PF3100 MANUAL - Profire Energy14. If the Safety Shutoff Valves (SSV) are required in your application, wire one valve to the SSV1 +/- terminals and the other valve to the SSV2 +/-

PF3100 MANUALwith UI, BMS Controller, Network Expansion,

Modbus RS-485, Ion Pilot, and Thermocouple Cards

REV: 1.0

IMPORTANT SAFETY INFORMATIONAmbient Operating Temperature Range -40°C to +60°C

GENERAL WARNINGS

Installation & use must conform to the directions in this guide.System must be properly connected to earth-ground for effective operation of flame detection circuitry.Electrical devices connected to the controller must meet certain electrical standards and be within voltage limits.Replacement fuses must be ceramic and of correct rating.Avoid unauthorized replacement of the fuse.

MODELS: PF3100-00A/C, PF3101-00A

Warnings

1. This equipment is suitable for use in Class I, Div 2, Groups A, B, C, and D hazardous locations or non-hazardous locations only.

2. WARNING – EXPLOSION HAZARD – Do not disconnect equipment while the circuit is live or unless the area is known to be free of ignitable concentrations.

3. WARNING – EXPLOSION HAZARD – Substitution of components may impair suitability for Class I, Div 1 hazardous locations.

MODELS: PF3102-00A

Warnings




4. The flame rods are not intended to be installed and mounted in a Class I, Division 1 or Division 2 hazardous location. Routing and installation of the flame rods shall be in accordance with the Canadian Electrical Code or National Electrical Code as per local requirements.

5. CAUTION – Conduit seal required within 18” of enclosure. Div 2 seal not required.

MODELS: PF3103-00B

Warnings




4. This assembly must be used with approved Profire probes and thermowells to maintain hazardous locations certification.

PRIMARY SAFETY CONTROL FOR USE IN HAZARDOUS LOCATIONS

CAMERA-READY LOGOTYPE FOR TYPE L AND TYPE R LISTING MARKS FOR CANADA AND THE U.S.

These Marks are registered by Underwriters Laboratories Inc.

The minimum height of the registered trademark symbol ® shall be 3/64 of an inch. When the overall diameter of the UL Mark is less than 3/8 of an inch, the trademark symbol may be omitted if it is not legible to the naked eye.

The font for all letter forms is Helvetica Condensed Black, except for the trademark symbol ®, which isHelvetica Condensed Medium. No other fonts are acceptable.

Please Note:The word "MARINE" should only be used for UL Classified marine products.

200-195F 20M/11/97

E474004

TABLE OF CONTENTS

Introduction 1

Modules 1

Features 2

Specifications 2

Mounting Considerations 3

Installation Warnings 4

Wiring Pinouts 4

Wiring 5

PFRN Power and Communication 7

Display User Interface 8

Menu Map 9

Operation 15

Troubleshooting 16

System Errors 17

Resetting to Defaults 17

1

PF3100 MODULE FAMILY

INTRODUCTION

The PF3100 burner management system consists of individual building blocks called modules which can be mixed and matched to form a complete solution. Each module performs a specific function and is intended to be installed close to the device they are measuring or controlling. This simplifies wiring and reduces issues with noise and signal loss compared to centralized control systems. This also allows the user to purchase only the modules which are necessary for a given application. The modules interact with one another using a network based communication method to perform a given task safely.

MODULES

UI Module

UI Network Module

UI BMS Module

UI BMS Network Module

UI Modbus Module

UI Modbus BMS Module

BMS Module

BMS Network Module

Ion Pilot Module

Type K Temperature Module

2

FEATURES

• Can view the status of other modules through the PFRN network from the UI Module

• Multiple UIs can show the same info on each screen

• Able to mount the UI away from the burner

• Simple indication of overall status through LEDs allowing end-users to check statuses from afar

• UI’s LCD screen shows statuses of overall system, individual modules, and groups of modules

• Numeric keypad is on the UIX enclosure for easy data entry

• Data logging and field firmware updates

• BMS modules in BMS enclosures can be placed near the burner housing away from the UI interface

• BMS Controller cards provide power to other modules through PFRN ports

• Network cards allow for connections to many other modules to form a single communication network

