PF2200-SB

PRODUCT MANUAL

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PROPRIETARY INFORMATION: THIS DOCUMENT IS PREPARED BY PROFIRE ENERGY FOR THE USE OF OUR CUSTOMER. PROFIRE ENERGY ASSUMES NO LIABILITY TO
ANY OTHER PARTY FOR ANY REPRESENTATIONS CONTAINED HEREIN.

TABLE of CONTENTS
1 INTRODUCTION .......................................................................................................................................................... 4

1.1 SCOPE AND PURPOSE ............................................................................................................................................................................ 4

1.2 TERMS AND ABBREVIATIONS .............................................................................................................................................................. 5
1.3 ACRONYMS ............................................................................................................................................................................................. 7
1.4 PRODUCT SUPPORT.............................................................................................................................................................................. 8
1.5 RELATED LITERATURE........................................................................................................................................................................... 8
1.6 REFERENCE STANDARDS .................................................................................................................................................................... 8

2 PF2200-SB PRODUCT DESCRIPTION ......................................................................................................................... 9

2.1 PRODUCT OVERVIEW ........................................................................................................................................................................... 9

2.1.1 USER INTERFACE CARD ................................................................................................................................................................10
2.1.2 BMS CARD .........................................................................................................................................................................................11
2.1.3 KEYPAD ..............................................................................................................................................................................................25
2.1.4 ENCLOSURE ......................................................................................................................................................................................26
2.2 OPERATING SEQUENCE .....................................................................................................................................................................28
2.2.1 POWER ON .......................................................................................................................................................................................29
2.2.2 LOCKOUT ..........................................................................................................................................................................................29
2.2.3 READY .................................................................................................................................................................................................30
2.2.4 ALARM ................................................................................................................................................................................................30
2.2.5 WAITING ............................................................................................................................................................................................31
2.2.6 IGNITION ...........................................................................................................................................................................................31
2.2.7 PILOT...................................................................................................................................................................................................32
2.2.8 MAIN LIGHT OFF .............................................................................................................................................................................33
2.2.9 PROCESS CONTROL .......................................................................................................................................................................34
2.3 GENERAL REQURIEMENTS ................................................................................................................................................................37
2.3.1 PF2200 DECLARATIONS ................................................................................................................................................................37
2.4 CERTIFICATION AND APPROVALS ...................................................................................................................................................38

3 INSTALLATION AND COMMISSIONING ................................................................................................................. 39

3.1 SYSTEM CONFIGURATION................................................................................................................................................................39

3.1.1 PASSWORDS .....................................................................................................................................................................................39
3.1.2 INTERFACING ...................................................................................................................................................................................40
3.1.3 ELECTRICAL and MECHANICAL RATINGS................................................................................................................................43
3.2 IMPORTANT SAFETY INFORMATION ............................................................................................................................................47
3.2.1 GENERAL WARNINGS ....................................................................................................................................................................47
3.2.2 EXPLOSION HAZARD WARNINGS .............................................................................................................................................47
3.2.3 INSTALLATION WARNINGS .........................................................................................................................................................48
3.3 MOUNTING CONSIDERATIONS ......................................................................................................................................................49

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 3.3.1 ORIENTATION & LOCATION .......................................................................................................................................................49
3.3.2 MOUNTING CARDS ........................................................................................................................................................................50
3.3.3 PROTECTIVE EARTHING ................................................................................................................................................................51
3.3.4 ELECTRICAL NOISE .........................................................................................................................................................................51

4 OPERATIONS AND MAINTENANCE ........................................................................................................................ 52

4.1 ASSUMPTIONS SPECIFIC TO USE .....................................................................................................................................................52

4.2 TRANSPORTATION & STORAGE CONDITIONS ..........................................................................................................................52
4.3 OPERATOR USER INTERFACE ...........................................................................................................................................................53
4.3.1 STATUS SCREEN...............................................................................................................................................................................53
4.3.2 SETTINGS SCREEN...........................................................................................................................................................................53
4.3.3 SETTINGS DESCRIPTIONS .............................................................................................................................................................57
4.3.4 SYSTEM SCREEN ..............................................................................................................................................................................69

5 TROUBLESHOOTING ................................................................................................................................................. 76

6 MAINTENANCE ......................................................................................................................................................... 78

6.1 REPAIR AND REPLACEMENT ..............................................................................................................................................................79

6.2 DECOMMISSIONING ..........................................................................................................................................................................79
6.3 USEFUL LIFE ...........................................................................................................................................................................................79
6.4 MANUFACTURER NOTIFICATION...................................................................................................................................................79

7 DOCUMENT REVISION HISTORY ............................................................................................................................. 81

8 APPENDIX A: ALARM CODES & RESPONSE TIMES ................................................................................................ 83

9 APPENDIX B: FUNCTIONAL SAFETY DESIGN PF2200-SB ...................................................................................... 89

9.1 SAFETY VS NON-SAFETY I/O .............................................................................................................................................................91

9.2 SAFETY FUNCTIONS............................................................................................................................................................................92
9.3 SAFETY INTEGRITY ...............................................................................................................................................................................93
9.3.1 SYSTEMATIC CAPABILITY ..............................................................................................................................................................93
9.3.2 RANDOM CAPABILITY ...................................................................................................................................................................93
9.3.3 RATE of DEMAND ............................................................................................................................................................................93
9.3.4 HARDWARE VERSIONS..................................................................................................................................................................94
9.3.5 SOFTWARE VERSIONS ...................................................................................................................................................................94
9.3.6 SAFETY PARAMETERS .....................................................................................................................................................................94
9.3.7 SUGGESTED PROOF TEST .............................................................................................................................................................97
9.3.8 DIAGNOSTIC TEST INTERVAL ......................................................................................................................................................97

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1 INTRODUCTION
1.1 SCOPE and PURPOSE
This document is intended to be a full description and the intended use of the PF2200-SB product in
accordance with the product life cycle. This document outlines the following:

• PF2200-SB Product Description: this section describes the intended use of the product; including I/O,
operating sequence, general requirements and approvals
• Installation and Commissioning: this section describes the actions needed to perform installation and
commissioning of the PF2200-SB; including electrical/mechanical ratings, configuration parameters,
mounting considerations and warnings
• Operations and Maintenance: this section describes the actions needed for ongoing operation and
maintenance of the PF2200-SB; including troubleshooting, maintenance, repair and replacement,
decommissioning and manufacturer notification

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1.2 TERMS and ABBREVIATIONS
1oo1 One out of one deployment configuration.

Alarm An indication of an abnormal condition in either the equipment or the process.

Continuous Pilot A pilot which, once placed in operation, is intended to remain ignited continuously until it is manually
interrupted

Digital Input An input to the system that can be one of only two states (Energized or De-energized).

Electronic Non-cycling interruption by an electronic device of a circuit for functional disconnection which
Disconnection provides a disconnection other than by means of an air gap by satisfying certain electrical
requirements in at least one pole
Flame Detector Device which provides the programming unit with a signal indicating the presence of absence of flame

Flame Detector Period of time between loss of the sensed flame and the signal indicating the absence of flame
Response Time
Flame Detector Self- Frequency of self-checking function of the flame detector (in number of operations per unit of time)
Checking Rate

Flame Failure Lock-out Period of time between the signal indicating absence of flame and lock-out
Time

Full Rate Start Condition in which the main burner ignition and subsequent flame supervision occur at full fuel rate

Ignition Time Period of time during which the ignition device is energized

Incorporated Control Control intended for incorporation in, or on, an equipment, but which can be tested separately.

Intermittent Pilot A pilot which is automatically ignited when an appliance is called on to operate and which remains
continuously ignited during each period of main burner operation. The pilot is automatically
extinguished when each main burner operating cycle is completed
Interrupted Ignition A type of ignition which is energized prior to the admission of fuel to the main burner and which is
de-energized when the main flame is established

Interrupted Pilot A pilot which is automatically ignited prior to the admission of fuel to the main burner and which is
automatically extinguished when the main flame is established

Lockout A state in which all powered outputs (Valves and Ignition) are de-energized and interaction from the
user is required in order to exit the state.

Low Rate Start Condition in which main burner ignition occurs at low fuel rate. Once ignition at low fuel rate occurs
and the flame is proven, full main burner fuel rate may be admitted

Main Permissive An event which causes the BMS to de-energize the main solenoid outputs (SSV) and remain in that
state until the event clears (or an alarm / wait condition forces the BMS out)

Maximum Flame-failure Period of time between the signal indicating absence of flame and the signal to energize the ignition
Re-ignition Time device. During this time period the fuel supply is not shut off.

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 Non-volatile Lockout Condition such that a restart can only be accomplished by a manual reset of the system and by no
other cause

Permanent Operation System which is intended to remain in the running position for longer than 24 h without interruption

Pilot-flame Establishing Period of time between the signal to energize the pilot fuel flow means and the signal indicating
Period presence of the pilot flame

Post-Ignition Time Period of time between the signal indicating presence of flame and the signal to de-energize the
ignition device

Post-Purge Time Purge time that takes place immediately following the shutting off of the fuel supply

Pre-Ignition Time Period of the ignition time between the signal to ignite and the signal to energize the fuel flow means

Pre-Purge Time Purge time that takes place between initiation of a burner control sequence and the admission of fuel
to the burner

Recycle Time Period of time between the signal to de-energize the fuel flow means following the loss of flame and
the signal to begin a new start-up procedure

Safety Output A powered electrical output from the PF2200 BMS card designed to control safety actuators (e.g.
safety shut off valves, ignition coils, etc.). Safety Outputs of the PF2200 BMS card are as follows: Pilot
1, Pilot 2, SSV, High Fire, Coil 1, and Coil 2.

Safety-interlock A term used to describe an input (either switch or Transmitter) that must be satisfied to run. If the
interlock is not satisfied (e.g. open switch or out of range transmitter) the system will proceed to lock-
out.

Shutdown The process the system goes through when it receives an alarm event while running. This is
immediately followed by entering the state of Lockout.

Signal for Absence of Maximum signal which indicates the loss of flame
Flame

Signal for Presence of Minimum signal which indicates the presence of flame when there was previously no flame
Flame

Start-up Lock-out Time Period of time between the signal to energize the fuel flow means and lock-out

Type 2 Action Automatic action for which the manufacturing deviation and the drift of its operating value, operating
time, or operating sequence have been declared and tested under the IEC 60730 standard.

Wait An event which causes the BMS to proceed to a state which will de-energize all safety outputs. When
all wait events clear, the BMS is free to automatically recycle.

Waiting Time Period between the start signal and the signal to energize the ignition device. For burners without
fans, natural ventilation of the combustion chamber and the flue passages normally takes place during
this time.

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1.3 ACRONYMS
BMS Burner Management System

ESD Emergency Shut Down – a mechanism that shuts down the system in the event of a
safety emergency

FIT Failure In Time (unit) – represents the number of failures occurring in 10 9 hours

FMEDA Failure Mode, Effects and Diagnostic Analysis

HFT Hardware Fault Tolerance

HFV High Fire Valve

I/O Generic name for a terminal that can be an input, output, or a combination or both.

PFDAVG Average Probability of Failure on Demand

PF2200-SB Model number for the PF2200 Single Burner BMS product. Consists of: BMS Card,
User Interface Card, keypad, enclosure and ignition switch

PFN Profire Network. Method of communication between User Interface Card and BMS
Card.

PTC Proof Test Coverage

PWM Pulse Width Modulation

RTD Resistive Thermal Device

SIL Safety Integrity Level. A discrete level (one out of a possible four) for specifying the
safety integrity requirements of the safety functions to be allocated to the E/E/PE
safety-related systems where Safety Integrity Level 4 has the highest level of safety
integrity and Safety Integrity Level 1 has the lowest

SIF Safety Instrumented Function. A set of equipment intended to reduce the risk
due to a specific hazard (a safety loop)

SFF Safe Failure Fraction. The fraction of the overall failure rate of a device that results
in either a safe fault or a diagnosed unsafe fault

SSV Safety shutoff valve. A valve that shuts off for safety reasons.

TCV Temperature Control Valve

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1.4 PRODUCT SUPPORT
Product support can be obtained from:

Profire Energy
1.855.776.3473
321 South, 1250 West Suite 1
Lindon, UT 84042, USA
support@profireenergy.com

1.5 RELATED LITERATURE

PF2200 Single Burner BMS – Modbus Registers

PF2200 Single Burner BMS – Software Release Notes

1.6 REFERENCE STANDARDS

IEC 61508:2010 Functional Safety of Electrical / Electronic / Programmable Electronic Safety-Related Systems

CSA 22.2 No. 60730-2-5 / ANSI Z21.20:14

UL 60730-2-5

CSA 22.2 No. 213-17

UL 121201. ED9

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2 PF2200-SB PRODUCT DESCRIPTION

2.1 PRODUCT OVERVIEW

The PF2200 Single Burner Controller (PF2200-SB) product is designed to provide safe and reliable control
over industrial heating appliances. This product consists of four main pieces:

• User Interface Card: the card which provides interaction to the user / operator. This card monitors
user input and displays all relevant status / setting information to the user.
• BMS Card: the “safety brain” of the product. This card stores all the relevant safety information and
performs the operating sequence in accordance with the timings in the safety settings.
• Keypad: allows the user / operator to interact with the product through a series of buttons.
• Enclosure: provides protection for the product against environmental conditions.

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2.1.1 USER INTERFACE CARD
The User Interface Card allows interaction with the system through the use of the keypad and a display. This
card interacts with the BMS card through a proprietary communication protocol, called PFN, which utilizes
the RS-485 physical transport layer. PFN and power to the User Interface are factory wired to the BMS card
through a wiring harness.

2.1.1.1 MODBUS
Remote access to status information and non-safety critical settings can be achieved via the Modbus port of
the User Interface card. The Modbus port supports Modbus RTU over the RS-485 physical layer. For a
complete register list, see PF2200 Single Burner BMS – Modbus Registers. By design, safety critical settings
are not accessible via Modbus.

2.1.1.2 USB
The USB port of the User Interface Card is used for data-logging, settings backup and restore and updating
firmware. Data-logging is enabled by going to the Firmware Update screen on the User Interface and is
limited by the size of USB stick-- a USB stick of size 1GB or larger is recommended. Firmware update is only
supported using authorized firmware bundles. Contact Profire Energy for an authorized firmware bundle.

2.1.1.3 STATUS LED

The User Interface Card has a tricolor Status LED which is visible on the front panel of the product. The states
of the Status LED are defined below:

State LED Behavior

System is not running and is in lockout Fast Blink Red
System is not running and has an alarm Blink Red
System is not running Solid Red
System is running – no warnings or waits present Solid Green
System is running – in wait state Blink Green
System is running – in wait state with a warning Blink Amber
present
System is running – with a warning present Solid Amber

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

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2.1.2.1 PILOT VALVE OUTPUTS (Pilot 1 and Pilot 2)
Two powered outputs (terminals 15-16 and 17-18) are intended to be connected to solenoid valves which
control the fuel line for the pilot. When Pilot 2 is enabled, both outputs work in conjunction with one another
meaning that they energize and de-energize in unison. If Pilot 2 is disabled, the Pilot 2 output will stay de-
energized. The Pilot Outputs are capable of PWM output mode at a fixed 3 kHz frequency. Supported duty
cycles for PWM mode are 10-100% and are configurable via the user interface.

2.1.2.2 MAIN VALVE OUTPUTS (SSV)

Two powered outputs (terminals 19-20 and 21-22) are intended to be connected to solenoid valves which
control the main fuel line for the burner. Both outputs work in conjunction with one another meaning that
they energize and de-energize in unison. The Main Valve Outputs are capable of PWM output mode at a
fixed 3 kHz frequency. Supported duty cycles for PWM mode are 10-100% and are configurable via the user
interface.

2.1.2.3 IGNITION OUTPUTS (Coil +/-)

Two powered outputs (terminals 55-56 and 59-60) are intended to be connected to an ignition source (e.g.
ignition transformer). When Pilot 2 is enabled, both outputs work in conjunction with one another meaning
they energize and de-energize in unison. If Pilot 2 is disabled, the Pilot 2 Coil output will stay de-energized.
Two ignition modes are supported by the system and configurable via the user interface: Coil Mode and High
Energy Ignition (HEI) mode. Coil mode sends a pulsed signal of fixed frequency and duty cycle and is
intended to be used in conjunction with an ignition transformer. In HEI mode, the output is energized with a
steady state DC voltage that can be used to enable an external High Energy Ignition source.

