highest pilot temperature encoded as a 4 20mA signal This is useful if a PLC on site needs to know the pilot temperature In this case wire the PF2100F s 4 20mA Output to a PLC s 4 20mA Input Note that the PF2100F 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 1350 C 2 7 4 Modbus Expansion Card An optional Modbus Expansion Card can be installed in the PF2100F which provides the following additional features REMOTE MONITORING This card allows for remote monitoring of the PF2100F status including process temperature and pilot temperature REMOTE START STOP This card can also be used to remotely start and stop the system and to adjust some setpoint values Refer to the Modbus Expansion Card Manual for further details on installation and operation of this card MODBUS EXPANSION CARD Some PF2100F models come with this card pre installed 2 Installation CES 3 User Interface amp Settings The user interface is comprised of two parts
38. alling the PF2100F please review the following list of warnings Failure to observe these may result in death electrocution property damage product damage and or government fines ALL MODELS 1 The PF2100F 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 PF2100F system The PF2100F is NOT designed to control a pilot or main solenoid The PF2100F is NOT CSA B149 compliant If you require automatic electronic control of a valve train please consider using our PF2100F system Failure to properly ground the pilot assembly back to the PF2100F s EGND screw may result in accidental electrocution product damage or simply failure to ignite the pilot The PF2100F 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 operating Even without making physical contact with the terminal it is possible to draw a spark from several inches away especially if the pilot bracket is not properly grounded Never leave the PF2100F 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
39. atus Contact Sertinga ccc cece cc cccccccccccecceccceccesscsssssetteteeeeeeeeesecseceveceeesess N A 3 4 4 Auxiliary Temperature Settings ooo eee ceeeeseceeseecccceeececeusnaeeeeeeeececceeeuuaraanaeeeeress N A 3 4 5 34 6 DISPO a is 52 3 4 7 Modbus Expansion Card Serina 53 3 4 8 Password Setting 53 3 4 9 Flare Control Settings brot 54 3 410 S tpoints raean aana reseed vee EI ieee 55 3 4 11 Restart Settings onsen tit ds 56 34 12 System VO o aa 57 3 4 13 Timing Delay Settings cccccesesccesssceecereuseseseteveccesesscsstesevensuscsuesaneesestesesens N A 3 4 14 Valve Modulation SettiMgS ooccoonconorccnorcnnorncnorcnnocnnnarononinnnnonanocnnnrcnnnronnnccnnnicanos 58 35 Operating the System idea 58 3 5 1 Starting the System 59 60 3 5 2 Stopping the SySteM oo cece cccccccccccesseeeeesesusssuansussessseesssessssesesseseseeeeeeecs 61 3 5 3 Adjusting Settings amp Reviewing Saus eee 62 3 5 4 Viewing Event COMME Soi lt ld aia atea 63 3 55 Viewing the Event Lo ninia ia ds 64 66 3 5 6 VIEWING Firmware Versions a ean 0 cido terrano dana area 67 3 5 7 Resetting TO Detalla dd did 67 68 35 8 Field Cal a att 68 71 4 Modes and Behavigut cnn nn ronn nono cnn nn nnaccnnnnnns 72 c ESP aa a aa a r eh estates 74 Ad Power Omnocg en add 74 412 Starting Auto ee ai a A A ETENE T 75 41 3 Testing in Manual Mod escorias 76 AMA Pare Contoh rinra seat ee A aa E E OE 77 78 AAS SS 79 4 1 6 Relignt Procedure a e i
40. c 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 The pilot went out and could not be relit automatically within the specified number of attempts Flame Fails 3 attempts on initial start user defined for other cases 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 VOLT he system input voltage exceeded the High Voltage Alarm threshold ESDs T 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 because the Level Contact was opened or the 4 20mA Low Level Level ESDs Setpoint was dropped belo
41. c instructions on how to wire up various common configurations There are four possible ways to wire the ignition coil and flame detection circuit with the PF2100F as illustrated in the table below Wiring instructions and diagrams are provided for each WIRE LENGTHS When wiring the ignition and flame detection circuits wire length must be carefully considered If the wire lengths are too long the PF2100F may not be able to deliver enough energy to the ignition rod to ignite the pilot Or the PF2100F may not receive enough signal from the flame rod to be able to detect flame GROUNDING Properly grounding the pilot assembly back to the PF2100F is critical for proper ignition and flame detection This can be accomplished many ways A ground wire should be run from the lon or EGND terminal of the PF2100F over to the pilot assembly This wire can either be connected to a ground screw on the pilot bracket or to the flare housing If it is connected to the flare housing use a multimeter to verify that the flare housing has electrical continuity with the pilot assembly If not another wire must be added to connect it ROD POSITIONING Rod positioning must also be carefully considered to ensure proper ignition and flame detection The 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