SPECIFICATIONS

Card Specs

Specs UI Card Network Card BMS Card Modbus Card Ion Pilot Card Thermocouple Card

Card Type Interface Network Controller IO IO IO

Power Method Power Consumer

Power Producer Power Producer Power Producer Power Consumer

Power Consumer

Voltage Input 36 VDC through PFRN

12/24 VDC 12/24 VDC 12/24 VDC 36 VDC through PFRN

36 VDC through PFRN

Number of Ports 1 PFRN Port 5 PFRN Ports 5 PFRN Ports 4 PFRN Ports 1 PFRN Port 1 PFRN Port

Fuse Rating N/A 6.3 A 10 A 500 mA N/A N/A

Fuse Part Number

N/A 3412.0113.22 1.2514 3412.0113.22 N/A N/A

Fuse MFG N/A Schurter Schurter Schurter N/A N/A

Enclosure Specs

Specs UIX Enclosure BMS Enclosure AUX Enclosure EPX Enclosure TLX Enclosure

Dimensions Width 30.9 cm (12.15 in)

Height 23.4 cm (9.23 in)

Depth 13.4 cm (5.28 in)

Width 30.9 cm (12.15 in)


Depth 13.4 cm (5.28 in)

Width 30.9 cm (12.15 in)


Depth 13.4 cm (5.28 in)

Top Width 11.7 cm (4.61 in)

Base Width 16.8 cm (6.63 in)


Depth 13.3 cm (5.25 in)

(Body Type)Standard ½” NPT Head Connection

Hazloc Rating Class I Div 2 Class I Div 2 Class I Div 2 Class I Div 1 Class I Div 1

Operating Temperature

-40°C to 60°C -40°C to 60°C -40°C to 60°C -40°C to 60°C -40°C to 60°C

Storage Temperature

-40°C to 60°C -40°C to 60°C -40°C to 60°C -40°C to 60°C -40°C to 60°C

3

MOUNTING CONSIDERATIONS

OrientationThe UIX, CTX, and AUX enclosures should be mounted upright.The EPX and TLX enclosures can be mounted in whichever direction makes sense for the application.

Location

1. The UI Module is typically mounted in an operator-safe, easily accessible area. The recommended mounting height is 1.5m (5ft) above where the operator will be standing for ease of use. If there is a BMS card in the UIX enclosure with the UI card, then you will need to adjust the location accordingly.

2. Mount any BMS enclosures near the corresponding valve train. 3. The Thermocouple card is included inside of a head connection (TLX enclosure) with a

thermocouple probe. The Type K Temperature module comes ready to install into the thermowells of each tank. Install in a Div 1 rated thermowell.

4. The Ion Pilot module should be located within 50 feet of the pilot it is igniting.5. The Network and Modbus cards will typically be mounted inside of a UIX, CTX, and AUX

enclosure. Must be within max PFRN run length of 250 ft.

HAZARDOUS LOCATION MOUNTING

In order to maintain the hazardous location rating for the EPX Enclosure, the following conditions must be met.

The EPX Enclosure lid must be tightened down until it is flush with the base. The locking screw must be installed into the base.Each unused base port must be sealed with pipe plugs. Use our plugs or figure out appropriately rated plugs that are equivalent.Any base ports in use must be sealed within 18 inches of the EPX Enclosure. All fittings must have at least 5 threads of engagement.

4

INSTALLATION WARNINGS

Before installing the PF3100, please review the following list of warnings.

Failure to observe the following may result in death, electrocution, property damage, product damage, and/or government fines.

1. For burners greater than 12.5 MMBtuh, additional modules may be required for use with the PF3100 system.

2. It is recommended that the low fire feature be used with anything above 1 MMBtuh. To use the PF3100 on burners greater than 5 MMBtuh, the Proof of Closure feature must be used.

3. Failure to properly ground the pilot assembly back to the PF3100’s Ion terminal may result in accidental electrocution, product damage, or failure to ignite the pilot.

4. The PF3100 generates 20kV - 40kV at its high voltage output terminal which can cause 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.

5. Make sure that the PF3100 enclosures are securely closed each time after opening the enclosure. This protects the internal circuitry from moisture damage and other environmental concerns. Moisture damage is not covered by the product warranty if the door has been left open.