2.1.2.4 FLAME DETECTION I/O (Ion +/-)

Two Ionization flame detection I/O (terminals 53-54 and 57-58) are supported by the PF2200-SB. These
terminals are intended to be connected to a flame rod which makes physical contact with the flame.

Through the use of the rectification property of the flame, the PF2200-SB measures the presence of flame by
applying an AC signal to the rod. If an open circuit event exists, the result will be a loss of flame.

Pilot 1 flame detection is always enabled, whereas Pilot 2 flame detection can be enabled or disabled via the
user interface. If Pilot 2 flame detection is enabled, both Pilot 1 and Pilot 2 flames must be established and
present in order for the system to continue to run.

2.1.2.5 HIGH FIRE VALVE (HFV) OUTPUT

One powered output (terminals 23 and 24) is intended to be connected to a solenoid valve when a staged
heating appliance is needed. In this application, the high fire valve output is intended to be the highest level

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of heat demand (Stage 2). If a lower level of heat demand is needed, the high fire valve will be de-energized
while the Main Valve Outputs (SSV) remain energized (Stage 1).

2.1.2.6 START/STOP SWITCH

The external Start/Stop switch can be used to start, stop or clear a lockout on the system. The various
positions / actions are outlined in the table below:

Switch State Behavior Switch State Mode

Stop Hold the system in lockout ESD or Shutdown
Run Transition to a ready state or maintain a running Ready
state.
Ignite If held for 1 second or more, transition into the System Start
Confirm Start state.
Run -> Stop -> Run Acknowledge and clear lockout condition N/A
Note: if switch is held in the Ignite state for longer than 5 seconds, the system will alarm.

2.1.2.7 EMERGENCY SHUTDOWN (ESD) INPUT

The ESD input (terminals 33-34) is an energized-to-run digital input that is always enabled. If the contact is
de-energized, the system will present an alarm and proceed to lockout (if running). If the contact is
energized, the alarm will clear.

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2.1.2.8 PRESSURE INPUT
The Pressure input (terminals 5-6) is meant to monitor an external pressure (e.g. fuel pressure) and provide
the necessary feedback in the event of a high and/or low pressure event. Configurable as disabled, digital
input or 4-20mA signal through the user interface; the pressure input can be connected to either a switch or
transmitter.

In digital input mode, the input can be configured as either an Alarm, Wait, Warning or Main Permissive when
the contact opens. This is intended to be connected to a low pressure switch.

In 4-20mA mode, a high pressure trip event will cause an alarm and a low pressure trip event can be
configured as an Alarm, Wait, Warning or Main Permissive; if the event persists after the mains have opened.
This mode is intended for use with a pressure transmitter.

The following table outlines the behavior of the Pressure Input:

Input Event System Behavior

Configuration
Disabled Any No Effect
De-energized with low pressure mode set to Wait Wait
De-energized with low pressure mode set to Alarm Alarm
De-energized with low pressure mode set to Main Main Permissive
Digital Input
Permissive
De-energized with low pressure mode set to Warning Warning
Energized Run
Out of range Alarm
Low trip with low pressure mode set to Alarm Alarm
Low trip with low pressure mode set to Wait Wait
Low trip with low pressure mode set to Main Permissive Main Permissive
4-20mA
Low trip with low pressure mode set to Warning Warning
Active range Run
High trip with mains ON Alarm
High trip with mains OFF Run

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2.1.2.9 LEVEL INPUT
The Level input (terminals 41-42) is meant to monitor an external level or flow measurement and provide the
necessary feedback in the event of a high and/or low level/flow event. Configurable as disabled, digital input
or 4-20mA signal through the user interface; the level input can be connected to either a switch or
transmitter.

In digital mode the level input can be used a Wait, Warning or Alarm when the contact opens. This can be
connected to a low or high trip switch depending on the application.

In 4-20mA mode the level input is used in conjunction with the low-trip and high-trip modes. These modes
are independent of one another and can be configured as a Wait, Warning or Alarm. This input is intended
to be connected to a level or flow transmitter.

The following table outlines the behavior of the Level Input:

Input Event System Behavior

Configuration
Disabled Any No Effect
De-energized with digital mode set to wait Wait
De-energized with digital mode set to warning Warning
Digital Input
De-energized with digital mode set to alarm Alarm
Energized Run
Out of range Alarm
Low trip with low trip mode set to wait Wait
Low trip with low trip mode set to warning Warning
Low trip with low trip mode set to alarm Alarm
4-20mA
Active range Run
High trip with high trip mode set to wait Wait
High trip with high trip mode set to warning Warning
High trip with high trip mode set to alarm Alarm

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2.1.2.10 TEMPERATURE INPUTS
The PF2200-SB has three distinct temperature inputs: Bath, Outlet and Stack; each of which are configurable
to be either a Type-K thermocouple or PT-100 RTD input.

Each of the three distinct temperature inputs mentioned above have the following set points that can be
configured via the user interface (note: depending on the mode, the temperature input may or may not
utilize all the set points below; see Temperature Mode for more details):

• High Temperature ESD Setpoint: temperature at which the system shuts down. If the temperature
input exceeds this trip point, the system will generate an alarm and if running proceed to lockout
• Pilot Off Setpoint: temperature at which the system de-energizes all valves, including the pilot, and
enters a waiting state. When the temperature falls back down below this value minus the deadband,
the system will reignite the pilot.
• Main Off Setpoint: temperature at which the system de-energizes the main valves and enters the
Pilot state. The main valves will be turned back on when the temperature drops below the Process
Control Setpoint minus the deadband.
• Process Control Setpoint: The setpoint about which the process temperature will be controlled. In
PID mode, the TCV will be actuated in relation to this setpoint. In Staged Heating mode, the HFV will
be actuated about this setpoint.
• Low Temperature Warning Setpoint: If the temperature drops below this trip point the system will
display a warning on the user interface and will continue to run.
The three temperature inputs listed above also have a user-configurable mode. The various temperature
modes are defined below:

• Disabled: Temperature input is ignored.

• High Temp ESD: Temperature input is monitored for High Temp ESD event only. Setpoints used in
this mode: High Temperature ESD and Low Temperature Warning
• Process Control Mode: Temperature input is monitored for High Temp ESD event as well as used for
process control. Setpoints used in this mode: High Temperature ESD, Pilot Off, Main Off, Process
Control and Low Temperature Warning Setpoint.
• Display Only: Temperature inputs are read in and displayed on the User Interface. The system does
NOT act on this information in any way. Setpoints used in this mode: none.

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 Input Terminals Type Modes Supported
Dual Element with cross comparison High Temp ESD
Bath 61-66
Single Element Process Control
Disabled
High Temp ESD
Outlet 67-69 Single Element
Process Control
Display Only
Disabled
Stack 70-72 Single Element High Temp ESD
Display Only

2.1.2.11 PROOF of CLOSURE (PoC) INPUT

The Proof of Closure input (terminals 11-12) is a digital input meant to be connected to a Proof of Closure
switch, indicating the closure of the main valve(s). An energized Proof of Closure input indicates that the
main valve is closed. The PF2200-SB monitors the Proof of Closure input and takes action, as outlined in the
table below.

Input Event System Behavior

Configuration
Disabled Any No Effect
De-energized with main off Alarm
Digital Input De-energized with main on Run
Energized Run

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2.1.2.12 REMOTE START INPUT
The Remote Start input (terminals 35-36) is a digital input intended to provide the ability to start the system
from an external source (e.g. a switch or PLC). The remote start input is an energized-to-run input, meaning
that if the contact is de-energized the system will proceed to a WAIT state. A toggle of the start input from
the energized to de-energized to energized position causes the system to either clear a lockout (if one is
present) or start the system (if there are no alarms). This means that if a lockout is present and the operator
wishes to start the system, two toggles of the start contact is necessary (one to clear the lockout, and the
other to start the system). This functionality is outlined in the table below.

Input Event System Behavior

Configuration
Disabled Any No Effect
De-energized and system is in a running state Wait
De-energized and system is not running No Effect
Acknowledge lockout if
Digital Input
Transition from energized to de-energize to energized present, start if no alarm
present
Energized Run

2.1.2.13 HIGH PRESSURE INPUT

The High Pressure input (terminals 7-8) is a digital input intended to be connected to a high pressure switch.
This contact is energized to run, meaning that a de-energized contact indicates a high pressure event. The
high pressure functionality is outlined in the table below.

Input Event System Behavior

Configuration
Disabled Any No Effect
De-energized Alarm
Enabled
Energized Run

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2.1.2.14 PROOF of MAIN LIGHT OFF (POL) INPUT
The Proof of Main Light Off input (terminals 9-10) is intended to be used in conjunction with either a TCV
capable of position feedback or a High Fire valve with light-off position indication. Capable of both 4-20mA
and Digital modes, the Proof of Main Light Off input gives the system the ability to prove a light off position
before opening the main gas valves.

In digital mode this input is intended to connect to a proof of closure switch on the HFV OR with a proof of
position switch on a TCV. In 4-20mA mode this input is intended to connect to a TCV that has positional
feedback. When in 4-20mA mode, the system will monitor the position input and cross-check with the user-
defined setpoint & tolerance fields. In either mode the input is monitored only during the transition from
pilot to main in the request light off sequence. If the contact is not proven within 60 seconds the system will
lockout.

Mechanically, the light off position proving requires a proof of closure valve for the HFV if the system is
utilizing staged heating control or in PID control mode a position switch / 4-20mA position feedback signal
from the TCV.

The following table outlines the functionality of the input.

Input Event System Behavior

Configuration
Disabled Any No Effect
De-energized during pilot to main transition (60s Alarm
elapsed)
Digital Input
Energized during pilot to main transition System transitions to main
De-energized or Energized in all other states No Effect
Out of range Alarm
Low trip or High Trip during pilot to main transition (60s Alarm
elapsed)
4-20mA Input
Low trip, Active Range, or High Trip during all other No Effect
states
Active range during pilot to main transition System transitions to main

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2.1.2.15 AUXILIARY TEMPERATURE INPUT
The Auxiliary Temperature Input (terminals 43-44) is intended to be connected to a temperature sensor with
a 4-20mA interface. This 4-20mA input can be mapped to a temperature using the span settings (Max and
Min) and can be configured as: Disabled, High Temp ESD, Process Control, or Display Only. For details on the
individual modes and setpoints, see the Temperature Inputs section of this document.

2.1.2.16 AUXILIARY INPUT

The Auxiliary Inputs 1 and 2 (terminals 45-46 and terminals 47-48 respectively) are intended to be connected
to a generic I/O device that does not fit into any of the above categories of inputs. Configurable as either a
digital or 4-20mA input, this input is intended to be connected to either a switch/PLC output (digital) or
transmitter (4-20mA).

The following table outlines the modes/behavior of the Auxiliary Input:

Input Event System Behavior

Configuration
Disabled Any No Effect
De-energized (input mode set to Alarm) Alarm
De-energized (input mode set to Wait) Wait
Digital Input De-energized (input mode set to Warning) Warning
De-energized (input mode set to Main Permissive) Main Permissive
Energized Run
Out of range Alarm
Low/High Trip (input mode set to Alarm) Alarm
Low/High Trip (input mode set to Wait) Wait
4-20mA
Low/High Trip (input mode set to Warning) Warning
Low/High Trip (input mode set to Main Permissive) Main Permissive
Active range Run

Appliance Firing Rate

In addition to the features mentioned above, both auxiliary inputs have the ability to map to the appliance
firing rate. This input maps directly to the TCV output position (e.g. 4mA = 0%, 20mA = 100%). This is,
however, gated by the TCV minimum opening position. The TCV output position can only be set by the
appliance firing rate input during any process control state, in any other state the rules outlined in the TCV
section of this document.

When this mode is enabled, the process setpoint is ignored by the system and the TCV is actuated based on
the 4-20mA input.

If this input goes invalid or out of range the appliance firing rate will be set to 0% and an alarm will be set to
shut the system down.

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Note that either Auxiliary Input 1 or 2 can be configured as an Appliance Firing Rate Input, but not both.

Process Setpoint Adjustment Input

In addition to the features mentioned above, both auxiliary inputs also support a Process Setpoint
Adjustment mode. The Process Setpoint Adjust mode is intended to be connected to a 4-20mA signal
sourced by a PLC which allows the application to provide advanced temperature control (e.g. cascaded PID).
By utilizing the span setting (max and min) for the setpoint, this system allows the process setpoint to be
adjusted based on the input signal. Note: the system still adheres to the safety constraints of the system
regarding setpoints (i.e. setpoint cannot exceed the high temp ESD setpoint). The following table outlines
the behavior of the system with respect to the Process Setpoint Adjustment input:

Input Event System Behavior

Configuration
Disabled Any No Effect
Out of range Alarm
Active range, system not in process No Effect
4-20mA control
Run with process setpoint set by Process
Active range, system in process control
Setpoint Adjustment Input

Note that either Auxiliary Input 1 or 2 can be configured as a Process Setpoint Adjust Input, but not both.

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2.1.2.17 TEMPERATURE CONTROL VALVE (TCV) OUTPUT
The Temperature Control Valve output (terminals 13-14) is a 4-20mA output that is intended to connect to a
proportional fuel gas valve on the main fuel train. The TCV output behavior corresponds to the state of the
system, as outlined by the table below:

System State TCV Position Behavior

Ready, Waiting,
Alarm, Lockout, Purge Position Holding
Power On
Ignition Pilot Position Holding
Main Light off TCV Minimum Position Holding
Transition from
TCV Minimum Position -> Requested Process Ramping according to ramp
Main Light Off to
Control Position time setting
Process Control
Process Control
Requested Process Control Position Actively controlled by PID
(PID)
Process Control
Output railed to maximum
(Staged Heating, 100%
value.
ON/OFF)

Where:

• Purge Position: User configurable setting from 0-100% corresponding to valve opening percentage
(0% = 4mA, 100% = 20mA) – position held while the system is not running
• Pilot Position: User configurable setting from 0-100% corresponding to valve opening percentage (0%
= 4mA, 100% = 20mA) – position held during the Ignition and Pilot states
• TCV Minimum Position: User configurable setting from 0-100% corresponding to valve opening
percentage (0% = 4mA, 100% = 20mA) – the minimum position the valve can be told to go by the
Process Control state
• Process Control Position: position of the TCV during process control. Either controlled by PID (if
enabled), or set to 100% in Staged Heating or On/Off control.
The TCV output also supports a manual override mode, where the output percentage is modifiable via the
user interface. When in manual override mode, the TCV output percentage is mapped to the manual output
position regardless of the system state.

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2.1.2.18 AUXILIARY OUTPUTS
The Auxiliary Outputs 1 and 2 (terminals 37-38 and 39-40 respectively) are configurable 4-20mA output
signals. Configuration modes and corresponding behavior are shown below:

Mode Behavior
Disabled N/A
The output will follow the selected temperature input of the system. The output range
Temperature will be between 4-20mA spanned between user configurable Min and Max temperature
Echo values. If the temperature is not valid (loss of temperature input or a temperature fault)
the output will send out a 0mA signal.
Level Echo The output will follow the level input measurement of the system. The output range will
be between 4-20 mA spanned from the user configurable level span Min to the level
span Max value. If the level input is not valid or it is not enabled (loss of input signal or
an input fault) the output will send out a 0mA signal.
Aux 1 Input The output will follow the Aux 1 Input. The output range will be between 4-20 mA
Echo spanned from the user configurable Aux 1 span Min to the Aux 1 span Max value. If the
aux input is not valid or it is not enabled (loss of input signal or an input fault) the
output will send out a 0mA signal.
Aux 2 Input The output will follow the Aux 2 Input. The output range will be between 4-20 mA
Echo spanned from the user configurable Aux 2 span Min to the Aux 2 span Max value. If the
aux input is not valid or it is not enabled (loss of input signal or an input fault) the
output will send out a 0mA signal.
Modbus Echo For Aux Out 1: The output will follow the Modbus register “Modbus Remote Echo for
Aux 1”.
For Aux Out 2: The output will follow the Modbus register “Modbus Remote Echo for
Aux 2”.
If the modbus is not configured the output will send out a 0 mA signal.