42. cc ccnnona naci n 32 31 Hardware USEF nieta tia 34 3 11 Keypad Diada 35 3 12 Indicators ti aa id 36 eX NN 36 E A E TN 37 3 2 Software User Interlace iii a ad 37 321 Manual vs Auto Mode ce e dis 38 322 HOME SChESM nencia a iaaea oaii ihi inr 39 PASS 39 3 2 4 Quick Setpoint AdjUStMeNt no nono nn n nono nono nnnnnnnnnnnnnnnncnincn n 40 AS A A Ea Laa sates 40 326 PROW MU A A les 40 3 2 7 Firmware Version SCre n 0 0 eecccececcceeccccuccccceccecuceecuececauecceueececueceeeececaueeeraeseeaues 40 3 2 8 Warning Messages 41 3 2 9 Sh tdown Screen ana arahan aaa ah Ra dees sauecbeusedussavievsecvsuscenssetes 41 33 Menu Map iio cido drid 42 43 3 3 1 Setpoint Menu Maca do rd aiii 44 3 3 2 History Menu 3 i 5 sessthitestincbladed taaiaatioradgnds ihuadeheredaen adecssdanetandlaatiedwlaeleidansens 44 45 3 33 System Info MENU B ocoocccccnnccnnconncnnncnnncnnnnnnonononononononononnnnonononononanonannronacnnncnnns 45 3 34 SystemiSetup Manu iii ir a riada 46 3 3 5 Control Setup MENU B useana nne a a a a cae dedica 47 3 3 6 Expansion Cards Menu O a Tr e arara a a A aeaa Ea RE EEIen iSS 48 3 3 7 Caliiraton Menu Mia a A 49 50 3 3 8 Review Men s ida 50 3 4 Settings Grouped AIpnabericallvi ceccecceccecceccecueenesaceuesacenesaseesseseeseneaeeaneaees 51 3 4 1 4 20mA Expansion Card SettiMQS oocccnnnnnccooonoaonanonnnnnonononononononnnnnnnnnnnonccinicicinos N A 3 42 4 20mA OUIDUL SEMNE adoos 51 3 4 3 Alarm St
43. e Calibration 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 AVA 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 Press 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 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 e Calibration of the Thermocouples e Calibration of the 4 20mA Output The procedure to do this is as follows 1 2 Ensure that the system is stopped Press the UP and Down Keys simultaneously to unlock the Calibration Menu Menu 7 which is normally hidden Press the Press OK
44. e from the flame rod and measure on the connector QUESTION ARE IN WHITE RECTANGLES 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 YES 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 S N d 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 ignition YES 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 CC Replace the coil Check the ION wire for shorts to ground or nicks 10otINg PREVIOUS PAGE Set the Multi Meter to measure DC voltage
45. es N Until Flame In this mode the PF2100F will only spark the ignition coil when there is no flame detected N Always In this mode the PF2100F will always spark the ignition coil regardless of whether or not a flame is detected The Spark Interval allows to frequency of sparking to be reduced once a flame is detected MED 3 User Interface amp Settings FLAME FAIL TIMEOUT MENU 5 When the PF2100F is started if a flame is not detected within the Flame Fail Timeout period the system will shut down Similarly if the flame is lost during operation and is not relit within this period the system will shut down This period can be adjusted from 1 minute to 2 hours but it can also be set to Never and disabled entirely With the timeout disabled the PF2100F will continue its Flare Control and spark indefinitely even if a flame is never detected SPARK INTERVAL MENU 5 When the PF2100F is in the Continuous spark mode the delay between sparks when a flame is detected can be adjusted through this setting The ignition coil sparks for a fixed 2 second period but the time between these sparks can be adjusted between 8 seconds default value and 1 minute Increasing this time can help reduce the wear on the ignition coil in the continuous spark mode 3 4 10 Setpoints The PF2100F uses three setpoints The following diagram illustrates the upper and lower bounds of each setpoint 1350 C 7 PILOT TEMP MINIMUM RUN TEMP
46. h 30 9 cm 12 15 in phere T a To E E E a a densas nia tan E Sue E oe a aana y F0000 Model 4 0lbs 1 8kg a ERRA ae amas ain Fuse Rating 5A 250V Ceramic Fast Blow Status Contact Fuse Rating 250mA 125V Ceramic Fast Blow ae ee as A erica Replacement Status Contact Fuse LittelFuse 0453 250 or 0451 250 www profireenergy com O 2013 PROFIRE 9 Troubleshooting CEN
