PF 3100 ION PILOT CARD PRO.FIRE

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1 PF 3100 ION PILOT CARD PRO.FIRE 1

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3 TABLE OF CONTENTS PF3100 ION PILOT CARD INFORMATION GUIDE INTRODUCTION Functional Description System Requirements HARDWARE Card Specifications Card Diagram Terminal Specifications Terminal Descriptions Enclosure Specifications Enclosure Diagram Enclosure Ports CONTROLS AND DIAGNOSTICS Ports LEDs and Buttons Important Safety Information APPENDIX A: NETWORK TERMINOLOGY All content is subject to copyright and may not be reproduced in any form without the express written consent of the author Profire Energy. All rights reserved. All the information described in this document is as is, without warranty of any kind and is published in good faith and for general information purposes only. Profire does not make any guarantees about the completeness, reliability and accuracy of this information. Profire may make changes in this manual or in the product(s) described in this manual at any time. Contact your Profire Sales representative for questions, comments or further assistance PRO.FIRE DOC A 3

4 INTRODUCTION 1.1 Functional Description The PF3100 Ion Pilot card is used to generate a spark to ignite a pilot burner and to detect the flame of both a pilot and main burner. This card is powered through the PFRN network via a Controller class or Network class card (typically a BMS Controller card or a Network Switch Card). 1.2 System Requirements Specific system requirements will vary according to which Controller class card is connected to the Ion Pilot card. For additional information, refer to the Hardware Guide corresponding to the Controller type card (e.g., BMS Controller card) specific to your application. IGNITION COIL WIRING The Ion Pilot card is usually sold in a Class I, Div 1 / Zone 1 explosion proof enclosure (EPX) which also includes an ignition coil. This allows the ignition and flame monitoring to be located close to the associated burner which reduces the need for long ignition wires. Internal Ignition Coil Ignition Wire 10 Ignition Rod Ion + Coil + Coil - Red White Black WIRE REQUIREMENTS WIRE LOCATION CONNECTION DESCRIPTION WIRE TYPE AND MIN GAUGE MAX LENGTH 5 Board to Main Flame Detect Rod 10 Coil to Pilot Ignition Rod 7 mm ignition wire 7 Board to Burner 14 AWG 6 Board to Pilot Flame Detect (Dual Rod Pilot only) 7 mm ignition wire Each wire should be limited to 25 ft maximum 7 mm ignition wire 4

5 SINGLE VS DUAL ROD PILOT WIRING Use the single rod pilot configuration when using a single rod for flame detection and pilot ignition. Use the dual rod configuration when using two separate rods for pilot ignition and flame detection. Single Rod Pilot Coil { + EGND Ion Ignition Coil 10 Straight Silicone Boot Ferrule Pilot Ignition and Flame Detect Rod Main Ion + 5 Straight Silicone Boot Ferrule Main Flame Detect Rod Dual Rod Pilot Coil { + EGND Ion Ignition Coil 10 Straight Silicone Boot Ferrule Pilot Ignition Rod Straight Silicone Boot Ferrule Pilot Flame Detect Rod Main Ion + 5 Straight Silicone Boot Ferrule Main Flame Detect Rod 5

6 HARDWARE 2.1 Card Specifications TYPE Model Number PFRN Class PFRN Power PFRN Ports Voltage Input Inputs Outputs SPECIFICATIONS PF IO Power Consumer 1 PFRN IO Network Port Powered via PFRN Power: EGND LEL In, Main Ion, Pilot Ion Pilot Valve, Coil 2.2 Card Diagram 6

7 2.3 Terminal Specifications This table provides connection details and a brief description of each terminal. TERMINAL EXPECTED CONNECTIONS INPUT/OUTPUT SAFETY RATED Main Ion + Connect to main flame rod. Flame Ionization Input Yes Ion + Coil + Coil - For a Dual Rod configuration, connect to the pilot flame rod. For a Single Rod configuration, connect to the Ion+ Terminal of the coil (red wire). Connect to the primary winding of the ignition coil. (white wire) Connect to the primary winding of the ignition coil. (black wire) Flame Ionization Input Coil Drive Output LEL In + Connect to an external LEL 12/24 VDC Power Output Yes LEL In - sensor (4-20 ma or Dry). Digital / 4-20 ma Input Yes Valve + Valve - Connect to Pilot Valve terminal 1. Connect to Pilot Valve terminal 2. Do not connect to ground. Powered Output EGND Earth Ground Ground N/A Yes Yes Yes Yes Yes 2.4 Terminal Descriptions MAIN ION, PILOT ION Connect each of these inputs to a Kanthal flame rod placed directly in the pilot/main flame. The pilot and main nozzles must be grounded for the flame detection to function properly. These inputs are protected from high voltage and can be connected in series with the high voltage terminals of an external ignition coil, allowing a single flame-rod to be used for both pilot ignition and pilot flame detection. A 65 VAC signal is applied to the flame rod. The source impedance is very high so there is no danger of sparking during detection. COIL The primary of the ignition coil should be connected to these terminals. A 12 V pulsed DC signal is applied by the card to the coil. This output is protected by a 250 ma thermal fuse. LEL IN This input can be connected to an optional LEL sensor to detect explosive gas concentrations in the burner housing. The input can be configured in software to be disabled, to require an LEL switch, or to require an LEL 4-20 ma transmitter. The system will not start if the contact is open or the 4-20 ma LEL input is above the trip point. 7