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2.1.2.19 STATUS RELAY OUTPUT
The Status Relay Output (terminals 25-27) is a normally open contact designed as an isolated output that has
a configurable mode of operation. The modes of operation are outlined below:

Configuration Behavior
- De-energized when in Power On, Lockout, Ready, and Alarm states
Run Status
- Energized when in Waiting, Ignition, Pilot, Main Light Off and Process Control states
- De-energized when in Power On, Lockout, Ready, Alarm, and Waiting states
Heating Status
- Energized when in Ignition, Pilot, Main Light Off and Process Control states
- De-energized when in Power On, Lockout, Ready, Alarm states OR Process
Low temp temperature is below low temp warning setpoint
Warning Status - Energized when in Ignition, Pilot, Main Light Off, Process Control states AND Process
temperature is above low temp warning setpoint
- De-energized when tank level is above high level setpoint
Level Control
- Energized when tank level is below high level setpoint minus dead band

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2.1.3 KEYPAD
The keypad is the primary method for the operator to interface with the PF2200 system. It allows for screen
navigation, start/stop control and the adjustment of settings.

The following outlines button functionality:

Button Behavior
When pressed the user interface will prompt for confirmation of system
shutdown. A second user action is required to shut the system down by
confirming the stop with either:
• A second press of the STOP button, or
• A press of the OK button
This confirmation window will timeout after 10 seconds of inactivity.
When pressed the user interface will prompt to confirm the start request. A
second user action is required to start the system by confirming the start
with the press of the OK button. This confirmation window will timeout after
10 seconds of inactivity. Once a start sequence is sent the system will start
only if safe to do so (e.g. no Alarms or Waits present).
Context sensitive return button which will:
- Escape the current dialog
- Go back to the previous screen
- Escape from setting configuration menus

User interface navigation.

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 Alternates between the Status screen, Settings screen, and System screen.

This button toggles display modes from Operator mode to Commissioner

mode. Commissioner mode enables access to all settings for
commissioning and Operator mode is intended as a mode to access key
operational settings that can be adjusted after the appliance has been
commissioned.

Toggles the status screen zoom level while on the status screen.
Increments/decrements a setting or cycle through items in configuration
lists when on the settings screen.

This button provides a help menu for keypad actions.

Safety Note: The keypad is intended to aid in commissioning and observe system status. As such, the
keypad is not considered part of nor should be incorporated into ANY safety function. If user shut-
down is a required safety function, then the user input must be hard-wired into the ESD input of the
BMS card.

2.1.4 ENCLOSURE
There are two options of enclosure-types for the PF2200-SB product:

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 • PF2200-SB-A: Stainless Steel Enclosure
• PF2200-SB-B: Polyester Enclosure (Coming Soon)
Both enclosure styles cannot be opened without the use of a tool (screwdriver).

2.1.4.1 PF2200-SB-A Stainless Steel Enclosure

Enclosure Construction 304 Stainless Steel

Ingress Protection / NEMA IP 66, Type 4X
Temperature Rating -40 to +55⁰C
Dimensions 13.17 x 11.00 x 5.70 “

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2.2 OPERATING SEQUENCE
Auto Restart Enabled
Previous Lo ckout on B oot AND No Alarms Present
Power On

Alarm
Condition
User Set
Acknowlege
Lockout Ready Alarm
Alarm
Alarm, Condition
Start
Flame Fail, or Clear
User Stop

Any Process
Wait Waiting
Control State Condition Set
OR All Wait
Automatic Conditions
Recycle Clear

Ignition
Flame
Established

Mains too hot

Pilot

Main Light Off

Process Control

Where:

• IGNITION: consists of first energizing the ignition coils, then followed by turning on the pilot
solenoid(s)
• Automatic Recycle is only permitted once the system has proven the main burner flame. Upon
flame loss, the system can attempt to relight the flame. If the maximum number of relight
attempts (default set to 3) is exceeded the system will shut down on Flame Fail
• Flame Loss event results in detecting an absence of flame that exceeds the Flame Failure Lock-out
Time

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2.2.1 POWER ON
Power On is the default state of the system when power is applied. In this state, the system will check if a
previous lockout condition was set and, if so, will force the system into a lockout state.

If the system previously shut-down due to a power loss and the Low Voltage Restart setting is enabled, the
system will purge and then proceed to system startup.

If there are no lockouts or alarms and the system is not automatically restarting then the system will
transition into the Ready state.

In the Power On state, the status of each powered outputs is as follows:

Powered Output Status

Pilot 1 / 2 De-energized
Coil 1 / 2 De-energized
SSV De-energized
HFV De-energized

2.2.2 LOCKOUT
The system transitions to Lockout state when an alarm event occurs while running. The system will stay in
the Lockout state until the lockout has been acknowledged. There are four ways to acknowledge a lockout:

• User Interface
• Toggling of the Start input from De-energized to Energized
• Toggling of the Start/Stop Switch
• Modbus Interface
In the Lockout state, the status of each powered outputs is as follows:

Powered Output Status

Pilot 1 / 2 De-energized
Coil 1 / 2 De-energized
SSV De-energized
HFV De-energized

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2.2.3 READY
Ready is the system state where the system is not running and no alarms are present. If there are any alarms
present while in this state, the system will move to the Alarm state. In the Ready state, the system may
proceed to start by one of the following methods:

• User Interface start

• Toggling of the Start input from De-energized to Energized
• Holding the Start/Stop switch in the ignite position for more than 2 second
• Writing a start command to “Start Stop Register” Modbus register
In the Ready state, the status of each powered outputs is as follows:

Powered Output Status

Pilot 1 / 2 De-energized
Coil 1 / 2 De-energized
SSV De-energized
HFV De-energized

2.2.4 ALARM
Alarm is the state of the system where there is an active and persistent alarm present. Typically this is
indicative of a static problem (e.g. transmitter not connected, system voltage too low, etc.) and the system
can only exit this state when all alarms have cleared.

In the Alarm state, the status of each powered outputs is as follows:

Powered Output Status

Pilot 1 / 2 De-energized
Coil 1 / 2 De-energized
SSV De-energized
HFV De-energized

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2.2.5 WAITING
Waiting is considered a “running” state of the system, with all powered outputs de-energized. The system
will hold this state until all wait conditions have been cleared or shut down if an alarm is present. Once all
waits have been cleared the system will automatically trigger a startup sequence without any user interaction
– provided no alarms are present. Note: purging after a flame loss is considered a wait.

In the Waiting state, the status of each powered outputs is as follows:

Powered Output Status

Pilot 1 / 2 De-energized
Coil 1 / 2 De-energized
SSV De-energized
HFV De-energized

2.2.6 IGNITION
Ignition is the state where pilot flame is safely established by energizing the coil and pilot outputs while
monitoring flame presence on the ionization inputs. Actuating and monitoring of Pilot 2 can be enabled /
disabled via the user interface and should only be enabled if a multiple-pilot configuration is desired.

The sequence begins by energizing the coil output(s) and waits the Pre-Ignition Time. After the Pre-Ignition
Time, the system then energizes the pilot output(s) and monitors flame presence. This stage is referred to as
Ignition on the user interface. If a flame is not detected within the Pilot-Flame Establishing Period window,
the system will purge and enter the waiting state, while decrementing the Relights Remaining counter. If the
system tries to light 3 times and fails to establish a flame, it will proceed to Lockout (Flame-Fail). Note that a
successful establishment of flame effectively resets the Relights Remaining counter. If a flame is detected
within the Pilot-Flame Establishing Period window, the system will proceed to hold a pilot flame for a startup
delay time. This startup delay helps warmup the appliance and establish draft in the appliance. Once the
flame has been established and the startup delay time has elapsed, the system will move into the Pilot state.

If the Pilot 2 is enabled, the system requires both flames to be satisfied within the Pilot-Flame Establishing
Period in order to proceed.

If the Pilot 2 is disabled, the system only requires Pilot 1 flame to be satisfied within the Pilot-Flame
Establishing Period in order to proceed.

Any alarms or waits that occur during this state will force the system to go the Lockout state or Waiting state,
respectively.

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In this system state, the status of each powered outputs is as follows:

Powered Output Status

De-energized during Pre-Ignition
Pilot 1
Energized after Pre-Ignition
De-energized if disabled
Pilot 2
Same as Pilot 1 if enabled
Energized during and after pre-ignition
Coil 1
De-energized during startup delay
De-energized if disabled
Coil 2
Same as Coil 1 if enabled
SSV De-energized
HFV De-energized

2.2.7 PILOT
The Pilot state is a system state which represents a minimum amount of heating required to light off the main
burner. It is typically tied to the Pilot valve in the fuel gas train – meaning that the pilot valve(s) are on in this
state but the main valves are off. This state is executed in one of following situations:

• Once a flame is established during the Ignition state,

• If one of the configured temperatures exceeds the Main Off setpoint, or
• If a main permissive is configured and not satisfied
Once in the Pilot state, the system must verify all configured process temperatures are below their respective
process setpoints AND main permissive(s) (if configured) have been cleared in order to enter the Main Light
Off state.

Any alarms or waits that occur during this state will force the system to go to the Lockout State or Waiting
state, respectively.

In the Pilot state, the status of each powered outputs is as follows:

Powered Output Status

Pilot 1 Energized
De-energized if disabled
Pilot 2
Energized if enabled
Coil 1 /2
SSV De-Energized
HFV

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2.2.8 MAIN LIGHT OFF
Once the system has a proven flame and all conditions are satisfied, the system enters the Main Light Off
state. If the system entered the Main Light Off state from the Ignition state, the Main Light Off state is held
for a configurable amount of time (Main Startup Delay Time). This parameter is configurable during
commissioning and is intended to give the appliance time to establish draft and heat up before the mains are
turned on. If the system entered the Main Light Off state from a Process Control state, the Main Startup
Delay Time is set to a fixed 5 seconds – since draft has already been established and the appliance is already
warm.

In addition to the minimum time requirements, the Main Light Off state also has the option of proving the
light off position. When Proof of Main Light off position (POL) is enabled, the Main Light Off state will hold
until either the position has been proven or 60 seconds have elapsed. If the position cannot be proven in the
allotted time, the system will enter Lockout state. For more details on the Proof of Main Light Off input, see
section 2.1.

Any alarms or waits that occur during Main Light Off still will force the system to transition to Lockout state
or Waiting state, respectively.

In the Main Light Off state, the status of each powered outputs is as follows:

Powered Output Status

Pilot 1 Energized
De-energized if disabled
Pilot 2
Energized if enabled
Coil 1 /2
SSV De-Energized
HFV

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2.2.9 PROCESS CONTROL
Once the system has determined the mains can be turned on, it enters the Process Control state. In this
state, the system actively tries to maintain the process temperature setpoint via the actuation of valves in
various configurations. The three process control modes are:

1. On/Off Control
2. Staged Heating
3. PID Control
Any alarms or waits that occur during this state will force the system to transition to the Lockout state or
Waiting state, respectively.

In the Process Control state, the status of each powered outputs is as follows:

Powered Output Status

Pilot 1 Energized
De-energized if disabled
Pilot 2
Energized if enabled
Coil 1 /2 De-Energized
Energized or De-energized, depending on process
SSV
control state. See process control modes below for
HFV
detailed valve behavior

2.2.9.1 ON/OFF CONTROL

This is the simplest mode of operation, requiring only the SSV outputs. In this mode, the SSV outputs are
energized when the process temperature is below the process setpoint and are de-energized when above the
setpoint. In the case that the process temperature exceeds the setpoint, the temperature must fall below the
setpoint minus the dead-band in order for the SSV outputs to re-energize.

Note: this process control mode does not utilize the HFV or the TCV outputs.

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2.2.9.2 STAGED HEATING
Staged Heating Mode is a slightly more advanced method of control than the On/Off control, allowing an
extra stage of heating. In this mode, the system utilizes the HFV output as another heating level – giving the
system a total of three stages:

• Pilot Only (Pilot)

• Pilot + SSVs (Stage 1)
• Pilot + SSVs + HFV (Stage 2)
The diagram below outlines the behavior of the system in Staged Heating Mode

1. When the process temperature is below the process setpoint the SSV and the HFV outputs will be
energized for maximum heat output
2. When the process temperature is above the process setpoint but below the main off setpoint the SSV
outputs will remain energized and the HFV outputs will be de-energized, reducing the burner’s firing
rate.
3. When the process temperature exceeds the main off setpoint the SSV outputs de-energize. The
system will transition to the pilot state to cool down.
4. When the process temperature cools down to the process temperature setpoint minus the dead band
the SSV and the HFV outputs will be energized to heat the system back up

Note: this process control mode does not utilize the TCV output.

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2.2.9.3 PID CONTROL
PID Control is the most advanced process control mode, allowing the system to be able to vary the heat
demand in response to the appliance. In this mode, the system utilizes the TCV output to control a
temperature control valve, allowing the system to incrementally change output heat.

The main gas valve outputs (SSV) remain on during PID control unless the process temperature exceeds the
Main Off Setpoint. In this case, the system transitions to the Pilot state and stops PID control. Once the
system cools off such that the process temperature falls below the process setpoint minus the deadband, the
system will proceed to light off the main and resume PID control.

While in PID control, the system will attempt to maintain the process temperature at the process temperature
setpoint by modulating the system firing rate via the TCV output. As long as there are no alarms / waits AND
the temperature does not exceed the Main Off setpoints, the PID will continue to function.

Note: this process control mode does not utilize the HFV output.

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2.3 GENERAL REQURIEMENTS
2.3.1 PF2200 DECLARATIONS
System Parameter Value
Maximum Flame Detector Response Time 50ms
Minimum Flame Detector Self-Checking Rate 1Hz
Maximum Flame Failure Lock-Out Time 4s
Maximum Flame-Failure Re-ignition Time Pre-Ignition Time
Maximum Ignition Time 10.6s
Maximum Pilot-Flame Establishing Period 10s
Maximum Post-Ignition Time 2.5s
Maximum Pre-Ignition Time 1s
Minimum Post-Purge Time 10s
Minimum Recycle Time Post-Purge Time
Maximum Start-up Lock-Out Time 10s[3]
Maximum Number of Start-Up Retries 3
Minimum Waiting Time 5s [1]
Pollution Degree 1 when installed in enclosure with a
rating of IP54 or equivalent
Signal for Presence of Flame -2.54V [2]
Signal for Absence of Flame -2.54V [2]
High Voltage Spark Gap Range 2 – 8mm
Types of Action Type 2: Electronic Disconnection, Non-
volatile Lockout, Permanent Operation
Types of Burners Full Rate Start and Low Rate Start
Type of Control Incorporated Control
Types of Ignition Interrupted
Types of Pilot Continuous, Intermittent and
Interrupted
[1]: Assuming a purge has already elapsed. If system is purging the start command is delayed until the purge is
complete.
[2]: Flame signal is amount the AC signal being applied to the flame rod is rectified (e.g. the DC offset to the AC
waveform)
[3]: Since recycling is allowed, this time is from fuel flow energizing on start-up to fuel flow de-energize due to
no flame presence

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2.4 CERTIFICATION and APPROVALS
The PF2200-SB (Single Burner BMS) is certified for use in a 1oo1 deployment configuration and is certified to
the following standard(s):

• IEC 61508: 2010 Parts 1-7

• CSA – C22.2 No. 60730-2-5 / ANSI Z21.20:14
• UL 60730-2-5
• CSA – C22.2 No. 213-17 – Class 1 Div 2 Group ABCD; T4; Type 4x, IP66
• UL 121201 Ed.9
** Standards denoted in Italics are pending certification **

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3 INSTALLATION and COMMISSIONING
Installers which integrate the PF2200 and commission the system must meet the following criteria:

• Must understand local codes and how they apply to the installation (for both electrical and
mechanical aspects of the installation).
• Must understand the electrical and mechanical limitations of the product and how that relates to the
installation.
• Must verify all required safety functions prior to completing the commissioning of the appliance.
• Must be fluent in the English language (the only language this product supports).
• Must be familiar with navigating the product menus and modifying settings.
• Must understand the effect modifying a setting has on the safety and operation of the appliance.