47. her types of wire can significantly disrupt the measurement If a head connection is used verify that none of the above wiring issues exist there either 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 Check that the PF2100F is in proper calibration using a process calibrator If not recalibrate the system 5 Troubleshooting es 5 2 Shutdown Messages The following is a list of messages that may flash on the PF2100F 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 POSSIBLE SOLUTIONS Ambient Temps Not Equal The Ambient Temperature read by the Door Card does not match the one reported by the Terminal Card Comparison Setpoints One of the Setpoints in the Door Card does not match the corresponding value in the Terminal Card Comparison The Door Card s internal control byte x did not match C_byte x y the Terminal Card s internal status byte y Comparison The Door Card and Terminal Card do not agree on the ESD DC xxx TC xxx state of the ESD Contact xxx will be e
48. hicker ground wire Connect the Kanthal Flame Detection Rod to the PF2100F s lon 9 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 PF2100F using 16 AWG or thicker wire Connect Coil terminal on the External Coil to the Coil terminal on the PF2100F 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 Ignition 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 2 Installation 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 2 6 7 External Coil Single Rod Use this configuration when the PF2100F is gt 5m 15ft from the flare and you want
49. hutdown 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 The 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 3 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 Igan 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 The Home Screen displays the System State and the Pilot Temperature The information displayed on the Home Screen is read only The Home Screen is accessible at any time by pressing and holding the OK Key for 3 seconds REVIEW MENU The Review Menu is used to check key setpoints and to view various real time system measurements such as temperature Al
50. ion 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 The system will display Parameter Saved and will then reboot After rebooting the system will display the message CONFIGURATION 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 calibration 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 used by the 2100F In general it should not be necessary to do this in the field because the sys
51. is configuration when the PF2100F is lt 5m 15ft from the flare and you want greater flexibility for rod placement WIRING STEPS 1 Connect the Pilot Assembly ground screw to the PF2100F s lon terminal using a 16 AWG or thicker ground wire Connect the Kanthal Flame Detection Rod to the PF2100F 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 PF2100F 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 CELS 2 6 6 External Coil Dual Rod Use this configuration when the PF2100F is gt 5m 15ft from the flare and you want greater flexibility for rod placement WIRING STEPS 1 Connect Pilot Assembly ground screw to the PF2100F s lon 8 terminal using a 16 AWG or t
52. ither ON or OFF Comparison The Door Card and Terminal Card do not agree on the VL DC xxx TC xxx state of the Level Contact Comparison The Door Card and Terminal Card do not agree on the AN DC xxx TC xxx state of the Main Valve Output xxx will be either ON or OFF Comparison The Door Card and Terminal Card do not agree on the PLT DC xxx TC xxx state of the Pilot Valve Output xxx will be either ON or OFF Comparison The Door Card and Terminal Card do not agree on the PoC DC xxx TC xxx state of the Proof of Closure Contact xxx will be either ON or OFF Comparison The Door Card and Terminal Card do not agree on the PRH DC xxx TC xxx state of the High Pressure Contact xxx will be either ON or OFF HE 5 Troubleshooting 5 2 Shutdown Messages Continued ON SCREEN DESCRIPTION POSSIBLE SOLUTIONS Comparison The Door Card and Terminal Card do not agree on the PRL DC xxx TC xxx state of the Low Pressure Contact xxx will be either ON or OFF Comparison The Door Card and Terminal Card do not agree on the STRT DC xxx TC xxx state of the Start Contact xxx will be either ON or OFF DC MSP430 No Communications he TC430 Temperature chip on the Door Card is not responding EEPROM Error The EEPROM settings are corrupted ESD Input The ESD Input was open while