WIRING PINOUTS

12/24 VDC

COMMON

EARTH GND

Power

InputRelay

Output

4-20mA

/ D

ry Contact

Inputs

Powered O

utputsD

ry Contact Inputs

STATUS

HFV -HFV +SSV2 -SSV2 +SSV1 -SSV1 +

Pilot -

Pilot +

Aux Out - (4-20mA)

Aux Out + (4-20mA)

START - START + POC - POC + AUX IN - AUX IN + ESD - ESD +

PRESSURE -

PRESSURE +

LEVEL -

LEVEL +

12/24 VDC

COMMON

EARTH GND

Power

InputRelay

Output

4-20mA

/ D

ry Contact

Inputs

Powered O

utputsD

ry Contact Inputs

STATUS

HFV -HFV +SSV2 -SSV2 +SSV1 -SSV1 +

Pilot -

Pilot +

Aux Out - (4-20mA)

Aux Out + (4-20mA)

START - START + POC - POC + AUX IN - AUX IN + ESD - ESD +

PRESSURE -

PRESSURE +

LEVEL -

LEVEL +

*Output terminals are limited to 4A max current draw. 4-20 mA output terminals are limited to 20mA.

5

WIRING

Modules

The wiring in this section of the document is required for all PF3100 installations. Skipping or performing any steps in this section incorrectly can result in the PF3100 not working properly.

6. Run appropriately zoned conduits between the modules. The UIX and CTX enclosures have pre-drilled conduit holes in two different sizes – 0.5 in (1.27 cm) and 0.75 in (1.91 cm). There are 4 of each size available. Remove the hole seals as needed and install the conduit.

7. Run a Cat5e or higher rated Ethernet cable through each conduit (between the BMS Controller Card and each other card). Make sure that the UI Card is plugged into the port on the BMS Controller Card labelled “UI Port”.

8. Make sure that all other cards are plugged into one of the other ports on the BMS Controller Card.

9. Connect power wires according to specifications from the BMS Controller to an appropriately rated power supply running at 12 or 24VDC.

10. Connect power wires according to specifications from each Ethernet switch to an appropriately rated power supply running at 12 or 24VDC.

11. Wire valves (including PoC, PoLF, and Temperature Control Valve) to the BMS Controller Card.

12. Wire the Pilot valve to the Pilot +/- terminals.13. Wire the Main valve to the High Fire / Main +/- terminals.14. If the Safety Shutoff Valves (SSV) are required in your application, wire one valve to the

SSV1 +/- terminals and the other valve to the SSV2 +/- terminals.15. Make sure that each valve has a separate return wire. Multiple valves sharing common

return wires will not function properly.16. Connect valve EGND wires to Earth Ground.17. Note that the PF2100 valve output called “Low Fire” has been replaced by two new

valve outputs called Safety Shutoff Valve 1(SSV1) and Safety Shutoff Valve 2 (SSV2). This is for applications that require two valves for safety. These two contacts always follow each other but are provided separately for improved current handling and also for improved troubleshooting.

18. Wire dry contact inputs to the BMS Controller Card as required.19. There are 5 dry contact inputs on the PF3100. 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.

20. Wire the start contact to the BMS Controller Card as required. 21. The Start Contact can be used to attach a remote start/stop switch. This is typically

connected to a PLC dry contact output.22. When the contact is open, the system is stopped. 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.

23. Wire the 4-20 inputs or Pressure/Level Switches to the BMS Controller Card if required. 24. The Level Contact can be connected to a Level Switch installed right above the fire tube.

This is used to signal when the tank level drops below a certain minimum. This is often the point at which the fluid in the tank is no longer covering the fire tube. Running the burner with an empty tank can damage both the fire tube and the tank.

25. The Level Contact is time averaged to help reject brief fluctuations in tank level which

6

might be a result of vibration. The contact must be open continuously for 2 or 20 seconds (depending on the “Pressure/Level Delay” setting) before the system will shutdown. If “Level Restart” is enabled, the system will restart automatically when the Level Contact recloses.

26. Note that the PF2100 has level and pressure contact inputs on the Terminal Card and corresponding 4-20 inputs on an expansion card. The PF3100 has contacts and 4-20 inputs overloaded on the same inputs. The behavior is selectable in software. Also note that there is not a separate low and high pressure contact. If both switches are desired, they need to be wired in series and connected to the pressure contact.

27. Wire thermocouples to the Thermocouple Card as required. The TC1A thermocouple inputs are mandatory and must be connected to a Dual Element thermocouple. The other thermocouples are only required when a second process temperature (such as the outlet temperature on a line heater) must be monitored.

28. Connect a dual element, Type K thermocouple to the TC1A inputs.29. Note that TC1A, TC1B, TC2A, and TC2B require dual element Type-k thermocouples. This

is different from the PF2100 which only supported a single TC for the auxiliary input.30. Wire the ignition coil and flame rod to the Ion Pilot Card.