3.1 SYSTEM CONFIGURATION

The PF2200 Single Burner BMS is designed to be configured from the user interface through a password
protection mechanism. End users are not given the ability to program any of the safety-related system
settings without the appropriate password.

3.1.1 PASSWORDS
Every setting in the PF2200 Single Burner BMS has a settings-level which is pre-programmed at the factory.
The settings level can be one of three levels:

• Level 0 (no level): settings that DO NOT impact the safety-integrity of the system AND DO NOT
impact the process operation
• Level 1: settings that DO NOT impact the safety-integrity of the system BUT can impact the process
operation
• Level 2: settings that DO impact the safety-integrity of the system
In order to modify a setting that has Level 1 or Level 2 access, the user is required to enter the appropriate
password via a prompt. Furthermore, modification of any safety critical settings must be validated prior to
starting the appliance.

Password protection and authentication of safety critical settings is done locally on the PF2200-SB BMS card,
making it more resilient to unauthorized modification.

For Level 1 and Level 2 passwords, please contact Profire Energy. Passwords shall only be distributed to
individuals that are capable of assessing the safety impact of the changes they intend to make.

Note: The PF2200 passwords timeout after 15 minutes regardless of activity from a user.

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3.1.2 INTERFACING
The PF2200 Single Burner BMS is a logic solver designed to interface with various sensors and final elements.
These configurations can be broken down into the following categories:

• Inputs
o Switch Contact Inputs: digital switch connection to the PF2200
o 4-20mA Loop Powered Inputs: 4-20mA input powered by the PF2200
o 4-20mA Self Powered Inputs: 4-20mA input powered from an independent supply
• Outputs
o Powered Outputs: switched output intended to power a solenoid
o Contact Output: switched output intended to provide status feedback
• Mixed I/O
o Ionization / Ignition: switched output to control primary winding of an ignition transformer
(Coil +/-) combined with ionization flame detection on the secondary of the ignition
transformer

3.1.2.1 INPUT WIRING

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DOC-001043 / v5.2
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3.1.2.2 OUTPUT WIRING

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3.1.2.3 MIXED I/O WIRING
Flame Detect & Ignition Wiring for Single-Rod Application

3.1.3 ELECTRICAL and MECHANICAL RATINGS

The PF2200 Single Burner BMS has been designed, validated and verified under the following environmental
conditions

• System Voltage Range:

o 12V mode: 10.2 – 16.2 V
o 24V mode: 20.4 – 32.4 V
• Ambient Temperature Range
o Operating: -40 to 55⁰C
o Storage: -40 to 55⁰C
• Humidity
o External to product: 0-100% Condensing
o BMS and User Interface Card: 0-90% Non-Condensing
• Vibration
o 3g swept form 10-150Hz, 10 consecutive sweeps, 3-axis

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3.1.3.1 USER INTERFACE CARD
Terminals Safety Electrical Rating Wire Gauge /
Rated Torque
4&7 7 – 35 VDC 14-30 AWG
No
(Power Input +/-) 500 mA Max 0.22-0.25 Nm
5&6 -7 to 17 V Common Mode 14-30 AWG
No
(PFN A/B) 0.22-0.25 Nm
-7V to 7V Common Mode Range
1-3 9600 and 19200 bps 14-30 AWG
No
(Modbus A/B/-) (configurable) 0.22-0.25 Nm
8 Data Bits, No Parity, 1 Stop Bit
5VDC
USB No N/A
200 mA Max
3VDC
Keypad No N/A
4.75k Source Impedance

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3.1.3.2 BMS CARD
I/O Type Terminals Safety Electrical Rating Wire
Rated Gauge /
Torque
15-16 (Pilot 1)
17-18 (Pilot 2) 12 / 24VDC, 5A Max 12-30 AWG
Powered Output Yes
19-20 (SSV) Expected Load: Inductive / Resistive 0.5-0.6 Nm
21-22 (SSV)
55-56 (Coil Pilot
12 / 24VDC
1) 12-30 AWG
Powered Output Yes Pulsed Output [PWM]
59-60 (Coil Pilot 0.5-0.6 Nm
Expected Load: Inductive
2)
53-54 (Ion Pilot 1) Intermittent 80-130 VRMS Output @ 5kHz 12-30 AWG
Ionization I/O Yes
57-58 (Ion Pilot 2) (with 20kΩ source resistance) 0.5-0.6 Nm
14-30 AWG
Start/Stop Internal (IGN, Power: 3.3V (1kΩ source resistance)
Yes 0.22-0.25
Switch RUN, PWR) Ignite / Run: 3.3VDC Max
Nm
7-8 (Press. High)
Energized State: 10VDC, 1.25mA Min
11-12 (PoC) 12-30 AWG
Digital Input Yes De-energized State: 3VDC, 500uA Max
33-34 (ESD) 0.5-0.6 Nm
30 VDC Max
35-36 (Start)
Power Out:
• 12V Mode = 12VDC, 24V Mode = 13.5
VDC
5-6 (Press.) • 30mA Max
9-10 (POL) Digital Input (if applicable):
Digital / 41-42 (Level) • Energized State: 10VDC, 1.25mA Min 12-30 AWG
Yes
4-20mA Input 43-44 (Aux. Temp) • De-energized State: 3VDC, 500uA Max 0.5-0.6 Nm
45-46 (Aux. In 1) • 30 VDC Max
47-48 (Aux. In 2) 4-20mA Input:
• +/- 0.1 mA accuracy
• 50mA current limit
• 30 VDC Max

RTD (PT-100):
Bath: • -100 to 850⁰C
61-66 (Bath) Yes* • +/- 0.5⁰C accuracy 14-30 AWG
Temperature
67-69 (Outlet) Outlet & Thermocouple (Type-K): 0.22-0.25
Input
70-72 (Stack) Stack: • -100 to 1350⁰C Nm
No • +/- 2⁰C accuracy
• Ground-biased

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 I/O Type Terminals Safety Electrical Rating Wire
Rated Gauge /
Torque
13-14 (TCV) 20 mA Max
12-30 AWG
4-20mA Output 37-38 (Aux. Out 1) No Expected Load: Resistive (< 350Ω)
0.5-0.6 Nm
39-40 (Aux. Out 2) +/- 0.1mA accuracy
120 VAC, 170V Peak Max. Rated to withstand
12-30 AWG
Relay Output 25-27 (Status) No impulse voltage up to 1500V.
0.5-0.6 Nm
1ARMS Max
12 / 24VDC, 5A Max 12-30 AWG
Powered Output 23-24 (HFV) No
Expected Load: Inductive / Resistive 0.5-0.6 Nm

14-30
7 – 35 VDC AWG
Power Out 1&4 (UI) No
500 mA Max 0.22-0.25
Nm
14-30
AWG
Communication 2&3 (PFN) No -7V to 7V Common Mode Range
0.22-0.25
Nm
12-24VDC 12-30 AWG
Power In 28-32 (Power) No
Class 2 Circuit** 0.5-0.6 Nm
* The Bath Temperature Input is safety rated ONLY if the input is configured as a Dual. If configured as a Single element
the Bath temperature input is NOT safety rated. In order to enable a single element for the Bath temperature, the user
will be prompted with a disclaimer.

** The PF2200 must be powered from a Class 2 circuit as defined in the Canadian Electrical Code (CSA 22.2
No 1-15) or US National Electrical Code (NFPA 70).

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3.2 IMPORTANT SAFETY INFORMATION
All PF2200 installations must be field inspected by the Authority Having Jurisdiction to ensure proper
compliance to local electrical and gas codes. In addition, before installing the PF2200 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.

3.2.1 GENERAL WARNINGS

• Installation and product use must conform to the directions in this manual.
• Solenoid powered outputs are rated to 5A max individually, however the power input to the BMS card
is fused at 10A. Care must be taken as to not exceed the 10A max input when using high-powered
solenoids.
• Do not jumper solenoid (-) terminals together under any circumstance, this will compromise the safety-
integrity of the system.
• Safety Functions must be end-to-end proven during commissioning (e.g. when using a high pressure
switch, ensure a high-pressure event presents a lock-out).

3.2.2 EXPLOSION HAZARD WARNINGS

• Do not disconnect power, open enclosure or otherwise service the product unless area is known to be
non-hazardous.
• Substitution of components may impair suitability for specified zones.
• Replacement fuses must be ceramic and of correct rating (10A, 150VDC, Slow Blow).
• Avoid unauthorized replacement of the fuse. Contact Profire Energy for fuse replacements.
• Do not remove or replace fuse when system is powered.

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3.2.3 INSTALLATION WARNINGS
• Electrical devices connected to the controller must meet local electrical codes and be within voltage
limits specified in this manual.
• Ensure enclosure is securely closed each time after opening. Improper closure may result in moisture
and/or other environmental damage and may also compromise the integrity of the product.
• System must be properly connected to earth-ground to prevent electrocution.
• No more than one conductor is to be used per contact point.
• Ensure field wiring is properly fused and sizes in accordance with local codes.
• Do not disassemble or modify the cards in any way. The cards are not field reparable and must be
sent back to Profire Energy for replacement if damaged.
• Card installation shall be performed in accordance with local electrical code(s) by a capable electrician.
Installation and modification shall NOT be performed while the system is energized.
• Failure to provide a low-impedance path from the burner assembly to the PF2200 may result in
accidental electric shock, product damage, failure to ignite the pilot, or failure to detect flame.
• Do not connect wires or handle the electronics when powered.
• Do not modify product once installed.
• Bypass of safety function(s) is required to update software.
• All screw connections must not rely on the structural integrity of insulating materials.

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3.3 MOUNTING CONSIDERATIONS
The PF2200 Single Burner BMS cards must be mounted in an enclosure of IP54 rating or greater. There are
two enclosure options for this product, the PF2200-SB-A and the PF22000-SB-B – both of which are outlined
in section 2.1.4. Both enclosure options have four holes, located in the four corners of the product. These
holes are intended to be used in conjunction with a fastening device (e.g. nut/bolt) to secure the product to a
rigid platform.

3.3.1 ORIENTATION & LOCATION

• The PF2200 enclosure shall be mounted upright in such a way that the screen is clearly visible and the
keypad is easy to access. Recommended height of 1.5m (5ft) above ground.
• Adequate space must be given such that the enclosure door can open during maintenance /
commissioning.
• Enclosure should be mounted to minimize run-lengths to valve train (solenoids), burner assembly
(ignition coil/rod and flame detect rod) and thermocouple elements.
• When wiring ignition and flame detection circuits, the wire length between the ignition coil and pilot
should be no more than 5m (15ft). The longer the run length the less energy delivered when
sparking.
• The PF2200 should be mounted in such a way to avoid direct sunlight exposure to the screen.
Extended UV exposure may compromise viewability.

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3.3.2 MOUNTING CARDS
If the need arises where the cards needs to be remounted (e.g. field repair / replacement), both cards should
be securely fastened with the appropriate screw size and number of screws. For the BMS card, there are 6 x
#10-32 machine screws [11] that secure the card [3] to the enclosure. For the User Interface card, there are 4
x #10-32 nuts [10] that secure the card [2] to the enclosure through the cover [7]. See the exploded view
below for more details

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3.3.3 PROTECTIVE EARTHING
For the PF2200-SB-A, the metal enclosure must be properly bonded to earth ground by the installer.
Bonding must be carried out in accordance with the local electrical code (e.g. NEC in the United States and
CEC in Canada).

To ensure proper functionality of the flame detection circuit, Profire recommends the DC power supply
reference be tied to Earth Ground.

3.3.4 ELECTRICAL NOISE

Due to the variability of installation (e.g. load configuration, wiring, etc.), a ferrite bead may be required to
suppress power supply related noise on the input power to the PF2200-SB-B. Typically this is only needed for
long power line / load line run lengths and at higher load currents (e.g. >2A).

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4 OPERATIONS and MAINTENANCE
Operators working on or maintaining the PF2200 must meet the following criteria:

• Be fluent in the English language (the only language this product supports).
• Be familiar with navigating the product menus and modifying settings.
• Understand the effect modifying a setting has on the safety and operation of the appliance.

4.1 ASSUMPTIONS SPECIFIC to USE

• All powered outputs that are in a de-energized state are assumed to be in safe state (e.g. a de-
energized pilot output should connect to a normally closed valve to shut off gas-flow in the de-
energized state).
• All digital inputs are energized-to-run (e.g. an open contact presents an alarm / shutdown).
• Power supply and external fusing should be determined using the local electrical code (e.g. NEC in the
United States or CEC in Canada)

4.2 TRANSPORTATION & STORAGE CONDITIONS

Transportation of the product shall be in the original product packaging or equivalent. Transportation of
cards without enclosure is not recommended and should be done with the utmost care utilizing an Anti-
Static/ESD bag.

Storage temperature should be kept within the operating temperature listed in Section 3 in a dry area. Avoid
moisture buildup inside the enclosure.

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4.3 OPERATOR USER INTERFACE
4.3.1 STATUS SCREEN
The Status Screen displays various information relevant to operation of the burner. To change the zoom level
of the Status Screen, use the or keys.

The Status Screen displays information in accordance with the configurable status priority settings.

Refer to the Status Priority section for information on adjusting how and what is shown on the Status Screen.

The user interface display remains on at all times to allow operations personnel to check key system status
information without any user interaction.

4.3.2 SETTINGS SCREEN

The Settings Screen contains all controller settings grouped by type for easy settings adjustment and
commissioning.

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4.3.2.1 COMMISSIONING MODE
Commissioning Mode is a mode that allows read-only access to all settings within the system. Users must
enter a valid password when prompted in order to enable settings modification.

Commissioning Mode Operator Mode

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4.3.2.2 SETTINGS MODIFICATION
Below is an example of the navigational sequence to enter the Bath Sensor Type setting. This sequence is
typical for all settings adjustments.

DOC-001043 / v5.2
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Drop-Down Menu Changes

Drop-down menu options can be selected using either of the following methods:

Method One:

1. Highlight the drop-down menu you wish to change and press or

2. Enter the password sequence if prompted then press the key and repeat step 1

Method two:

1. Highlight the drop-down menu you wish to change and press

2. Enter the password sequence if prompted then press
3. Press again to expand the drop-down menu
4. Use and to highlight your selection
5. Press to set the selection

Numerical Setting Changes

Numerical settings can be changed as follows:

1. Highlight the numerical setting you wish to change and press or

2. Enter the password sequence if prompted then press the key and repeat step 1

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4.3.3 SETTINGS DESCRIPTIONS
4.3.3.1 BATH TEMPERATURE INPUT
Options / Configuration
Name Default Description
Range Notes
Temperature sensing element type. Can be
TC
Type RTD Type K Thermocouple (grounded or
RTD
ungrounded) or PT100 RTD
Bath Input mode is
Configuration control for the Bath input. Dual required to be set to
Dual
Input Dual requires two unique temperature sensing Dual if the Bath Input is
Single
elements, whereas single only requires one. specified as a safety
function.
At least one of Bath
Mode for the temperature input, used by the
Mode, Outlet Mode, or
Process Process Control system to determine how the input is to be
Mode Aux Temp Mode must
Control High Temp ESD used. See Temperature Inputs section for
be set to Process
more details.
Control
High Temp Setpoint
must be greater than
High Temp 90 °C 0 °C - 1350 °C Temperature threshold at which, if exceeded,
Pilot Off Setpoint and
Setpoint 194 °F 32 °F - 2462 °F the system will shut down.
In RTD mode must be
less than 850 °C
Pilot Off Setpoint must
be greater than Main
85 °C 0 °C - 1350 °C Temperature threshold at which, if exceeded,
Pilot Off Setpoint Off Setpoint and less
185 °F 32 °F - 2462 °F the system will turn off the pilot valve(s).
than High Temp
Setpoint
Main Off Setpoint must
be greater than
85 °C 0 °C - 1350 °C Temperature threshold at which, if exceeded,
Main Off Setpoint Process Setpoint and
185 °F 32 °F - 2462 °F the system will turn off the main valve(s).
less than Pilot Off
Setpoint
Process Setpoint must
80 °C 0 °C - 1350 °C Temperature setpoint the system attempts to be greater than Low
Process Setpoint
176 °F 32 °F - 2462 °F maintain when in Process Control mode. Temp Setpoint and less
than Main Off Setpoint
Low Temp Setpoint
0 °C 0 °C - 1350 °C Temperature threshold at which, if not
Low Temp Setpoint must be less than
32 °F 32 °F - 2462 °F exceeded, the system will warn the user.
Process Setpoint
The deadband prevents the system from
bouncing between states when the input
2 °C 0 °C - 100 °C
Deadband reading is close to the corresponding
3.6 °F 0 °F - 180 °F
setpoint. See Temperature Inputs section for
more details.