53. l information in this menu is read only To access it press the Up or Down Key while on the Home Screen SYSTEM MENUS Menus 1 4 5 and 6 are used for checking and adjusting settings Menus 2 and 3 are used for read only values Menu 7 is used for calibration and is usually hidden The System Menus are accessed by pressing the Menu Key from the Home Screen while in Manual Mode System menus are not accessible while the system is running Menu 3 contains some system status information that is not found elsewhere in the menu system Refer to section 3 3 3 System Info for more details When the system is stopped all settings can be checked and adjusted When the system is running only some settings can be checked through the Review Menu and none of the settings can be 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 REVIEW MENU AVAILABLE System Stopped System State Yes Pilot Temperature lonization System Running System State Yes Pilot Temperature lonization 620 3 User Interface amp Settings SYSTEM MENUS AVAILABLE 1 6 and sometimes 7 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 partic
54. lame Timeout Flame Quality Spark Mode Auto Restart High Temp Reading High Temp Shutdown TC Debug Screen Low Temp Alarm Setpoint Minimum Run Temperature High Temp Shutdown Flame Fails Resets ESDs Level ESDs 4 20mA Output Percent Door Card Temp Ambient Temp Auto Restart Password Enable Door Card Voltage Voltage Reading Commission Date Display Sleep Pilot Solenoid PWM High Pressure ESDs Low Pressure ESDs Location Main Solenoid PWM Control State System Voltage Thermocouple Errors Terminal Card Errors System Errors View Event Log Clear History Terminal Card State EVENT LOG Event 1 Event 2 L e e Event 31 Event 32 Temperature Units Commission Date Entry Commission Location Entry Reset to Factory Defaults 3 3 Menu Map Continued SYSTEM MENUS 5 7 SCREEN NAVIGATION ADJUSTMENTS HOME 5 CONTROL SETUP E 6 exransion CARDS E gt 7 cauerarion screen IEA TO ENTER REVIEW i o El El U U HOME 2 T JA O ENTER REVIEW we AAOC N E rassworo may se reQuirED SCREEN Du ES z ES REVIEW BB TO CYCLE A B TO RETURN HOME EVENT E tO cycle JA 0 RETURN HOME E Pilot Off Enable High Temp TC Cal Span MENUS E E To AccerT ES TO CANCEL ANY ES TOGGLES MODES WA HEI Coil Enable Pilot TC 2 Cal Span AUTO MANUAL ES A CHECK FIRMWA
55. latest firmware Some older firmware versions 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 The 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 Thermocouple Readings are Bouncing 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 100 for regular valves Verify that proper system grounding is being observed Especially check that all solenoids are properly connected to earth ground Thermocouple Readings are Incorrect Check if the thermocouple wiring polarity is reversed Yellow should be connected to positive and red to negative Check that no thermocouple pairs are crossed ie positive from one TC paired with negative from another TC Ensure that only type k thermocouple wire and connectors are used Even small sections of ot
56. nce then adjusting the on screen reading Calibrate Pilot 1 point by applying a calibrated reference then adjusting th e on screen reading Yes No Calibrate 4 20mA Output zero point by Thermocouple calibration zero point or debug Thermocouple calibration span informa Display Thermocouple Calibration Zero Factors Calibrate Pilot 2 then adjusting th adjusting output Thermocouple span point by applying a calibrated reference e on screen reading until multimeter reads Calibrate 4 20mA Output span by adjusting ou 20mA put information tion until multimeter reads N A A 35 JA JA 35 N A N A 35 wn ni sn wn i sen win nn sen wn nn sn M YYYY Calibration Span Factors 9 3 User Interface amp 3 3 7 Calibration MENU 7 Continued MENUMAP ON SCREEN DESCRIPTION RANGE DEFAULT SETTING SECTION Clear Calibration Setting Clear All CAL Restore all calibration settings to their Yes No 31518 Settings factory defaults 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 running C E inimum Run Temperature Temp A A iaa nn isi A ETA n gt A S R S ii izicid o ia A a O Bite esta ends oa aaa an nda ES NS 5 FR ee po renee adn oh E o i tn in A pea a o a a AT G diaas EAT E a NA E o va ae TR
57. nected to power or ground so these connections must be provided externally as required When the system is running 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 PF2100F s status An alarm siren trouble lamp or PLC are examples of devices that might be connected 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 status 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 is15Q There is a fuse on the status contact to protect it A spare fuse is also included HED 2 Installation 2 7 2 Dry Contact Inputs There are 6 dry contact inputs on the PF2100F 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 its 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 st
58. 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 HED 3 User Interface amp Settings 3 5 1 Starting the System There are five different ways to start the system MANUALLY VIA THE START 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 Start Key and 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 flame detection status 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 AND IGNITE KEYS This method of starting the system is useful primarily during commissioning when it may be desired to te