Flame Rod/Ignition Coil

This section provides some tips to set up the system for reliable ignition and flame detection.

Wire Lengths

When wiring the ignition and flame detection circuits, the wire length between the ignition coil and pilot should be no more than 5m (15ft). If the wire lengths are too long, the PF3100 may not be able to deliver enough energy to the ignition rod to ignite the pilot. The PF3100 may also fail to receive a signal from the flame rod for detecting flame.

Grounding

Properly grounding the pilot assembly back to the PF3100 Ion Pilot module is critical for proper ignition and flame detection. The Earth Ground wire should run from the EGND terminal of the Ion Pilot card to the pilot assembly. This wire should be connected to the burner housing. Use a multimeter to verify that the burner housing has electrical continuity with the pilot assembly.

IgnitionCoil Straight

SiliconeBoot

PF3100 Ion PilotCard Header

Ferrule SingleRod

EGND

+Ion

{Coil+

7

PFRN POWER AND COMMUNICATION

Below is a small sample network describing module communication through Profire’s propriety communication network, PFRN.

UI CARD(Interface Class)

BMS CARD(Controller Class)

ION PILOT CARD(IO Class)

THERMOCOUPLE CARD

(IO Class)

NETWORK EXPANSION CARD

(Network Class)

MODBUS CARD(Network/Controller Class)



THERMOCOUPLE CARD

(IO Class)



THERMOCOUPLE CARD

(IO Class)



THERMOCOUPLE CARD

(IO Class)

8

DISPLAY USER INTERFACE

POWER LED

Off: UI is not powered On: UI is powered

STATUS LED

Off: UI is not powered Flashing Green: Startup sequence Green: System is running Red: System is stopped Amber: Warning or alarm is present

LCD SCREEN

Displays diagnostics, current settings, and options when navigating through menus.

STOP KEY

Used to stop the system which immediately turns off the burner.

BACK KEY

Used to go back one screen and cancel out of dialog boxes.

ARROW KEYS

Used to navigate through menus.

TRIPLE BAR KEY

Menu key that opens a menu of global options.

OK KEY

Used to enter a menu, acknowledge a prompt, save an edited setting or return to the home screen.

? (HELP) KEY

Allows access to system help. One button press brings up tooltips for items on the current screen. Two button presses opens the integrated user manual for the selected item.

+/- KEYS

Used to adjust settings up or down.

START KEY

Used to start the system.

NUMBER PAD

Used to key in changes in settings.

DELETE KEY

Used to delete the last character entered when using the number pad.

ENCLOSURE DOOR LOCKMechanism for securing the door. A flat-head screwdriver is needed to open and close the enclo-sure.

9

MENU MAP

The following sections include brief descriptions of each PF3100 menu, including the valid settings range and default setting. Any entries highlighted in gray are hidden in the menu by default.

Settings: Temperature Setpoints

This menu is used to adjust the Temperature Setpoints.