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4.3.3.2 OUTLET TEMPERATUR INPUT
Options / Configuration
Name Default Description
Range Notes
Temperature sensing element type. Can be
TC
Type RTD Type K Thermocouple (grounded or
RTD
ungrounded) or PT100 RTD
At least one of Bath
Disabled Mode for the temperature input, used by the
Mode, Outlet Mode, or
Process Control system to determine how the input is to be
Mode Disabled Aux Temp Mode must
High Temp ESD used. See Temperature Inputs section for
be set to Process
Display Only more details.
Control
High Temp Setpoint
Temperature threshold at which, if exceeded,
must be greater than
High Temp 90 °C 0 °C - 1350 °C the system will shut down. Only applicable if
Pilot Off Setpoint and
Setpoint 194 °F 32 °F - 2462 °F the mode is set to High Temp ESD or Process
In RTD mode must be
Control.
less than 850 °C
Pilot Off Setpoint must
be greater than Main
85 °C 0 °C - 1350 °C Temperature threshold at which, if exceeded,
Pilot Off Setpoint Off Setpoint and less
185 °F 32 °F - 2462 °F the system will turn off the pilot valve(s).
than High Temp
Setpoint
Main Off Setpoint must
be greater than
85 °C 0 °C - 1350 °C Temperature threshold at which, if exceeded,
Main Off Setpoint Process Setpoint and
185 °F 32 °F - 2462 °F the system will turn off the main valve(s).
less than Pilot Off
Setpoint
Process Setpoint must
80 °C 0 °C - 1350 °C Temperature setpoint the system attempts to be greater than Low
Process Setpoint
176 °F 32 °F - 2462 °F maintain when in Process Control mode. Temp Setpoint and less
than Main Off Setpoint
Low Temp Setpoint
0 °C 0 °C - 1350 °C Temperature threshold at which, if not
Low Temp Setpoint must be less than
32 °F 32 °F - 2462 °F exceeded, the system will warn the user.
Process Setpoint
The deadband prevents the system from
bouncing between states when the input
2 °C 0 °C - 100 °C
Deadband reading is close to the corresponding
3.6 °F 0 °F - 180 °F
setpoint. See Temperature Inputs section for
more details.

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4.3.3.3 STACK TEMPERATURE INPUT
Options / Configuration
Name Default Description
Range Notes
Temperature sensing element type. Can be
TC
Type RTD Type K Thermocouple (grounded or
RTD
ungrounded) or PT100 RTD
Mode for the temperature input, used by the
Disabled
system to determine how the input is to be
Mode Disabled High Temp ESD
used. See Temperature Inputs section for
Display Only
more details.
High Temp Setpoint
Temperature threshold at which, if exceeded, must be greater than
High Temp 90 °C 0 °C - 1350 °C
the system will shut down. Only applicable if Pilot Off Setpoint and
Setpoint 194 °F 32 °F - 2462 °F
the mode is set to High Temp ESD. In RTD mode must be
less than 850 °C
The deadband prevents the system from
bouncing between states when the input
2 °C 0 °C - 100 °C
Deadband reading is close to the corresponding
3.6 °F 0 °F - 180 °F
setpoint. See Temperature Inputs section for
more details.

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4.3.3.4 AUX TEMPERATURE INPUT
Options / Configuration
Name Default Description
Range Notes
At least one of Bath
Disabled Mode for the temperature input, used by
Mode, Outlet Mode, or
Process Control the system to determine how the input is to
Mode Disabled Aux Temp Mode must
High Temp ESD be used. See Temperature Inputs section for
be set to Process
Display Only more details.
Control
High Temp Setpoint
Temperature threshold at which, if
must be greater than
High Temp 90 °C 0 °C - 1350 °C exceeded, the system will shut down. Only
Pilot Off Setpoint and
Setpoint 194 °F 32 °F - 2462 °F applicable if the mode is set to High Temp
In RTD mode must be
ESD or Process Control.
less than 850 °C
Pilot Off Setpoint must
Temperature threshold at which, if be greater than Main
85 °C 0 °C - 1350 °C
Pilot Off Setpoint exceeded, the system will turn off the pilot Off Setpoint and less
185 °F 32 °F - 2462 °F
valve(s). than High Temp
Setpoint
Main Off Setpoint must
Temperature threshold at which, if be greater than
85 °C 0 °C - 1350 °C
Main Off Setpoint exceeded, the system will turn off the main Process Setpoint and
185 °F 32 °F - 2462 °F
valve(s). less than Pilot Off
Setpoint
Process Setpoint must
80 °C 0 °C - 1350 °C Temperature setpoint the system attempts be greater than Low
Process Setpoint
176 °F 32 °F - 2462 °F to maintain when in Process Control mode. Temp Setpoint and less
than Main Off Setpoint
Low Temp Setpoint
0 °C 0 °C - 1350 °C Temperature threshold at which, if not must be less than
Low Temp Setpoint
32 °F 32 °F - 2462 °F exceeded, the system will warn the user. Process Setpoint and
greater than Span Min
The deadband prevents the system from
bouncing between states when the input
2 °C 0 °C - 100 °C
Deadband reading is close to the corresponding
3.6 °F 0 °F - 180 °F
setpoint. See Temperature Inputs section
for more details.
Span Min must be less
0 °C -100 °C - 1350 °C Temperature value corresponding to 4mA
4-20 Span Min than Span Max and
32 °F -148 °F - 2462 °F output from the 4-20mA transmitter.
Low Temp Setpoint
Span Max must be
1350 °C -100 °C - 1350 °C Temperature value corresponding to 20mA greater than Span Min
4-20 Span Max
2462 °F -148 °F - 2462 °F output from the 4-20mA transmitter. and High Temp
Setpoint

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4.3.3.5 PROOF of CLOSURE INPUT
Name Default Options Description
Disabled Controls whether the Proof of Closure input is enabled or disabled.
Proof of Closure Enabled
Enabled See Proof of Closure (PoC) Input section for more details.

4.3.3.6 REMOTE START INPUT

Name Default Options Description
Disabled Controls whether the Remote Start input is enabled or disabled. See
Remote Start Enabled
Enabled Remote Start Input section for more details.

4.3.3.7 LEVEL/FLOW INPUT

Options /
Name Default Description Configuration Notes
Range
Disabled Level/Flow sensor type. Can be
Type Digital Digital configured as a switch (digital),
4-20 transmitter (4-20), or disabled.
Alarm
Action the system will take when a de- Type is must be set to
Digital Mode Alarm Wait
energized contact occurs. Digital
Warning
Alarm
4-20 Low Trip Action the system will take when a low-
Alarm Wait Type is must be set to 4-20
Mode trip event occurs.
Warning
Alarm
4-20 High Trip Action the system will take when a high-
Alarm Wait Type is must be set to 4-20
Mode trip event occurs.
Warning
0L 0 L - 100000 L Level/Flow value corresponding to 4mA Span Min must be less than
4-20 Span Min
0 gal 0 gal - 26417 gal output from the 4-20mA transmitter. Span Max and 4-20 Low Trip
Span Max must be greater
120 L 0 L - 100000 L Level/Flow value corresponding to 20mA
4-20 Span Max than Span Min and 4-20
31.7 gal 0 gal - 26417 gal output from the 4-20mA transmitter.
High Trip
Input threshold at which, if not exceeded,
the system will initiate a low-trip event.
4-20 Low Trip 12 mA 4 mA - 20 mA Type is must be set to 4-20
The low-trip event is defined by the 4-20
Low Trip Mode setting.
Input threshold at which, if exceeded, the
system will initiate a high-trip event. The
4-20 High Trip 19.6 mA 4 mA - 20 mA Type is must bet set to 4-20
high-trip event is defined by the 4-20 High
Trip Mode setting.
To clear a low trip, input
The deadband prevents the system from must be greater than 4-20
bouncing between states when the input Low Trip plus deadband.
4-20 Deadband 0.2 mA 0 mA - 1 mA
reading is close to the corresponding trip To clear a high trip, input
point. must be less than 4-20 High
Trip minus deadband.
The amount of time the system requires a
Level/Flow Delay 2 sec 2 sec - 20 sec low-input event be consistent for before
performing the low-trip action.

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4.3.3.8 PRESSURE (LOW SWITCH / 4-20) INPUT
Name Default Options / Range Description Configuration Notes
Disabled Pressure sensor type. Can be configured as a
Type Digital Digital switch (digital), transmitter (4-20), or
4-20 disabled.
Span Min must be less
4-20 Span 0 kPa 0 kPa - 100000 kPa Pressure value corresponding to 4mA output
than Span Max and 4-20
Min 0 psi 0 psi - 14504 psi from the 4-20mA transmitter.
Low Trip
Span Max must be
4-20 Span 206.843 kPa 0 kPa - 100000 kPa Pressure value corresponding to 20mA output
greater than Span Min
Max 30 psi 0 psi - 14504 psi from the 4-20mA transmitter.
and 4-20 High Trip
Pressure threshold that, if not exceeded, the
4-20 Low system will initiate a low-pressure event. The Type is must be set to 4-
4 mA 4 mA - 20 mA
Trip low-pressure event is defined by the Low 20
Pressure Mode setting.
4-20 High Pressure threshold that, if exceeded, the Type is must be set to 4-
17.73 mA 4 mA - 20 mA
Trip system will shutdown. 20
To clear a low trip, input
must be greater than 4-
The deadband prevents the system from 20 Low Trip plus
4-20 bouncing between states when the input deadband.
0.2 mA 0 mA - 1 mA
Deadband reading is close to the corresponding trip To clear a high trip, input
point. must be less than 4-20
High Trip minus
deadband.
Low The amount of time the system requires a
Pressure 2 sec 2 sec - 20 sec low-pressure event be consistent for before
Delay performing the low-pressure action.
Alarm
Low
Wait Action the system will take when a low-
Pressure Alarm
Warning pressure event occurs.
Mode
Main Permissive

4.3.3.9 PRESSURE HIGH INPUT

Name Default Options Description
Disabled Controls whether the Pressure High input is enabled or disabled. See
Pressure High Enabled
Enabled High Pressure Input section for more details.

4.3.3.10 PROOF OF LIGHT OFF POSITION INPUT

Name Default Options / Range Description
Disabled
Light Off Position sensor type. Can be configured as a switch
Type Disabled Digital
(digital), transmitter (4-20), or disabled.
4-20
Setpoint 50% 0 – 100% Point at which the sensor is in the Light Off position.
Allowable tolerance of the setpoint. System will consider a
Tolerance 1.5% 0 – 6.2%
position of setpoint +/- tolerance adequate for proving position

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4.3.3.11 AUX IN 1 & AUX IN 2 INPUTS
Name Default Options / Range Description Configuration Notes
Disabled Input sensor type. Can be
Type Digital Digital configured as a switch (digital),
4-20 transmitter (4-20), or disabled.
High/Low Trip
Various modes for the Aux input
Appliance Firing Rate
High/Low when configured as a 4-20 type.
4-20 Mode Bath Process SP Adjust Type is must be set to 4-20
Trip See Auxiliary Inputs section for
Outlet Process SP Adjust
more details.
Aux Temp Process SP Adjust
Alarm
Wait Action the system will take when Type is must be set to
Digital Mode Alarm
Warning a de-energized contact occurs. Digital
Main Permissive
Alarm
4-20 Low Trip Wait Action the system will take when
Alarm Type is must be set to 4-20
Mode Warning a low-trip event occurs.
Main Permissive
Alarm
4-20 High Trip Wait Action the system will take when
Alarm Type is must be set to 4-20
Mode Warning a high-trip event occurs.
Main Permissive
Input threshold at which, if not
exceeded, the system will initiate
4-20 Low Trip 0% 0 – 100% a low-trip event. The low-trip Type is must be set to 4-20
event is defined by the 4-20 Low
Trip Mode setting.
Input threshold at which, if
exceeded, the system will initiate
4-20 High Trip 100% 0 – 100% a high-trip event. The high-trip Type is must be set to 4-20
event is defined by the 4-20 High
Trip Mode setting.
To clear a low trip, input
The deadband prevents the
must be greater than 4-20
system from bouncing between
Low Trip plus deadband.
4-20 Deadband 1.2% 0 – 6.2% states when the input reading is
To clear a high trip, input
close to the corresponding trip
must be less than 4-20
point.
High Trip minus deadband.
Input value corresponding to
Span Max must be greater
4-20 Span Min 0% 0% - 100% 4mA output from the 4-20mA
than Span Min
transmitter.
Input value corresponding to
Span Max must be greater
4-20 Span Max 100% 0% - 100% 20mA output from the 4-20mA
than Span Min
transmitter.

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4.3.3.12 STATUS OUTPUT
Name Default Options / Range Description Configuration Notes
Run Status
Defines the behaviour of the
Status Contact Heating Status
Run Status Status Contact. See Status Relay
Mode Low Temp Warning
Output section for more details.
Level/Flow Control

4.3.3.13 AUX OUT 1 & AUX OUT 2 OUTPUTS

Name Default Options / Range Description Configuration Notes
Disabled
Level/Flow Echo
Aux In 1 Echo
Aux In 2 Echo Defines the behaviour of the
Mode Disabled Modbus Echo Auxiliary Output. See Auxiliary
Bath Temp Echo Outputs section for more details.
Outlet Temp Echo
Stack Temp Echo
Aux Temp Echo
Temperature value
Temp Echo 0 °C -100 °C - 1350 °C Span Max must be greater
corresponding to 4mA from the
Span Min 32 °F -148 °F - 2462 °F than Span Min
Auxiliary Output.
Temperature value
Temp Echo 1350 °C -100 °C - 1350 °C Span Max must be greater
corresponding to 20mA from the
Span Max 2462 °F -148 °F - 2462 °F than Span Min
Auxiliary Output.

4.3.3.14 VALVE OUTPUTS

Name Default Range Description
Pilot Valve Duty cycle of the output. Higher value corresponds to higher
60 % 10 % - 100 %
PWM average output.
Duty cycle of the output. Higher value corresponds to higher
SSV PWM 60 % 10 % - 100 %
average output.
Duty cycle of the output. Higher value corresponds to higher
Aux PWM 60 % 10 % - 100 %
average output.

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4.3.3.15 TCV OUTPUT
Name Default Options / Range Description
Minimum position for the TCV output. See Temperature
Min Position 40 % 0 % - 70 %
Control Valve (TCV) output section.
Position for the TCV output during the Purge state. See
Purge Position 0% 0 % - 100 %
Temperature Control Valve (TCV) output section.
Position for the TCV output during the Ignition and Pilot
Pilot Position 0% 0 % - 100 % states. See Temperature Control Valve (TCV) output
section.
Manual override TCV functionality, used in conjunction
Disabled
Manual Override Disabled with Manual Position setting. See Temperature Control
Enabled
Valve (TCV) output section.
Position of TCV when Manual Override is enabled. See
Manual Position 0% 0 % - 100 %
Temperature Control Valve (TCV) output section.