59. ng on the display If no Shutdown Message is present it is not required to do this but it will still work if you do 2 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 steps to do this are as follows 1 The remote device should write 1234 to the 40100 register to place the system into Auto Mode 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 3 The remote device should poll the 10001 register and wait for it to become set to one which indicates that process control is running 60 3 User Interface amp Settings 3 5 2 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 and display a shutdown message reading User Stop 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 are as follows 1 Open the Start Contact and leave it open The system will stop immediately VIA A SHUTDOWN CONDITION Whenever any s
60. ntended mode of operation MED 3 User Interface amp Settings 3 2 2 Home Screen 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 and log out from any point in the user interface the user can press and hold the OK key for three seconds On the Home Screen one of three values is always shown on the bottom line of the display with System State always displayed on the top line 1 Pilot Thermocouple 1 temperature 2 Pilot Thermocouple 2 temperature 3 lonization flame quality If the Pilot Thermocouple 1 input is an open circuit i e no thermocouple connected the system will display the Pilot Thermocouple 2 input If this thermocouple is also an open circuit the system will display the ionization flame quality 3 2 3 System State The System State is the Process Control State of the system In both modes the top line of the Home Screen always shows the System State 3 User Interface amp Settings CES 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 sys
61. oil Adjusts the time between ignition coil sparks when a flame is detected and the Spark Mode is set to Always Spark lt Pilot SP Continuous 30 600 sec Spark lt Pilot SP 3 4 Hidden 30 sec gm Flame Fail Timeout Flame Fail Timeout Adjusts how long the system attempts to ignite or re ignite before shutting down Disabled 1 to 120n High Temp TC Enable High Temp TC Enables the High Temperature Thermo couple for shutdown Disabled Enabled Disabled Enabled Disabled 3 3 6 Expansion Cards MENU 6 This menu contains settings relating to expansion cards MENUMAP sd ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING MORE INFO Modbus Card Enable and Ad Modbus Card Enable control and set an address for Disabled 1 Disabled dress Selection the Modbus Expansion Card to 254 Modbus Card Firmware Version MBUS FW Display Modbus Expansion Card firm N A N A 3 4 ware version 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 MENUMAP ON SCREEN DESCRIPTION RANGE DEFAULT SETTING SECTION Calibrate High Temp Thermocouple zero he inpu Calibrate High Temp TC Zero Point Thermocouple span Cal Proc TC point by shorting Thermocouple zero he inpu Calibrate High Temp Thermocouple span point by applying a calibrated refere
62. opped For safety reasons a double action is required to start the system remotely via this contact 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 PROOF OF CLOSURE CONTACT The Proof of Closure Contact is unused on the PF2100F A main valve should not be connected to the system so there is no need for Proof of Closure HIGH PRESSURE CONTACT The High Pressure Contact can be connected to a High Pressure Switch installed in the fuel train LOW PRESSURE CONTACT The Low Pressure Contact can be connected to a Low Pressure Switch installed 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 seconds before the system will shutdown If Auto Restart is enabled the system will restart automatically when the Low Pressure Contact recloses 2 Installation CIS 2 72 Dry Contact Inputs Continued LEVEL CONTACT The Level Contact can be connected to a Level Switch This is used to sign
63. ow 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 System State System State Pilot Temp Flame Quality Pilot Temp Flame Quality FW VERSION WARNING SCREEN MESSAGES SHUTDOWN FW VERSION WARNING SCREEN SCREEN MESSAGES 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 In Manual Mode an operator can manually open the pilot valve and spark the ignition coil using the PF2100F keypad This can be used during commissioning to test the pilot valve and ignition coil but it cannot be used for continuous operation In Auto Mode the PF2100F performs its Flare Control Algorithm which is the i