MENU MAP BRIEF DESCRIPTION RANGE DEFAULT SETTING CUSTOM SETTINGS

HighTempSetpoint High Temp Setpoint for Process TC

0 to 1350˚C 32 to 2462˚F

90˚C 194˚F

PilotOffSetpoint Pilot Off Setpointfor Process TC

0 to 1350˚C 32 to 2462˚F

85˚C 185˚F

LowFireSetpoint Low Fire Setpoint for Process TC

0 to 1350˚C 32 to 2462˚F

85˚C 185˚F

ProcessTempSetpoint Process Temp Setpoint for Process TC

0 to 1350˚C 32 to 2462˚F

80˚C 176˚F

LowTempAlarmSetpoint Low Alarm Setpoint for Process TC

0 to 1350˚C 32 to 2462˚F

50˚C 122˚F

AuxHighTempSetpoint High Temp Setpoint for Aux TC

0 to 1350˚C 32 to 2462˚F

90˚C 194˚F

AuxProcessTempSetpoint Process Setpoint for Aux TC 0 to 1350˚C 32 to 2462˚F

20˚C 68˚F

Settings: Deadband


TemperatureDeadband Deadband setting used for various temperature setpoints

0 to 13˚C 2˚C

AuxTempDeadband Deadband setting used for Aux temperature setpoints

0 to 13˚C 2˚C

420AuxIn1Deadband Deadband setting used for various 4-20mA Aux In 1 setpoints

0-16 mA 2 mA

LELDeadband Deadband setting used for LEL setpoint

0-16 mA 2 mA

FuelPressureDeadband Deadband setting used for various fuel pressure setpoints

0-16 mA 2 mA

TankLevelDeadband Deadband setting used for various tank level setpoints

0-16 mA 2 mA

VoltageDeadband Deadband setting used for various voltage setpoints

0 to 5V 2 V

Settings: 4-20 Input Setpoints


420AuxIn1HighSetpoint 4-20mA Aux In 1 High Setpoint

4-20 mA 14 mA

420AuxIn1LowSetpoint 4-20mA Aux In 1 Low Setpoint

4-20 mA 9 mA

10

420LELSetpoint 4-20mA Lower Explosive Limit Setpoint

4-20 mA 14 mA

420FuelPressureHighSetpoint 4-20mA Fuel Pressure High Setpoint

4-20 mA 17.33 mA

420FuelPressureLowSetpoint 4-20mA Fuel Pressure Low Setpoint

4-20 mA 5.6 mA

420TankLevelHighSetpoint 4-20mA Tank Level High Setpoint

4-20 mA 19.6 mA

420TankLevelLowSetpoint 4-20mA Tank Level Low Setpoint

4-20 mA 12 mA

Settings: Commissioning


ControllerCommissionDate Controller Commissioning Date, YYYY-MM-DD

0 - 0xFFFFFFFF 0

ControllerLocation Controller Location 0 to 64 chars "Test Location"

ControllerName Controller Name (User Assigned)

0 to 64 chars "Test Name"

ControllerVoltageSetting The Voltage Setting of the Controller Module

0 = 12V 1 = 24V

1

L1PasswordEnable Enable Level 1 Password Enable, Disable Disable

L1Password Level 1 Password 1 to 8 chars 1397

L2Password Level 2 Password 1 to 8 chars 2684

DeviceConfig[0] Ignition Module MAC address

6 hex bytes -

DeviceConfig[1] Temperature Module MAC address

6 hex bytes -

Settings: Process Control


RestartOptions Restart Options Bit Vector: b0 = Low Voltage Restart Enable b1 = High Voltage Restart Enable b2 = Low Fuel Pressure Restart Enable b3 = Low Tank Level Restart Enable

Defined Bits 0

StatusContactMode Status Contact Mode: 0 = Default 1 = Alarm when Remote Stop 2 = Process Control 3 = Follow Flame 4 = Low Temp Alarm

In List 0

11

420AuxOutMode 4-20mA Aux Output Mode: 0 = Disabled 1 = Proportional Valve Control 2 = Process Temperature Echo 3 = Aux Temperature Echo 4 = Fuel Gas Pressure Echo 5 = Tank Level Echo

In List 0

PilotOffEnable Pilot Off Enabled: 0 = Disabled 1 = Enabled

In List 1

LowFireEnable Low Fire Enabled: 0 = Disabled 1 = On at Process Setpoint 2 = On at Low Fire Setpoint

In List 0

AuxTempEnable Aux Temp Enabled: 0 = Disabled 1 = Secondary Process Control 2 = Secondary High Temp ESD 3 = Display Only

In List 0

ProcessControl Process Control Enabled: 0 = Disabled 1 = On/Off Control

In List 1

RelightAttempts The number of times that the controller will attempt to relight the pilot in the event of a flame fail

0-3 3

Settings: Valves


PilotValvePWM Pilot Valve PWM Duty Cycle 20-100% 60%

SSV1PWM SSV1 PWM Duty Cycle 20-100% 60%

SSV2PWM SSV2 PWM Duty Cycle 20-100% 60%

HighFirePWM High Fire PWM Duty Cycle 20-100% 60%

ProportionalValveMinOpening Proportional Valve (TCV) Minimum Opening (Also used as the Low Fire Setting)

0-70% 40%

Settings: IO


ProofOfClosureEnable Used to enable the Proof Of Closure Dry Contact Input.

0-1 0

AuxInContact Function of the AuxIn Contact: 0 = Disabled 1 = PoLF (Wire to HFV) 2 = PoC2 (Wire to SSV2) 3 = PoP (Wire to Pilot Valve)

In List 0

12

TankLevelInputMode Tank Level Input Mode: 0 = Disabled 1 = Dry Contact 2 = 4-20mA Input

In List 0

420TankLevelMax The 4-20mA Tank Level Maximum value which is the value that is associated with a 20mA loop current.