4.3.3.16 CONFIGURATION
Name Default Options Description
On/Off Control
Staged Heating
Process Control On/Off Bath PID Control Control mode of the system. Refer to Process Control section for
Mode Control Outlet PID Control more details.
Aux PID Control
Cascaded PID Control
Defines when the system turns off the Pilot valve, specifically:
• Disabled: Pilot remains on so long as the burner is running
Disabled • Off at Pilot Off Setpoint: Pilot remains on so long as the
Pilot Off Mode Disabled Off At Pilot Off Setpoint burner is running and no configured temperature is above
Follow Main Pilot Off Setpoint
• Follow Main: Pilot remains on so long as the main valves
are on
Disabled Enables the second Pilot valve output and flame detection input.
Pilot 2 Disabled
Enabled

4.3.3.17 TIMING
Name Default Range Description
Purge Time 60 sec 10 sec – 900 sec Time which the system will remain in the Purge state.
Pilot Startup Minimum time which the system will remain in the Pilot state
15 sec 15 sec – 600 sec
Delay Time when starting.
Main Startup Minimum time which the system will remain in a minimum firing
30 sec 30 sec – 600 sec
Delay Time state when prior to entering the Process Control state.

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4.3.3.18 IGNITION
Name Default Range Description
Determines the number of relight attempts the system will use
Relight Attempts 0 0 - 3 attempts
when establishing flame.
Controls the Coil output behaviour when in the ignition state:
• Coil: Pulsed output mode, typically connected to a rated
Coil
Ignition Mode Coil ignition coil
HEI
• HEI: constant output mode, typically connected to a high
intensity ignitor

4.3.3.19 PID CONTROL

Name Default Range Description
Process This is the proportional Band used for the PID calculation. In
10 °C 0 °C - 1000 °C
Proportional cascaded control mode this value applies to the bath PID
18 °F 0 °F - 1800 °F
Band loop.
Process Integral 4 0 mins/rep - 1000
This is the integral time used for the PID calculation.
Time mins/rep mins/rep
Process
0 min 0 min - 1000 min This is the derivative time used for the PID calculation.
Derivative Time
This is the boundary of the integral windup range. If the
Process Integral 10 °C 0 °C - 1000 °C
process temperature is outside of this range the integral term
Reset Range 18 °F 0 °F - 1800 °F
will not accumulate.
Cascade This is the proportional Band used for the cascaded PID
10 °C 0 °C - 1000 °C
Proportional calculation for the outlet temperature. If cascaded PID is not
18 °F 0 °F - 1800 °F
Band used, this value has no effect.
This is the integral time used for the cascaded PID calculation
Cascade Integral 0 0 mins/rep - 1000
for the outlet temperature. If cascaded PID is not used this
Time mins/rep mins/rep
value has no effect.
This is the derivative time used for the cascaded PID
Cascade
0 min 0 min - 1000 min calculation for the outlet temperature. If cascaded PID is not
Derivative Time
used this value has no effect.
In cascaded mode this is the boundary of the integral windup
Cascade Integral 10 °C 0 °C - 1000 °C
range for the outlet temperature. If the outlet temperature is
Reset Range 18 °F 0 °F - 1800 °F
outside of this range the integral term will not accumulate.
This is the limit for the maximum output change of the TCV
Output Rate 100 per second. A larger value allows for a quicker change in
0.1 %/sec - 100 %/sec
Limit %/sec output. A smaller value slows down any change in output.
This can help prevent fast movements from the TCV.
Once the system enters process control mode after light off
delay it will slowly ramp to the requested firing rate over this
Ramp Time 10 sec 0 sec - 255 sec time. This can prevent the firing rate from jumping hard from
the minimum opening position to the maximum firing rate
too quickly.

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4.3.3.20 COMMISSIONING
Name Default Range Description
12V Sets the voltage mode of the system. Setting this mode affects the
Voltage Setting 12V
24V thresholds for the low and high voltage alarms / warnings.
Enabling this mode allows the system to restart from a low voltage
Disabled
Voltage Restart Disabled event, provided the system was running when the low voltage
Enabled
event occurred.
L1 Password Disabled Enabling this mode allows L1 password control on some non-safety
Disabled
Enable Enabled critical settings.
Commissioning Incomplete Setting to confirm commissioning is complete. While this setting is
Incomplete
Complete Complete Incomplete, the system is incapable of running.

4.3.3.21 UNITS
Name Default Range Description
Temperature Celsius
Celsius Display units for Temperature inputs.
Units Fahrenheit
kPa
psi
inch wc
Pressure Units kPa oz/in2 Display units for Pressure input.
kg/cm2
Percent
Milliamps
Litres
m3
US Gallons
bbl
ft3
L/sec
L/min
m3/sec
Level/Flow Units Litres m3/min Display units for Level/Flow input.
US Gal/sec
US Gal/min
bbl/sec
bbl/min
ft3/sec
ft3/min
Percent
Milliamps
Percent
Milliamps
Aux In 1 &
Percent Temperature Display units for Auxilliary inputs.
Aux In 2 Units
Pressure
Level/Flow

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4.3.3.22 MODBUS
Name Default Range Description
Slave Address 1 1 - 247 Modbus slave address of the PF2200.
9600 Baud rate for the RS-485 link.
Baud Rate 9600
19200
1 Number of stop bits. Used for configuring the RS-485 protocol.
Stop Bits 1
2
None Parity bit support. Used for configuring the RS-485 protocol.
Parity None Odd
Even
Modbus Disabled Termination enable. Used for configuring the RS-485 protocol.
Disabled
Termination Enabled
Modbus RTU Disabled Modbus enable.
Disabled
Communication Enabled

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4.3.4 SYSTEM SCREEN
The PF2200 Systems screen holds the more global settings and information on the PF2200. Here you will find
troubleshooting information such as Diagnostics, Logging, Reset, Backup, Restore, as well as Status Priority,
and Firmware tools.

4.3.4.1 TEMPERATURES
The Temperatures diagnostics screen delivers a real-time
temperature status of all the commissioned elements the
system controls.

4.3.4.2 INPUTS
The Inputs diagnostics gives real-time conditions of all
system Inputs.

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4.3.4.3 OUTPUTS
The Outputs diagnostics gives real-time conditions of the
configured system Outputs.

4.3.4.4 FLAME DIAGNOSTICS

The Flame Diagnostics screen shows a real-
time evaluation of the Pilot status, including
flame strength, DC High voltage as well as
AC voltage in millivolts.

Along with the real-time flame status, this

screen also provides Flame Fails and Relights.
On the right side of the screen displays a
graphical representation of the flame health
ranging from Strong to None. In order for
the system to register an adequate flame, the
flame must be at Weak or higher.

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4.3.4.5 POWER
The Power Diagnostics displays the Voltage, Current,
System Power, as well as the Hourly Energy Consumption
of the system in real-time.

4.3.4.6 RUN TIMES

Run Time diagnostics gives a summation of the run times of
the System, Pilot Solenoid, SSV, and Fan.

4.3.4.7 MODBUS
The Modbus diagnostics allows for diagnosing the
health of the Modbus connection to the BMS.

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4.3.4.8 KEYPAD
The Keypad diagnostics is a tool to test the functionality of the
keypad. Upon opening the Keypad diagnostics screen, the
Keypad test starts by instructing the user to press the Start
Button then leading the user through a test of each key on the
keypad. As keys are pressed, a checkmark is displayed next to
the associated key. If no keypad is detected within a set time
parameter, the keypad test stops and displays an error.

4.3.4.9 EVENT LOG

The Event Log continuously records events during system operation to a USB storage device (if installed). The
event log is configurable, allowing the user to choose what is recorded.

To select what is recorded in the event log, navigate to the Event Log menu item on the Setup screen. Press
the OK key to open the event log screen. The Event Filters screen is displayed where the user can scroll up
and down the list of filters using the UP ARROW and DOWN ARROW keys. Highlight the event to be
recorded and press the OK key.

When the supplied USB storage device is installed in the USB port of the PF2200, the system automatically
creates the event log folder and begins to record system events.

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4.3.4.10 DATA LOGGING
The Data Logging tool monitors various inputs and outputs data and automatically logs this data to the USB
storage device.

Navigate to the Systems screen and highlight the Data Log menu item. Press the OK key to display the Dato
Log Configuration screen. Up to 8 items can be selected to log. To select the items to be logged, use the
ARROW UP and DOWN ARROW keys to highlight an item. Press the OK key to make the selection. Once
the selections are complete, highlight the Accept button and press OK.

To get statistics of the used and unused portion of the USB storage device, highlight the Statistics button
while in the Data Log screen and press OK. A pop up displays showing the statistics of the USB device.

4.3.4.11 STATUS PRIORITY

The Status Priority screen allows the user to change the
information shown on the three available Status Zoom
screens.
By using the PLUS and MINUS keys, the user can arrange
the available information in the order that best suits the
process. This list corresponds with the three Zoom options
also shown on the screen.

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4.3.4.12 INFORMATION
The Information screen shows all the information about the
Hardware and Software for the PF2200. This includes, but not
limited to such information like Hardware Model, Serial
Number, Manufacturing Date, Testing Date, Firmware
Version, as well as information on the User Interface software.

4.3.4.13 RESET SETTINGS

Reset Settings allows the user to reset all the Burner Management
Systems settings back to the factory defaults. When this action is
taken the user will be prompted to confirm the intention to reset all
settings to defaults.

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4.3.4.14 BACKUP & RESTORE SETTINGS
BMS settings may be saved to a USB backup. This will create a human
readable .csv file that may be restored on the same unit later or used to
configure other units to the same settings.

Settings can only be restored to another single burner BMS unit, settings
are not compatible between Profire product lineups.

Settings can be restored between different firmware version, however

there is no guarantee of compatibility.

Not all settings may be restored due to mismatches in settings between

different firmware versions.

In these cases, the settings that have failed to restore are listed on the UI
screen. The commission date is always reset to default during the restore.
The operator must validate all setting on the BMS unit and acknowledge
by setting the new commission date.

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5 TROUBLESHOOTING
Problem Diagnosis
System has visible flame
but cannot detect
Card is unresponsive or
BMS card will not
communicate with User
Interface card
Ignition transformer
“clicks” but no visible
spark
Solenoids are not
turning on, or turning on
then over time turn off
Digital input will not
energize
DOC-001043 / v5.2
1. Ensure pilot assembly, flame rod, and the gap between are fully engulfed in
flame. If not, adjust rod position
2. Ensure flame detection wiring does not exceed the recommended maximum
3. Ensure burner assembly has a low impedance path to Ion- terminal of BMS
4. For longer run lengths, ensure ignition cable is used to avoid ground-
loading
1. Ensure the Status LEDs for both cards are functioning. If status LED is not
functioning, cycle power (if safe to do so) and check again.
2. If status LED is still not functioning, card is likely faulty.
1. Ensure all wires in the ignition path are properly terminated and that there is
a low impedance path from the primary-windings to the BMS card as well as
the secondary-windings to the ignition rod.
2. Ensure the gap between the ignition rod and the burner housing is within
the tolerances specified in this manual under PF2200 Declarations section
under ”High Voltage Spark Gap Range”. Often times there is either excess
buildup or the rod has drooped to compromise the gap distance.
1. Ensure the solenoid is wired correctly and to the appropriate terminals.
• To ensure proper solenoid wiring, a multi-meter in OHM mode can
be used to measure the resistance between the + and – terminal of
the associated output. Note: this measurement should be done with
the BMS card powered off.
• If properly wired, the multi-meter should read a resistance of the
solenoid coil plus the run length (i.e. if the multimeter reads open,
there is likely a problem with wiring).
2. Ensure the PWM setting is correct for the appropriate solenoid.
• If using a peak-and-hold solenoid, the appropriate PWM setting can
be found in the solenoid data sheet. Typically add a margin of 5-
10% to allow for temperature variance
• If using a non-peak-and-hold solenoid, ensure the PWM setting is
set to 100%
1. Ensure the input is properly wired. See section 4 for Interfacing / Wiring
configurations.
2. In the case of a dry contact, ensure the PWR terminal is connected and is
sourcing the correct voltage.
3. Ensure adequate amount of wetting current is being applied to through
contact.
• Run a current meter in series with the digital input switch and verify
the energized state meets the requirements outlined in the “Electrical
and Mechanical Ratings” section of this document
76
 • If there is not adequate wetting current, the digital input either has
too high of an impedance or the wiring has been compromised

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6 MAINTENANCE
During maintenance, with respect to software and setup, visual inspection should be done to determine the
following:

• What is the firmware version being used?

• What are the appliance specific settings? An example list of settings can be found below
o Is Pressure used? Is Level Used? Is TCV Used?
o Is Pilot 2 Used? Is Outlet Temp Used? Is Stack Temp Used?
When gas fitting installation is done, a visual inspection should be done to determine the following:

• Whether drip legs are installed on the final drop and condensation points?
• Whether the pilot piping is taken off the top or the side of the supply and not the bottom?
• Whether piping and fittings are clear from burrs and defects?
• Whether an overpressure protection device is required and installed?
• Whether the regulator is of a positive shut off type for supply above 0.5 psig?
• Whether gas pressure is indicated at shutoff valves and penetrations are required?
• Whether piping is supported securely and the support spacings do not exceed 8 feet?
• Whether gauges are correctly sized to match the pressure range?
• Whether the gas line is painted or marked according to code?
• Whether swing joints are installed if they are required?
• Whether all exposed gas piping is painted?
• Whether the ends of piping are reamed?
• Whether the appliance vents are mounted securely?
• Whether all indicators and gauges can be read easily?
• Whether gas shutoffs in the upstream pilot valve train are present and easily accessible?
• Whether gas shutoffs in the downstream pressure regulator are present and easily accessible?
• Whether gas shutoffs in the upstream pressure regulator are present and easily accessible?
• Whether appliance gas shutoffs are present and easily accessible?

When any electrical installation is done, visual inspection should be done to determine the following:
• Whether all wires are stripped correctly (no copper should be seen out of the connectors)?
• Whether all wires and conduits are appropriately secured?
• Whether the correct conduit, cable seals and fittings are used for the zone?
• Whether the enclosure lugs are wired to earth ground?

A functional test should be performed to verify all appropriate user-configurable I/O ring in as alarms.
The best way to verify this is to tabulate a list of all safety-critical sensors and I/O that are wired into the

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PF2200 and test their functionality one at a time. This can be done by forcing an alarm on each I/O
separately and verifying the PF2200 annunciates the appropriate alarm.

6.1 REPAIR and REPLACEMENT

Profire Energy does not support on-site repairs for cards. For replacement cards contact Profire Energy
customer service.

In the event replacement card(s) are used, care must be taken to ensure proper firmware is loaded on both
the User Interface and BMS cards. If the User Interface and BMS cards have different software bundles
loaded on them, the system will fail to operate correctly and will require a firmware update to match.

For more details on the firmware update procedure, contact Profire Energy.

6.2 DECOMMISSIONING
When decommissioning the system, the appliance should be safely shut down (i.e. all safety outputs are
turned off and there are no gas leaks on site). Once the appliance is in a safe state, the power should be
disconnected from the PF2200. All cards should be treated like any other piece of electronics (e.g. be sent to
a recycling depot).

6.3 USEFUL LIFE

The useful life of the PF2200 is 10 years. Prior to the expiry of that period the customer should contact
Profire Energy for a suitable replacement.

6.4 MANUFACTURER NOTIFICATION

Any detected failures that compromise the functional safety of the system should be reported to Profire
Energy immediately. Please contact Profire Energy customer service.