64. ple 2 negative lead RED 2 5 Terminal Description Continued TERMINAL EXPECTED CONNECTIONS DESCRIPTION SECTION igh Fire Main Unused in PF2100F Haren Va e SN V K o Hipica T EEST o oido o Dion ea satiate ee ada e a connect to ground Solenoid valves must be connected between the and DASA terminals The negative terminal is not directly connected to ground so a common return wire for the High Fire Low Fire and Pilot valves cannot be used Maximum continuous current is 2A If Low Power mode is enabled a peak load of 4A is permitted lon Optional flame detection positive input Connect to flame rod or exter nal coil lon terminal depending on configuration lon Flame Detection negative input Connect to ground screw on pilot assembly or burner housing Coil Driver for the low voltage primary of the ignition coil 2 Installation A Kanthal rod should be placed directly in the pilot flame and connected 2 6 4 2 6 7 o this input The pilot assembly must be grounded for the flame detec ion 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 lame detection A 65VAC signal is applied to the flame rod The source impedance is very high so there is no danger of sparking onization flame detection is option
65. quence When power is applied to the system it will display PF2100F in large text followed by the firmware versions of the Door and Terminal 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 FW F1 7 040 Ready PF2100F 4 Modes and Behaviour 4 1 2 Starting in Auto Mode When the system is started in Auto Mode it will run through the ignition sequence NOTE automatically In Auto Mode the PF2100F will automatically attempt to relight the pilot if a The Flare Control state in the flame is not detected diagram is actually a collection of several states that will be explained in more detail further on Start FLARE POWER gt CONTROL ON No Alarm Alarm 2s and Behaviour 75 4 1 3 Testing in Manual Mode When the system is started in Manual Mode it must be manually moved through the ignition sequence Manual Mode should only be used for testing the functionality of the pilot valve and ignition coil and is not intended for flare control Pilot Key Released POWER Pilot Key Held PILOT OPEN Ignite Key Held Flame ON No Alarm Alarm 4 1 4 Flare Control The key to the PF2100F s Flare Control Algorithm is pilot flame detection The majority of flare control decisions made by the PF2100F are based on whether or not a flame is detected by the system The PF
66. s due to failure to Terminal Card Errors Term Errs umber of Terminal Card Shutdowns O to 1000 A 35 3 3 2 History MENU 2 Continued MENUMAP o ON SCREEN BRIEF DESRIPTION RANGE DEFAULT SETTING SECTION System Errors Sys Errs Number of System Errors Shutdowns 0 to 1000 View Event Log View Events Log of recent events Yes No No SiS Clear History Clear History Clears all History and logged events Yes No No SiS 3 3 3 System Info MENU 3 This menu contains read only information about the system MENUMAP si ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTING SECTION 4 20mA Output Percent 4 20 Current status of the 4 20mA Output 0 to 100 Bal AD Output Ambient Temperature Reading Ambient Temp Current ambient temperature Used for 55 C to 65 C A 2 6 thermocouple cold junction compensa 70 F to 150 F tion Voltage Reading System Voltage Current voltage applied to the system 8V to 35V A 3 4 Commision Date Commission Date Date that the system was commis DD MMM A 3 4 sioned YY YY Location Location The install location of the system if N A A 3 4 entered by user Control State Control State Debug Information N A idden Terminal Card State Term Card Debug Information N A idden 3 3 4 System Setup MENU 4 This menu contains various optional system settings It cannot be accessed while the PF2100F is running Ce ON SCREEN BRIEF DESCRIPTION RANGE DEFAULT SETTI
67. st 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 Continue holding the two keys with the Flame LED lights showing that a flame is detected 5 Release both keys to stop the system 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 Ign 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 showi
68. tem has already been calibrated at the factory However 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 correctly If it is deemed necessary to proceed with recalibrating the PF2100F 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 PF2100F 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 NED 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 hot
69. tem 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 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 MED 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 PRS event Others persist until the warning condition is resolved eg LO Volt Warning 3 2 9 Shutdown Screen When the system shuts down 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 on 3 3 Menu Map System State 1 SETPOINTS ME 2 HISTORY EI 3 SYSTEM INFO E 4 SYSTEM SETUP N Pilot Temp Flame Quality PASSWORD MAY BE REQUIRED LEVEL 2 PASSWORD LEVEL 1 OR LEVEL 2 Minimum Run Temp Low Temp Alarm Setpoint Pilot TC 1 Temp Pilot TC 2 Temp F