0-65535L 120L

420TankLevelMin The 4-20mA Tank Level Minimum value which is the value that is associated with a 4mA loop current.

0-65535L 0L

FuelPressureInputMode Fuel Pressure Input Mode: 0 = Disabled 1 = Dry Contact 2 = 4-20mA Input

In List 0

420FuelPressureMax 4-20mA Fuel Pressure Max 0-65535 kPa 30 kPa

Settings: Ignition


CoilDriveMode Coil Drive Mode: 0 = Default Spark Pattern

In List 0

FlameDetectionGain Flame Detection Gain 1-7 3

Settings: Timing


PurgeTime Purge Time 10-900 s 30 s

PilotToMainDelay Pilot to Main delay 5-600 s 15 s

LowToHighFireDelay Low fire to High fire delay 30-600 s 30 s

Settings: Temp Module Field Calibration


ProcTemp1SpanCal Span Calibration Factor for TC1A

-32768 to 32767 1

ProcTemp1ZeroCal Zero Calibration Factor for TC1A

-32768 to 32767 0

ProcTemp2SpanCal Span Calibration Factor for TC1A_Check -32768 to 32767 1

ProcTemp2ZeroCal Zero Calibration Factor for TC1A_Check

-32768 to 32767 0

ProcTemp3SpanCal Span Calibration Factor for TC1B

-32768 to 32767 1

ProcTemp3ZeroCal Zero Calibration Factor for TC1B

-32768 to 32767 0

AuxTemp1SpanCal Span Calibration Factor for TC2A

-32768 to 32767 1

AuxTemp1ZeroCal Zero Calibration Factor for TC2A

-32768 to 32767 0

AuxTemp2SpanCal Span Calibration Factor for TC2A_Check

-32768 to 32767 1

13

AuxTemp2ZeroCal Zero Calibration Factor for TC2A_Check

-32768 to 32767 0

AuxTemp3SpanCal Span Calibration Factor for TC2B

-32768 to 32767 1

AuxTemp3ZeroCal Zero Calibration Factor for TC2B

-32768 to 32767 0

Settings: Ignition Module Field Calibration


FlameTemp1SpanCal Span Calibration Factor for TCA

-32768 to 32767 1

FlameTemp1ZeroCal Zero Calibration Factor for TCA

-32768 to 32767 0

FlameTemp2SpanCal Span Calibration Factor for TCA_Check -32768 to 32767 1

FlameTemp2ZeroCal Zero Calibration Factor for TCA_Check

-32768 to 32767 0

FlameTemp3SpanCal Span Calibration Factor for TCB

-32768 to 32767 1

FlameTemp3ZeroCal Zero Calibration Factor for TCB

-32768 to 32767 0

Settings: Controller Configuration


DeviceConfig[0]

DeviceConfig[30]

MAC_Address[n] The Ethernet MAC Address 0x000000000000 to 0xFFFFFFFFFFFF

0

ModelNumber[n] The model number: 3100, 3101, 3102, etc.

3100-3199 0

Role[n] 0 = No Assigned Role 1 = Default Role 2-255=Secondary Function (not implemented)

In List 0

Settings: Appliance Configuration


ControllerConfig[0] Configuration info for the first expected controller within this appliance

ControllerConfig[11] Configuration info for the last expected controller within this appliance

MAC_Address[n] The Ethernet MAC Address 0x000000000000 to 0xFFFFFFFFFFFF

0

ModelNumber[n] The model number: 3100, 3101, 3102, etc.

3100-3199 0

14

Role[n] 0 = No Assigned Role 1 = Independent Temperature 2 = Primary Temperature Source 3 = Secondary Temperature Source 4 = Temperature Sink 5-255 = Not Implemented

In List 0

MinControllersRunning The minimum number of controllers that must be running in order for the appliance to keep running.

0-12 0

MaxAdjacentShutdown The maximum number of adjacent controllers that can shutdown before and the appliance keep running.

0-12 0

EndsAreAdjacent Treat the controller at the beginning of the list as being adjacent to the controller at the end of the list.

0-1 0

RunningDefinition This setting determines how the appliance decides if a given controller is running or not: 0 = Communicating 1 = Green State 2 = Blue or Green State

In List 1

ShutdownTimeout One or more rules must be broken continuously for this amount of time before the appliance will shutdown. The counter will only stop counting down if no rules are being violated. The counter will keep counting down if the particular rules being violated change during this time so long as one or more rules are always being violated.