DOC-001043 / v5.2
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 UNITED STATES CANADA

1.801.796.5127 1.780.960.5278

321 South, 1250 West Suite 1 9671 – 283 Street

Lindon, UT 84042, USA Acheson, Alberta T7X 6J5, Canada

support@profireenergy.com support@profireenergy.com

DOC-001043 / v5.2
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7 DOCUMENT REVISION HISTORY
Version
Number Date Description of Changes
v1 JUL-23-2019 Initial Release
v2 AUG-12-2019 • Modified Flame Presence/Absence threshold in section 2.3.1 to -
2.54V
• Added a sentence in section 7.3 specifying the PF2200-SB is a
Type B product
• Revamped alarm descriptions in Appendix A for Alarm Codes
v3 NOV-05-2019 • Modified SIL-related information in section 7.1 of Appendix B
• Added recommendation to reference DC power to Earth Ground
(Section 3.3.3)
• Modified Open, Short, Out of Range, Stale Data and Ambient
Temp Alarm times to 6s (Appendix A)
• Added Process Setpoint Adjust Unit Configuration Error alarm
(Appendix A)
• Updated Section 2.1.2.9 to include Flow
• Updated firmware release to SB 1.2.1
• Updated Menu Maps
v4 DEC-02-2019 • Added Electrical Noise section (3.3.4)
• Updated Certification and Approvals (2.4)
v5 APR-01-2020 • Rebranded Document
• Process Setpoint Adjust and Appliance Firing Rate can be set to
either Auxiliary Input 1 or 2 (2.1.2.16)
• Updated Flame Diagnostics to be consistent with SB 1.2.3 release
(4.3.4.3)
• Updated Level Alarms to read Level/Flow (Appendix A)
• Revamped Section 4.3: added settings description table and
removed wire map
• Updated ESD alarm time in Appendix B to be 1s (was 600ms)
• Changed power rating in 3.1.3.2 to Class 2 circuit (as per CSA
certification requirement)
• Updated system screen diagnostics
• Updated Steel Enclosure Image
• Updated the Front panel image
• Updated requested changes due to testing.
• Updated section 3.1.3.2 to add verbiage to support Class 2 Circuit
below table.
V6 • Removed Firmware Update section (as per request of CSA)

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DOC-001043 / v5.2
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8 APPENDIX A: ALARM CODES & RESPONSE TIMES
The following is a complete list of all Alarms the PF2200-SB can generate. Note: the following list has been
generated for the SB 1.3 bundle package.
# Description
1 Proof of Closure Contact Open
2 ESD Contact Open
3 Pressure Out of Range
4 Low Pressure
5 High Pressure 4-20
6 High Pressure Out of Range
7 High Pressure Contact
8 Pressure Configuration Error
Proof of Light Off Out of
9 •
Range
Failed to Prove Light Off
10
Position
11 Level/Flow Out of Range
12 Low Level/Flow
13 High Level/Flow
14 Level Configuration Error
15 Aux In 1 Contact Open
16 Aux In 1 Out of Range
DOC-001043 / v5.2
Alarm Condition Set Time
POC input is open AND Safety Shut Off Valve(s) de-energized 2s
ESD input is open 1s
Pressure Input In 4-20 mode:
• Input is less than 3 mA OR
• Input is greater than 21 mA 1s
Pressure Input In Digital mode:
• Input is not outside valid range [1]
Pressure Input In 4-20 mode:
• Input is less than Pressure Low Trip setting
2s
Pressure Input In Digital mode:
• Input is open
Pressure input in 4-20 mode:
• Input is greater than Pressure High Trip AND Safety Shut Off Valve(s) are
energized 2s
Pressure input in Digital mode:
• This alarm cannot be set
High Pressure input is not within valid range [1] 1s
High Pressure input is open 2s
Pressure High Trip setting is less than Pressure Low Trip plus Pressure Deadband OR
0
Pressure Span Max is less than Pressure Span Min
Proof of Light Off Input In 4-20 mode:
• Input is less than 3 mA OR
Input is greater than 21 mA 1s
Pressure Input In Digital mode:
• Input is not within a valid range [1]
Light off position not proven during the Main Light Off state. 0
Level Input In 4-20 mode:
• Input is less than 3 mA OR
• Input is greater than 21 mA 1s
Level Input In Digital mode:
• Input is not within a valid range [1]
Level Input In 4-20 mode:
• Input is less than Level Low Trip setting
2s
Level Input In Digital mode:
• Input is open
Level input in 4-20 mode:
• Input is greater than Level High Trip
2s
Level input in Digital mode:
• This alarm cannot be set
Level High Trip setting is less than Level Low Trip plus Level Deadband OR
0
Level Span Max less than Level Span Min
Aux In 1 input in 4-20 mode:
• This alarm cannot be set
2s
Aux In 1 input in Digital mode:
• Input is open
Aux In 1 Input In 4-20 mode:
• Input is less than 3 mA OR
• Input is greater than 21 mA 1s
Aux In 1 Input In Digital mode:
• Input is not within a valid range [1]
83
 # Description Alarm Condition Set Time
Aux In 1 Input In 4-20 mode:
• Input is less than Aux In 1 Low Trip setting
17 Aux In 1 Low Trip 2s
Aux In 1 Input In Digital mode:
• This alarm cannot be set
Aux In 1 Input In 4-20 mode:
• Input is greater than Aux In 1 High Trip setting
18 Aux In 1 High Trip 2s
Aux In 1 Input In Digital mode:
• This alarm cannot be set
Aux In 1 Input In 4-20 mode:
• Firing Rate Enable is Disabled AND Input High Trip less than Input Low Trip plus
Input Deadband
OR
• Firing Rate Enable is Enabled AND Process Control Mode is not set to Staged
Heating
OR
19 Aux In 1 Configuration Error 0
• Input Span Max less than Input Span Min
OR
• Input High Trip greater than Input Span Max
OR
• Input Low Trip less than Input Span Min
Aux In 1 Input In Digital mode:
• Firing Rate Enable is Enabled
Aux In 2 input in 4-20 mode:
• This alarm cannot be set
20 Aux In 2 Contact Open 2s
Aux In 2 input in Digital mode:
• Input is open
Aux In 2 Input In 4-20 mode:
• Input is less than 3 mA OR
21 Aux In 2 Out of Range • Input is greater than 21 mA 1s
Aux In 2 Input In Digital mode:
• Input is not within a valid range [1]
Aux In 2 Input In 4-20 mode:
• Input is less than Aux In 2 Low Trip setting
22 Aux In 2 Low Trip 2s
Aux In 2 Input In Digital mode:
• This alarm cannot be set
Aux In 2 Input In 4-20 mode:
• Input is greater than Aux In 2 High Trip setting
23 Aux In 2 High Trip 2s
Aux In 2 Input In Digital mode:
• This alarm cannot be set
Aux In 2 Input In 4-20 mode:
• Process Setpoint Adjust is Disabled AND Input High Trip less than Input Low Trip
plus Input Deadband
OR
• Input Span Max less than Input Span Min
24 Aux In 2 Configuration Error OR 0
• Input High Trip greater than Input Span Max
OR
• Input Low Trip less than Input Span Min
Aux In 2 Input In Digital mode:
• Process Setpoint Adjust is Enabled
Process Setpoint Adjust
25 Process Setpoint Adjust is using a temperature that is not set up for Process Control. 0
Configuration Error
26 Bath High Temp ESD Bath Temperature Input is greater than High Temp ESD setpoint 2s
27 Bath Temp Mismatch Bath Temperature Input 1 does not match Bath Temperature Input 2 2s

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 # Description Alarm Condition Set Time
Bath Temperature Input settings are configured incorrectly with respect to one another,
mainly:
• Pilot Off setpoint less than Main Off Or Process setpoints
OR
Bath Temp Configuration
28 • High Temp setpoint less than Main Off OR Pilot Off OR Process setpoints 0
Range Error
OR
• Low Temp setpoint greater than Process Setpoint
OR
• High Temp out of range
29 Bath 1 Sensor Open Bath Temperature Input 1 sensor has an open circuit 6s
Bath Temperature Input 1 in RTD Mode:
• Input is measuring a short circuit
30 Bath 1 Sensor Short 6s
Bath Temperature Input 1 in Thermocouple Mode:
• This alarm cannot be set
Bath Temperature Input 1 in RTD Mode:
• Input is measuring outside of the valid range for RTD
31 Bath 1 Out of Range 6s
Bath Temperature Input 1 in Thermocouple Mode:
• Input is measuring outside of the valid range for Thermocouple
32 Bath 1 Stale Data Bath Temperature Input 1 is not reading valid data 6s
33 Bath 2 Sensor Open Bath Temperature Input 2 sensor has an open circuit 6s
Bath Temperature Input 2 in RTD Mode: 6s
• Input is measuring a short circuit
34 Bath 2 Sensor Short
Bath Temperature Input 2 in Thermocouple Mode:
• This alarm cannot be set
Bath Temperature Input 2 in RTD Mode: 6s
• Input is measuring outside of the valid range for RTD
35 Bath 2 Out of Range
Bath Temperature Input 2 in Thermocouple Mode:
• Input is measuring outside of the valid range for Thermocouple
36 Bath 2 Stale Data Bath Temperature Input 2 is not reading valid data 6s
37 Outlet High Temp ESD Outlet Temperature Input is greater than High Temp ESD setpoint 2s
Outlet Temperature Input settings are configured incorrectly with respect to one another,
mainly:
• Pilot Off setpoint less than Main Off Or Process setpoints
OR
Outlet Temp Configuration
38 • High Temp setpoint less than Main Off OR Pilot Off OR Process setpoints 0
Range Error
OR
• Low Temp setpoint greater than Process Setpoint
OR
• High Temp out of range
39 Outlet Sensor Open Outlet Temperature Input sensor has an open circuit 6s
Outlet Temperature Input in RTD Mode: 6s
• Input is measuring a short circuit
40 Outlet Sensor Short
Outlet Temperature Input in Thermocouple Mode:
• This alarm cannot be set
Outlet Temperature Input in RTD Mode: 6s
• Input is measuring outside of the valid range for RTD
41 Outlet Out of Range
Outlet Temperature Input in Thermocouple Mode:
• Input is measuring outside of the valid range for Thermocouple
42 Outlet Stale Data Outlet Temperature Input is not reading valid data 6s
43 Stack High Temp ESD Stack Temperature Input is greater than High Temp ESD setpoint 2s
Stack Temperature Input settings are configured incorrectly with respect to sensor type,
mainly:
• Pilot Off less than Main Off
Stack Temp Configuration
44 OR 0
Range Error
• High Temp Less than Main Off
OR
• High Temp Less than Pilot Off
45 Stack Sensor Open Stack Temperature Input sensor has an open circuit 6s

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 # Description Alarm Condition Set Time
Stack Temperature Input in RTD Mode: 6s
• Input is measuring a short circuit
46 Stack Sensor Short
Stack Temperature Input in Thermocouple Mode:
• This alarm cannot be set
Stack Temperature Input in RTD Mode: 6s
• Input is measuring outside of the valid range for RTD
47 Stack Out of Range
Stack Temperature Input in Thermocouple Mode:
• Input is measuring outside of the valid range for Thermocouple
48 Stack Stale Data Stack Temperature Input is not reading valid data 6s
49 Aux High Temp ESD Aux Temp Input is greater than High Temp ESD setpoint 2s
Aux Temp Input:
50 Aux Temp Out of Range • Less than 3 mA OR 1s
• Greater than 21 mA
Aux Temp Input settings are configured incorrectly with respect to one another, mainly
• Pilot Off less than Main Off
Aux Temp Configuration OR
51 0
Range Error • High Temp Less than Main Off
OR
• High Temp Less than Pilot Off
52 Ambient Temp Mismatch Ambient Temperature Measurement mismatch between sensors. [2] 6s
53 Ambient Temp 1 Invalid Ambient Temperature sensor 1 on BMS card is reporting an invalid reading. 6s
54 Ambient Temp 2 Invalid Ambient Temperature sensor 2 on BMS card is reporting an invalid reading. 6s
55 No Process Temp None of Bath, Outlet, or Aux temp are configured to be in Process Control mode 0
56 Pilot 1 Flame Fail Pilot 1 has lost flame and/or failed to re-light 0
57 Pilot 2 Flame Fail Pilot 2 has lost flame and/or failed to re-light 0
Pilot 1 Flame Detected While
58 Flame has been detected on Pilot 1 input before Ignition 0
Off
Pilot 2 Flame Detected While
59 Flame has been detected on Pilot 2 input before Ignition 0
Off
Flame 1 Load Monitor Check AC voltage on Pilot 1 input too low to reliably detect flame.
60 2s
Failure Note: Usually caused by loading of the flame rod to ground.
Flame 2 Load Monitor Check AC voltage on Pilot 2 input too low to reliably detect flame.
61 2s
Failure Note: Usually caused by loading of the flame rod to ground.
62 Pilot ADC Start Fault BMS Card fault associated with internal ADC. [2] 2s
63 Pilot ADC Read Fault BMS Card fault associated with internal ADC. [2] 2s
64 Pilot ADC Stop Fault BMS Card fault associated with internal ADC. [2] 2s
65 Flame 1 Voltage Fault Pilot Flame 1 flame test failure. [2] 2s
66 Flame 2 Voltage Fault Pilot Flame 2 flame test failure. [2] 2s
System Voltage Input is less than Low Voltage Threshold: 2s
67 Low Voltage • In 12V Mode: 9.5V
• In 24V Mode: 19.0V
System Voltage Input is greater than High Voltage Threshold: 2s
68 High Voltage • In 12V Mode: 16.8V
• In 24V Mode: 33.6V
69 System ADC Start Fault BMS Card fault associated with internal ADC. [2] 2s
70 System ADC Read Fault BMS Card fault associated with internal ADC. [2] 2s
71 System ADC Stop Fault BMS Card fault associated with internal ADC. [2] 2s
72 Incomplete Commissioning The commissioning setting is set to Incomplete. 0
73 NOT USED
One or more Settings / Status register(s) do not agree between primary and secondary
74 Cross Compare Failure processors. 2s
Note: the event log will call out which register(s) have failed the cross comparison.
75 External Switch Stuck External switch input is stuck in the Ignite position. 4.5s
76 External Switch Invalid External switch input is in an invalid position. 0
77 User Stop via External Switch External switch input is in the off position. 0
78 User Stop via Interface The BMS card received a stop command from the UI or remote modbus device. 0

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 # Description Alarm Condition Set Time
79 NOT USED
Settings have been corrupted and cannot be verified.
80 Settings CRC Failed 0
Note: a settings reset is usually required.
The primary and secondary processors of the BMS card disagree on the process control
81 State Mismatch 0.8s
state.
82 Pressure I2C Bus Fault Diagnostic detection of communication bus issue related to the Pressure input. 2s
83 High Pressure I2C Bus Fault Diagnostic detection of communication bus issue related to the High Pressure input. 2s
84 Proof of Light Off I2C Bus Fault Diagnostic detection of communication bus issue related to the Proof of Light Off input. 2s
85 Level I2C Bus Fault Diagnostic detection of communication bus issue related to the Level input. 2s
86 Aux Temp I2C Bus Fault Diagnostic detection of communication bus issue related to the Aux Temp input. 2s
87 Aux In 1 I2C Bus Fault Diagnostic detection of communication bus issue related to the Aux 1 input. 2s
88 Aux In 2 I2C Bus Fault Diagnostic detection of communication bus issue related to the Aux 2 input. 2s
89 Pilot 1 I2C Bus Fault Diagnostic detection of communication bus issue related to the Pilot 1 output. 2s
90 Pilot 2 I2C Bus Fault Diagnostic detection of communication bus issue related to the Pilot 2 output. 2s
91 SSV1 I2C Bus Fault Diagnostic detection of communication bus issue related to the SSV1 output. 2s
92 SSV2 I2C Bus Fault Diagnostic detection of communication bus issue related to the SSV2 output. 2s
93 High Fire I2C Bus Fault Diagnostic detection of communication bus issue related to the High Fire output. 2s
System Voltage Current I2C 2s
94 Diagnostic detection of communication bus issue related to the System Voltage input.
Bus Fault
95 IO Short Switch Run Fault BMS Card fault associated with Ignition switch. 1.5s
96 IO Short Switch Ignition Fault BMS Card fault associated with Ignition switch. 1.5s
97 IO Short Start Fault BMS Card fault associated with Start input. 1.5s
98 IO Short POC Fault BMS Card fault associated with PoC input. 1.5s
99 Reserved
100 Reserved
101 IO Short ESD Fault BMS Card fault associated with ESD input. 1.5s
102 Analog Output 1 Fault BMS Card fault associated with Level Echo output. 2s
103 Analog Output 2 Fault BMS Card fault associated with Temperature Echo output. 2s
104 Analog Output 3 Fault BMS Card fault associated with TCV output. 2s
BMS card fault associated with reading last shutdown code and/or relights remaining
105 Flash Failed To Read 0
status from non-volatile memory.
BMS card fault associated with writing last shutdown code and/or relights remaining status
106 Flash Failed To Write 0
to non-volatile memory.
107 Descriptor Failure BMS card fault associated with failing to load board identification information. 0
BMS card board identification information does not match software that has been
108 Descriptor Mismatch 0
programmed.
109 Pilot 1 Output Voltage Fault Valve is de-energized and measured voltage on the (+) terminal is greater than 5V. 10s
110 Pilot 2 Output Voltage Fault Valve is de-energized and measured voltage on the (+) terminal is greater than 5V. 10s
111 SSV1 Output Voltage Fault Valve is de-energized and measured voltage on the (+) terminal is greater than 5V. 10s
112 SSV2 Output Voltage Fault Valve is de-energized and measured voltage on the (+) terminal is greater than 5V. 10s
113 Start Contact Out of Range Input is not within a valid range [1] 2s
114 POC Contact Out of Range Input is not within a valid range [1] 2s
115 ESD Contact Out of Range Input is not within a valid range [1] 2s
116 Reserved
117 Reserved
118 Reserved
119 Digital Input ADC Start Fault BMS Card fault associated with internal ADC. [2] 2s
120 Digital Input ADC Read Fault BMS Card fault associated with internal ADC. [2] 2s
121 Digital Input ADC Stop Fault BMS Card fault associated with internal ADC. [2] 2s
The primary and secondary processors of the BMS card disagree on the state of the Safety
122 Safety Output Mismatch 2s
Outputs.
123 Processor Reset Primary and/or secondary processor(s) of the BMS have reset due to a lock-up. 0
124 Calibration CRC Failed Periodic Calibration CRC check has failed 0