70. ternal 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 PF2100F while the External Coil Configuration refers to a coil not included with the PF2100F and located in a separate enclosure or inside the flare 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 CONFIGURATION COIL TYPE SINGLE ROD DUAL ROD Internal Coil N External Coil HEND 2 Installation IGNITION COIL VS HIGH ENERGY IGNITION In addition to a standard ignition coil the PF2100F supports the use of a High Energy Ignition HEI system for ignition To use an HEI system connect the HEI system s positive input to the Coil terminal on the PF2100F and the HEI system s negative input to the Coil terminal Consult the HEl system s documentation for information on connecting it to a pilot assembly and properly grounding it The wiring instructions in the following sections only apply to systems installed with traditional ignition coils 2 6 5 Internal Coil Dual Rod Use th
71. test 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 short HT to HT short Proc to Proc and short Aux to Aux Press the UP and Down Keys simultaneously to unlock the Calibration 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 AVY A ox Cal High Temp 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 Parameter 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 Pilot TC 1 Zero and Cal Pilot 2TC Zero menu items Reconnect the 3 pairs of thermocouple wires High Temp Process and Aux to the P8 Pluggable Header on the Terminal Card 12 13 14 15 16 17 18 Set the High Temp Pilot 1 and Pilot 2 thermocouples to a known reference temperature using a dry block or other calibrated reference The reference
72. the product warranty if the door has been left open o 2 Installation BATTERY MODELS 6 Never store or ship the unit with the battery connected Disconnect 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 electrocution 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 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
73. the system was running or attempting to start Expansion Card Error Modbus Card The Modbus Expansion Card is not responding This Card Fail may indicate that it is not installed correctly or that it is enabled when not present at all Flame Fail The system failed to ignite the pilot within the allocated flame fail timeout period Flame Rod Test Error Adjust Flame The Flame Rod or associated wiring may be shorted to Rod Position ground thus preventing it from properly detecting flame High Pressure The 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 read ing remains above the 4 20 Pressure High Setpoint for 2s after the main valve opened igh Temp The Process Temperature rose above the High Temp ESD Setpoint igh Temp Setpnt Mismatch The Door Card and Terminal Card do not agree on the value of the High Temp ESD Setpoint 5 2 Shutdown Messages Continued ON SCREEN DESCRIPTION POSSIBLE SOLUTIONS High Voltage xx x Volts The system voltage remained above the High Volt age 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 The Ignite Key was held for more than 30s while in manual mode KEY STUCK ERROR XXXX One of the keypad
74. ular 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 Pilot Temp or High Temp if enabled or a high or low voltage alarm HIGH PRESSURE ESDs Increments each time the system shuts down as a result of the High Pressure Contact opening LEVEL ESDs Increments each time the system shuts down as a result of the Level Contact opening LOW PRESSURE ESDs Increments each time the system shuts down as a result of the Low Pressure Contact opening THERMOCOUPLE ERRORS Increments each time the system shuts down as a result of a thermocouple issue such as a short circuit open circuit or ground short 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 internal system error TERMINAL CARD ERRORS Increments each time the system shuts down as a result of a terminal card error 3 User Interface amp Settings CES 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 such as System Starts Stops Shutdowns Menu Accesses et