1-600 10

15

OPERATION

STARTING THE SYSTEM

From any screen on the UI, press the Start Key on the keypad. If there are alarms present, you will be notified.

If no alarms are present, you will be prompted to confirm that you want to start. Press the OK key to confirm or the Back key to cancel.

If you are on the Status Tab, the system will show a count down of 5 seconds (or more if the purge cycle has not been completed). At the end of the countdown, the system will open the pilot valve, and ignite the pilot with the ignition coil. The flame quality should go to 100% on the screen. Then the system will begin its process control trying to maintain the process setpoint.

STOPPING THE SYSTEM

From any screen on the UI, press the Stop Key on the keypad.

You will be prompted to confirm that you want to stop. Press the OK key to confirm or the Back key to cancel.

Note that the Stop function on the UI is not safety rated! It is provided as a convenience. This function may be unavailable if the UI is offline, disconnected from the network, or otherwise incapacitated. If a safety rated stop button is required, connect an appropriately rated mushroom switch to the ESD contact on the BMS controller.

16

TROUBLESHOOTING

ETHERNET COMMUNICATIONS

BLUE POWER LEDS NEXT TO THE ETHERNET PORTS OF THE MODULES ARE OFF1. Verify that the Ethernet cable is plugged in on both ends.2. Check that the port supplying power has a Blue LED illuminated indicating that it is

currently supplying power. 3. Check that the Ethernet cable is wired correctly to the T568B standard. (use a standard

Ethernet cable tester)4. Verify that the Ethernet cable is not cut or otherwise damaged.5. Check all user replaceable fuses on the module.

GREEN LINK LEDS NEXT TO THE ETHERNET PORTS OF THE MODULES ARE OFF1. Verify that the Ethernet cable is plugged in on both ends.2. Check that the Ethernet cable is wired correctly to the T568B standard. (use a standard

Ethernet cable tester)3. Verify that the Ethernet cable is not cut or otherwise damaged.4. Ensure that all Ethernet switches in the system are wired correctly and receiving power5. Ensure that there are no more than 4 cascaded Ethernet switches between any two

modules in the system

FLAME DETECTION

SYSTEM HAS VISIBLE FLAME BUT CANNOT DETECT IT1. The flame rod, pilot assembly and the gap between them should be fully engulfed in

flame. If not, adjust the rod positioning.2. Check that the flame detection wiring does not exceed the recommended maximum

length.3. Check that the Ion+ wire is securely connected as per the appropriate wiring diagram.4. Check that the ground connection between the PF3100 and the pilot assembly is

present and secure.5. Put the PF3100 into Manual Mode and use the Review Menu to check the flame quality

level.6. The PF3102-00C Ignition Module is designed to be mounted in the burner housing to

minimize the length of flame ionization wire required. Generally speaking, the shorter the wire, the less problems you will experience.

7. Ensure that the ground wire from the pilot nozzle is connected to the ground terminal on the ignition module.

8. If you need to use a long length of ignition wire, try increasing the flame detection gain setting under the “Ignition” settings on the UI

17

SYSTEM ERRORS

The UI screen will display any shutdown messages, alarm codes, or warning messages that the system is currently experiencing. For each of these entries, an explanation will accompany the system error.

Shutdown messages

These indicate the reason that the system last shutdown. In the event of a safety shutdown (ESD), the system will shutdown in 1 second or less. The flame failure response time (FFRT) spans 2 seconds, after which the system will initiate shutdown.

Alarm codes

These indicate a persistent problem that must be cleared before the system can be restarted.

Warning messages

These indicate a problem that may be developing or a condition from which the system may automatically restart once cleared.

RESETTING TO DEFAULTS

The system settings can all be reset to factory defaults by following these instructions:1. Make sure that the system is stopped.2. Navigate to the “Reset to Factory Defaults” menu item.3. Use the Arrow Keys to change the setting to “Yes” and then press the OK Key. The

system will display “Parameter Saved” and will reboot. 4. 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.

This process only resets the user settings back to factory defaults and does not affect the calibration settings.

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Documents

PF3100 MANUAL - Profire Energy14. If the Safety Shutoff Valves (SSV) are required in your application, wire one valve to the SSV1 +/- terminals and the other valve to the SSV2 +/-