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 # Description Alarm Condition Set Time
Brownout Reset Voltage
125 BMS card has been programmed with the incorrect brownout reset voltage. [2] 0
Incorrect
126 Flame 1 DC Input Open BMS card internal circuit fault associated with Pilot 1 flame input. [2] 2s
127 Flame 2 DC Input Open BMS card internal circuit fault associated with Pilot 2 flame input. [2] 2s
128 Factory Calibration Error BMS card calibration descriptor error. [2] 0
Process Setpoint Adjust Unit
129 Process Setpoint Adjust Input units are not valid (i.e. not set to a valid Temperature Unit) 0
Configuration Error
130 System Voltage Mismatch INA226 system voltage is NOT within 2V of ADC reading Default
[1] This fault can occur in one of two scenarios: a negative voltage is present on the Signal In terminal OR the BMS card has been compromised

[2] This fault usually occurs when the BMS card has been compromised

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9 APPENDIX B: FUNCTIONAL SAFETY DESIGN PF2200-SB
The PF2200 Single Burner controller is a product which:

• Interfaces / actuates one fuel train

• Monitors / maintains up to two independent flames
• Monitors tertiary I/O (e.g. level, pressure, flow, etc.)
• Monitors / maintains process temperature
It is intended to be used with the following sensors / final elements:

Sensors

• Temperature sensors (RTDs, Thermocouples, 4-20mA Transmitters)

• Pressure switch / transmitter
• Level switch / transmitter
• Emergency Shut-Down switch
• Flame rod(s) for ionization flame detection
• Proof of Closure switch for proving safety shut-off valve position
• Proof of Light-Off switch / transmitter for proving light off position
• Start / Stop Switch
Final Elements

• Safety Shut-off Valves for Fuel Flow Control

• Ignition Coil for sparking
The following diagram is an example of the PF2200-SB safety system integrated with sensors / final elements:

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 Pilot 1
Switch ESD
To Pilot
Nozzle 1
Pilot 2

To Pilot
Dual Nozzle 2
Temp Bath SSV
SSV
Sensor
To Main
Nozzle
Switch
To Igniter
/ PLC Start Coil 1
Rod
Output

External
Ignition Switch Start / Stop Coil 2 To Igniter
Switch Rod

Switch PF2200 Single Pilot 1 Ion To Flame

Pressure
/ TRx Burner BMS Rod
[Logic Solver]

Switch To Flame
Level Pilot 2 Ion
/ TRx Rod

Switch
Switch PoC POLO
/ TRx

Switch Temp
Aux In Aux Temp
/ TRx TRx

Where:
Switch Pressure High = Enabled During Commissioning

= Always Enab led

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9.1 SAFETY vs NON-SAFETY I/O
The PF2200 supports the following interfaces for safety-related functionality

o Pilot and Main Valve Outputs (Pilot 1&2, SSV)

o Ignition Outputs (Coil 1&2)
o Flame Detection Inputs (Ion)
o External Start/Stop Switch
o ESD Input
o Pressure Input
o Level Input
o Dual-Element Bath Temperature Input
o Proof of Closure Input
o Remote Start Input
o High Pressure Input
o Proof of Main Light Off Input
o 4-20mA Temperature Input
o Auxiliary Inputs (Aux In 1 & 2)
The PF2200 Single Burner BMS supports the following interfaces for non-safety certified functionality

o 4-20mA Temperature Control Valve (TCV) Output

o 4-20mA Auxiliary Output (Aux Out 1 & 2)
o Status Relay Output
o Stack And Outlet Temperature Inputs
o High Fire Valve Output
o Modbus I/O
o USB Port

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9.2 SAFETY FUNCTIONS
The PF2200 Single Burner BMS monitors and controls a burner using a pre-defined operating sequence. This
operating sequence includes controlling gas valves and ignition coils while continually monitoring flame
presence and interlock inputs. In the event of a loss of flame, the system will proceed to de-energize the gas
flow means with the user-configurable option of re-lighting. If the pre-defined operating sequence fails due
to an alarm, the system will proceed to lockout and requires a user action before continuing. The following is
a list of safety functions, associated timing and demand modes:

Safety Function / Event Associated Timing Demand

Mode
ESD Contact Open to Powered Outputs De-energized 1.0 seconds Low
Pilot 1 Flame Loss to Powered Outputs De-energized 4 seconds Low
Pilot 2 Flame Loss to Powered Outputs De-energized 4 seconds Low
Start Input Contact Open to Powered Outputs De-energized 1 second Low
External Switch Stop Input to Powered Outputs De-energized 1 second Low
Bath Temperature High Temp ESD to Powered Outputs De-energized 3 seconds Low
Outlet Temperature High Temp ESD to Powered Outputs De- 2 seconds Low
energized
Stack Temperature High Temp ESD to Powered Outputs De- 2 seconds Low
energized
Aux Temperature High Temp ESD to Powered Outputs De-energized 3 seconds Low
High Pressure Event to Powered Outputs De-energized 2 seconds Low
Low Pressure Event to Powered Outputs De-energized Low Pressure Delay Low
Time*
High Level Event to Powered Outputs De-energized Level Delay Time* Low
Low Level Event to Powered Outputs De-energized Level Delay Time* Low
PoC Open event to Powered Outputs De-energized 2 seconds Low
PoL Open event to Powered Outputs De-energized 60 seconds ** Low
Aux In 1 high/low trip event to Powered Outputs De-energized 2 seconds Low
Aux In 2 high/low trip event to Powered Outputs De-energized 2 seconds Low
*: Configurable setting, adjustable during commissioning
**: Proof of Light off input is monitored in a 60 second window, if the input is not satisfied during this time the
system will shut down

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The above alarm response times are the maximum response times of the PF2200-SB as a logic solver only.
To understand the impact of these response times on the SIF Process Safety Time, the full safety function
must be analyzed. For example, a simple safety function consists of an ESD switch connected to the ESD
input and solenoid(s) connected to the Pilot & SSV outputs. To understand the SIF Process Safety time, all
three elements must be analyzed as follows:

𝑇𝑃 = 𝑇𝐸𝑆𝐷 + 𝑇𝐿𝑂𝐺𝐼𝐶 + 𝑇𝑆𝑂𝐿𝐸𝑁𝑂𝐼𝐷

Where,

TP = total process safety time

TESD = response time of the switch element
TLOGIC = response time of the logic solver for this respective safety function (0.6 seconds in this case)
TSOLENOID = response time of the solenoid to actuate

9.3 SAFETY INTEGRITY

The PF2200-SB has been designed and certified to meet functional safety standards according to IEC 61508
Parts 1 through 3. This section is intended to provide safety-related product information related to the
aforementioned standard.

9.3.1 SYSTEMATIC CAPABILITY

The PF2200-SB has met manufacturer design process requirements of SIL 2. These requirements are
intended to assure sufficient integrity against systematic errors of design by Profire Energy. A SIF designed
with this product must not be used at a SIL level higher than SIL 2 without “prior use” justification by the end
user or use of diverse technology redundancy in the SIF design.

9.3.2 RANDOM CAPABILITY

The PF2200-SB is a Type B product, meaning the product is deemed a “Complex” element (using micro
controllers). Based on a Safe Fail Fraction (SFF) between 90% and 99%, when the PF2200-SWB is used non-
redundantly, it can be used in a SIL 2 application @ HFT=0. Note that the SFF must be calculated based on
the physical configuration of the product (i.e. including required sensors and final elements in the
calculation).

9.3.3 RATE of DEMAND

The PF2200-SB has been certified for use in low demand applications.

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9.3.4 HARDWARE VERSIONS
The latest version(s) of hardware for the PF2200 Single Burner BMS are as follows:

Card Name Hardware Version

PF2200-SB Single Burner Controller v2.3
PF2200 User Interface v3.2

9.3.5 SOFTWARE VERSIONS

The latest version of software for the PF2200 Single Burner BMS is SB 1.3.1. See the PF2200-SB Software
Release notes for detailed changes associated with this and previous versions of software.

9.3.6 SAFETY PARAMETERS

The following failure rates of the PF2200 safety function(s) are derived using a Site Safety Index of 2 (SSI=2).
An SSI of 2 assumes that: repairs are usually correctly performed, testing is done correctly and mostly on
schedule, most equipment is replaced before end of useful life, etc. Please contact Profire Energy if failure
rates are desired for different Site Safety Indices.

Component λSD λSU λDD λDU N/E

Common to all components 292 57 225 51 555
Temperature Input (RTD Mode) 0 0 7 0.01 8
Temperature Input (Thermocouple Mode) 0 0 7 0.1 8
Digital Input (ESD, Start, PoC) 0.14 5 0 1 5
Configurable Input (Pressure, Level, Aux In 1&2, Aux Temp, 31 0.3 11 0.15 34
POLO)
Flame Detection Input (Ion 1&2) 13.4 0.24 0 0.24 5.13
Ignition Output (Coil 1&2) 0 1 55 2 50
Powered Output (Pilot 1&2, SSV) 50 0.3 16 0.16 28
Where:

λSD = Fail Safe Detected

λSU = Fail Safe Undetected
λDD = Fail Dangerous Detected
λDU = Fail Dangerous Undetected
N/E = No Effect Failures

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9.3.6.1 EVALUATING a SAFETY FUNCTION
The Safety Parameters in the above table provide a synopsis of the failure rates in the PF2200 Single Burner
BMS from a component perspective. In order to utilize the parameters in a safety function, the safety
function must first be identified and the associated failure rates must be formulated together.

Note: the following examples only concern the logic solver (PF2200) failure rates. For a complete analysis, the
failure rates of the endpoints (actuators / sensors) must also be taken into consideration).

Example 1) A Safety Function must exist which turns off both the pilot and main gas valves when the system
detects there is no flame present while running. It is also desired that this Safety Function ensures that Ignition
does not happen out of sequence.

The first step in evaluating the Safety Function is to identify the PF2200 components that are needed. In this
example, the following components are utilized:

• Common: whenever a safety function is utilized in the PF2200, the common component must be
included
• Flame Detection Input (Ion 1)
• Powered Output (Pilot 1 and SSV)
• Ignition Output (Coil 1)
The failure rate of the resultant Safety Function is a summation of all its corresponding pieces, i.e.)

𝜆 = 𝜆𝐶𝑜𝑚𝑚𝑜𝑛 + 𝜆𝐼𝑜𝑛1 + 𝜆𝑃𝑖𝑙𝑜𝑡1 + 𝜆𝑆𝑆𝑉 + 𝜆𝐶𝑜𝑖𝑙1

The resultant calculations are as follows:

𝜆𝑆𝐷 = 292 + 13.4 + 50 + 50 + 0 = 405.4 𝐹𝐼𝑇

𝜆𝑆𝑈 = 57 + 0.24 + 0.3 + 0.3 + 1 = 58.84 𝐹𝐼𝑇

𝜆𝐷𝐷 = 225 + 0 + 16 + 16 + 55 = 312 𝐹𝐼𝑇

𝜆𝐷𝑈 = 51 + 0.24 + 0.16 + 0.16 + 2 = 53.56 𝐹𝐼𝑇

(𝜆𝑆𝐷 + 𝜆𝑆𝑈 + 𝜆𝐷𝐷 ) 405.4 + 58.84 + 312
𝑆𝐹𝐹 = = = 93.5%
(𝜆𝑆𝐷 + 𝜆𝑆𝑈 + 𝜆𝐷𝐷 + 𝜆𝐷𝑈 ) 405.4 + 58.84 + 312 + 53.56

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Example 2) A Safety Function must exist which turns off Pilot 1, SSV and Coil 1 outputs if the ESD input is de-
energized OR if the Temperature Input (RTD) reports a high temperature OR if the Pressure Input reports a high
pressure.

Same as Example 1, we first must identify the PF2200 components that are needed:

• Common: whenever a safety function is utilized in the PF2200, the common component must be
included
• Temperature Input (RTD)
• Configurable Input (Pressure)
• Digital Input (ESD)
• Powered Output (Pilot 1 and SSV)
• Ignition Output (Coil 1)
Calculations will now flow the same way as Example 1:

𝜆 = 𝜆𝐶𝑜𝑚𝑚𝑜𝑛 + 𝜆𝑅𝑇𝐷 + 𝜆𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 + 𝜆𝑃𝑖𝑙𝑜𝑡1 + 𝜆𝑆𝑆𝑉 + 𝜆𝐶𝑜𝑖𝑙1

𝜆𝑆𝐷 = 292 + 0 + 31 + 0.14 + 50 + 50 + 0 = 423.14 𝐹𝐼𝑇

𝜆𝑆𝑈 = 57 + 0 + 0.3 + 5 + 0.3 + 0.3 + 1 = 63.9 𝐹𝐼𝑇

𝜆𝐷𝐷 = 225 + 7 + 11 + 0 + 16 + 16 + 55 = 330 𝐹𝐼𝑇

𝜆𝐷𝑈 = 51 + 0.01 + 0.15 + 1 + 0.16 + 0.16 + 2 = 54.48 𝐹𝐼𝑇

(𝜆𝑆𝐷 + 𝜆𝑆𝑈 + 𝜆𝐷𝐷 ) 423.14 + 63.9 + 330
𝑆𝐹𝐹 = = = 93.7%
(𝜆𝑆𝐷 + 𝜆𝑆𝑈 + 𝜆𝐷𝐷 + 𝜆𝐷𝑈 ) 423.14 + 63.9 + 330 + 54.48

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9.3.7 SUGGESTED PROOF TEST
The following is a suggested Proof Test for the PF2200-SB:

1. Bypass the safety function and take appropriate action to avoid a false trip.
2. Retrieve any diagnostic and take appropriate action.
3. Get the system into a fired state (e.g. with flame present and being monitored by the PF2200)
4. Remove the flame and confirm all PF2200-SB safety critical outputs (main valve, pilot valve, and coil
outputs) have become de-energized and a manual reset is required to return to normal operation.
5. For any other safety functions involving sensor signals (e.g. ESD, Temperature, Pressure, Level, etc.)
repeat steps 3 and 4, but by tripping the sensor signal instead of removing flame.
6. Inspect the PF2200 for any visible damage or contamination
7. Remove the bypass and otherwise restore normal operation
The above suggested proof test yields the following Proof Test Coverage:

Component λDUPT PTC

Common to all components 36 29%
Temperature Input (RTD Mode) 0.01 0%
Temperature Input (Thermocouple Mode) 0.1 0%
Digital Input (ESD, Start, PoC) 0.15 99%
Configurable Input (Pressure, Level, Aux In 1&2, Aux Temp, POLO) 0.01 0%
Flame Detection Input (Ion 1&2) 0.24 0%
Ignition Output (Coil 1&2) 1 47%
Powered Output (Pilot 1&2, SSV) 0.16 0%
Where: λDUPT = Dangerous undetected failure rate after performing the recommended proof test0

9.3.8 DIAGNOSTIC TEST INTERVAL

The diagnostic test interval of the PF2200 Single Burner BMS is 10s.

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