75. utdown Detect Door Card failed to detect this Terminal Card he Terminal Card detected that the system voltage Voltage Sense was outside of allowable limits The Door Card failed to detect this See section 3 4 12 System Voltage for a description of these alarm points Thermocouples The High Temp and Process Thermocouples are reading Not Equal Check Wiring temperatures that are too far apart This may indicate a failed thermocouple or improper wiring User Stop 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 PF2100F display Tese codes indicate a persistent problem that must be cleared before the system can be restarted Use the table below to determine the meaning of hese codes ON SCREEN DESCRIPTION POSSIBLE SOLUTIONS PilotTC The system is in a mode that requires the Pilot Ther mocouple and the Thermocouple is open or otherwise wired incorrectly The TC430 temperature sensor on the Door Card is not responding There is a problem with the Flame Detection wiring or circuitry PoC_Inp The Proof of Closure contact is open Volt he system voltage is above the High Voltage Alarm poin T ESD The Process Temperature is above the High Temp ESD Setpoin T_TC The High Temp Thermocouple is open or otherwise wired incorrectly oVolt he system voltage is below the Low Voltage Alarm poin LowPrs The Low
76. w 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 ay 3 User Interface amp Settings 3 5 5 Viewing Event ENTRY The Proof of Closure Contact was open when it should not have been causing the system to Log Continued DESCRIPTION The system input voltage dropped below the Low Voltage Alarm threshold shutdown ASSOCIATED COUNTER TCERR PROC 3 User Interface Thermocouple Errors gt The Process Thermocouple is out of range 3 5 5 Viewing Event Log Continued ENTRY DESCRIPTION ASSOCIATED COUNTER TC NOT EO The system detected an unacceptable 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 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 firmware versions in sequence CARD CURRENT FW VERSION NOTE Door Card DC FW F1 7040 MBUS FW v4 Will show not installed or not enable Modbus Expansion Card The expans
77. w Pressure Ground Level Input from a float switch mounted in the bath tank Level Ground 2 6 Required Wiring The wiring in this section of the document is required for all PF2100F installations Skipping or performing any steps in this section incorrectly will likely result in the PF2100F not functioning properly 2 6 1 Power The PF2100F can be powered from 12VDC or 24VDC The maximum current that the PF2100F 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 consumed 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 MED 2 Installation 2 6 2 Valves Only two of the four valve control outputs are supported by the PF2100F Pilot and High Fire Main WIRING STEPS 1 Wire the Pilot valve to the Pilot terminals 2 Connect valve EGND wires to Earth Ground NOTES 1 It is possible to connect multiple valves to the same control output in parallel or series If
78. 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 HET 3 User Interface amp Settings STOPPED LIGHT Indicates that the system is stopped 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 START KEY Used to start the system and switch to Auto Mode SPARK IGHT Indicates that the system is sparking to ignite the pilot PILOT KEY Used to test the pilot valve while the system is stopped IGNITE KEY Used to test the ignition coil while the system is stopped 3 1 4 Display The display on the PF2100F 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 PF2100F display Through it the state of the system is presented to the user The user can also change settings via this interface Bel
79. you do this ensure that the configuration you are using meets local codes and also does not exceed the total current rating of the PF2100F 2 The negative valve control wires are NOT connected directly to ground Therefore you cannot use a common return wire for all valves PILOT VALVE The Pilot valve is optional It will typically be used when the pilot gas comes from a tank LOW FIRE VALVE The Low Fire valve output is not supported by the PF2100F HIGH FIRE MAIN VALVE The PF2100F supports the use of a main valve This configuration is not recommeded for flare operation but information on the valves behavior can be provided in section 5 6 2 Installation CHN 2 6 3 Thermocouples All thermocouple inputs in the PF2100F are optional The Process TC and AUXTC terminals can be connected to two independent pilot thermocouples each capable of being used for flame detection The HighTemp TC terminal can be connected to a seperate thermocouple for high temperature shutdown applications All thermocouples are cold junction compensated For this reason it is important to ensure that Type k thermocouple wire and connectors are used exclusively The temperature compensation is done using an ambient temperature sensor located on the terminal card near the thermocouple terminals WIRING STEPS OPTIONAL 1 Connect a single Type k thermocouple to the Process TC input and place this thermocouple in the location of the pilot flame

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