8 VALVE Solenoid valves must be connected between the + and - terminals. The negative terminal is not directly connected to ground. This output is driven by 12 V and will only work with 12 V valves. EGND This terminal must be connected to the same ground as the pilot and main burner assemblies. Modules come pre-wired with a connection to the enclosure ground lug. 2.5 Enclosure Specifications The Ion Pilot card is mounted in the EPX enclosure. SPECIFICATIONS Dimensions EPX ENCLOSURE Top Width 11.7 cm (4.61 in) Base Width 16.8 cm (6.63 in) Height 21.7 cm (8.53 in) Depth 13.3 cm (5.25 in) Hazloc Rating Class I, Div 1, GRP BCD, Type 4X; Class I, Zone 1, AEx d IIB + H2 T6 Gb; Ex db IIB+H2 T6 Gb, IECEx Mounting Enclosure Construction Channel Bar or Direct Mount Aluminum Operating Temperature -40 C to 60 C Storage Temperature -40 C to 60 C Standards: Complies with IEC :2011, 6th Edition and IEC :2014, 7th Edition 8

9 2.6 Enclosure Diagram Enclosure options compatible with this card include the EPX enclosure. Port 3 Port 4 (not shown) Port 2 Port 1 All ports are ¾-14 NPT and must have appropriate pipe fittings or plugs installed. A minimum of 5 threads must be engaged in each port to maintain Div 1 / Zone 1 ratings. 9

10 CONTROLS AND DIAGNOSTICS The following is a list of all of the user interface items on the Ion Pilot card. 3.1 Ports PFRN PORTS 1 PFRN IO Network Port This port is classified as an IO class port and is also the port through which the card is powered. See the Card Diagram for the port location. 3.2 LEDs and Buttons POWER LED A Power LED is located next to the PFRN port indicating whether the port is receiving power from the network. INDICATION COLOR STATE Off - Port is not powered On Blue Port is powered LINK LED A link LED is located next to the PFRN port indicating traffic on the PFRN port. INDICATION COLOR STATE Off - PFRN network is not available On Green PFRN network is ready for communication Blinking Green Indicates that network traffic is going through the link FAULT LED ERRORS* A bank of Fault LEDs corresponds to the state of a specific input or output as noted below. INPUT/OUTPUT COLOR ERROR Pilot Red Wiring error. Reporting as open, grounded, etc. Main Red Wiring error. Reporting as open, grounded, etc. Coil Red Fault in ignition. LEL Red Fault in LEL wiring / signaling. *If one of these lines is not required for the application and is left unused, a fault will be present but the system will still be functional. 10

11 3.3 Important Safety Information Before installing the PF3100 Ion Pilot card, 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. WARNING: EXPLOSION HAZARD Do not disconnect while circuit is live unless area is known to be non-hazardous or equivalent. Substitution of components may impair suitability for specified zones. Do not service unless area is known to be non-hazardous. Do not open enclosure while energized. Installation and use must conform to the provided installation instructions. System must be properly connected to earth-ground for effective operation of flame detection circuitry. Electrical devices connected to the controller must meet certain electrical standards and be within voltage limits. INSTALLATION WARNINGS Failure to properly ground the pilot assembly back to the PF3100 Ion Pilot Module s EGND terminal may result in accidental electric shock, product damage, failure to ignite the pilot, or failure to detect flame. The PF3100 Ion Pilot Module generates 20 kv - 40 kv at the high voltage output terminal of the ignition coil which can cause cardiac arrest. Do not touch or place any object near the ignition coil s high voltage terminal or connected ignition wire while the product is operating. Even without making physical contact with the terminal, it is possible to draw a spark from several inches away, especially if the pilot bracket is not properly grounded. Make sure that the enclosures are securely closed each time after opening. To properly close the enclosure, the lid must be fully threaded on and the set screw tightened. This protects the internal circuitry from moisture damage and other environmental concerns. Moisture damage is not covered by the product warranty. To properly close the enclosure, the lid must be fully threaded on and the set screw tightened. 11

12 Do not drill holes in or otherwise modify the EPX enclosure. Any such modifications will compromise suitability for Class I, Div 1/Zone 1. The flame rods are not intended to be installed and mounted in a Class I, Division 1 or Division 2 hazardous location. Routing and installation of the flame rods shall be in accordance with the Canadian Electrical Code or National Electrical Code as per local requirements. Unused 3/4 NPT conduit ports must be plugged using appropriately rated pipe plugs in order to maintain the Div 1 / Zone 1 rating of the enclosure. Refer to the Canadian Electrical Code or National Electrical Code as applicable. APPENDIX A: NETWORK TERMINOLOGY The following terms are used to explain the network operations: Interface Class Card - Any PF3100 card that provides a control or monitoring interface to a user or remote PLC. Examples include the User Interface card and the Modbus card. Controller Class Card - Any PF3100 card that provides safety control for a specific application. Examples include the BMS Controller card and Combustor Controller card. Network Class Card - Any PF3100 card that provides multiple network ports so that additional cards may be connected together on the PFRN network. Examples include the Network Switch card, Modbus card, and the BMS Controller card. IO Class Card - Any PF3100 card that provides input and output terminals for control and monitoring. Examples include the Ion Pilot card and the Thermocouple card. PFRN - Profire Reliability Network. A proprietary safety network developed by Profire which can also be used to distribute power. The PFRN has two sub-networks: the Controller Network and the IO Network. Controller Network - A sub-network of PFRN Interface class and Controller class cards talk to each other on this network. There is usually only one of these networks in an installation. IO Network - A sub-network of PFRN IO class card talk to a single Controller class card. There is one of these networks for each Controller class card in the system. 12

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