ProFire PF3100 FARC Manuel utilisateur

FARC User Guide

DOC-001065 v8.0

PF3100 FARC User Guide

DOC-001065 v8.0

855.PRO.FIRE | [email protected]

CONTENTS

1IMPORTANT SAFETY INFORMATION......................................................................................3

2DOCUMENT SCOPE ..................................................................................................................4

Applicable Firmware Versions .......................................................................................................................................... 4

Additional Documentation ................................................................................................................................................4

3HARDWARE REQUIREMENTS...................................................................................................5

PF3100 Components..........................................................................................................................................................5

Peripheral Equipment Requirements ..............................................................................................................................6

4INSTALLATION .........................................................................................................................7

5FARC AND O2TRIM TERMINOLOGY .......................................................................................8

FARC Channels ....................................................................................................................................................................8

FARC Table ..................................................................................................................................................................................... 8

Leading vs. Lagging Channels...................................................................................................................................................... 9

Channel Limitations ...................................................................................................................................................................... 9

O2 Trim .............................................................................................................................................................................. 10

Table Configuration .................................................................................................................................................................... 10

O2Sensor Warmup ..................................................................................................................................................................... 11

O2 Trim PI Controller...................................................................................................................................................................11

Operating Sequence........................................................................................................................................................ 12

Position Monitoring......................................................................................................................................................... 13

Cross Limiting................................................................................................................................................................... 13

System Firing Rate vs. Effective Firing Rate..............................................................................................................................13

Flat Line Tolerance ......................................................................................................................................................................13

Cross Limiting Examples ............................................................................................................................................................14

6COMMISSIONING...................................................................................................................16

FARC Configuration Procedure ...................................................................................................................................... 16

Create and Assign FARC Inputs and Outputs...........................................................................................................................16

Configure General FARC settings .............................................................................................................................................. 17

Calibrate Outputs........................................................................................................................................................................19

Tune System for stable Pilot Light Off ......................................................................................................................................20

Configure FARC Table at the Light Off Firing Rate................................................................................................................... 21

Configure FARC Table at the Minimum Firing Rate.................................................................................................................21

Configure FARC Table at the Maximum Firing Rate ................................................................................................................ 22

Configure Fuel Channel across Entire Table ............................................................................................................................ 23

Tune the FARC Table Between 5% and 95% ............................................................................................................................ 23

Validate FARC Table ....................................................................................................................................................................24

O2TRIM Configuration Procedure................................................................................................................................. 25

Set O2 Trim Parameters ..............................................................................................................................................................25

7TROUBLESHOOTING ..............................................................................................................26

8CANADIAN FIELD APPROVAL REQUIREMENTS....................................................................28

9VERSION HISTORY .................................................................................................................31

PF3100 FARC User Guide

DOC-001065 v8.0

855.PRO.FIRE | PROFIREENERGY.COM

1IMPORTANT SAFETY INFORMATION

Warning: Do not disconnect power, open enclosures, or otherwise service the product unless area is

known to be non-hazardous.

Warning: Installation and modification shall not be performed while the system is energized.

Disconnect power source prior to connecting devices or modifying wiring.

Warning:

System settings and appliance configuration details must only be modified by qualified

personnel familiar with the both the appliance under PF3100 control and related plant processes that

could be affected.

Warning: Do not bypass any of the safety

functions or modify any of the internal circuitry of the system.

Doing so can lead to death, serious injury, electrocution, property damage, product damage and/or

government fines

The configuration examples provided in this guide are for demonstration purposes only and do not necessarily represent

safe or reliable configurations. Installation, commissioning and tuning of a FARC system must be performed by a qualified

technician with experience in commissioning and tuning forced draft positioning-type FARC systems in accordance with

local safety codes, design documentation and appliance manufacturer specifications. Regular maintenance should be

performed on the system to verify tuning and system operation.

PF3100 FARC User Guide

DOC-001065 v8.0

855.PRO.FIRE | PROFIREENERGY.COM

2DOCUMENT SCOPE

The Profire PF3100 combustion control system can be configured to operate as a parallel positioning fuel-air ratio

control (FARC) system for forced draft applications requiring up to five control channels (fuel, air, and up to three

auxiliary channels). The system allows specific output positions to be configured for each channel at 5% firing rate

intervals across the entire operating range of the appliance. Channel feedback inputs are constantly monitored to

ensure accurate positioning and outputs are adjusted to maintain precise ratio control in relation to all configured

FARC channels. The system also supports single channel O2Trim to maintain desired stack oxygen readings and

increase appliance efficiency. Desired stack oxygen levels can also be configured at 5% firing rate intervals across

the entire operating range of the appliance.

This user guide contains a general overview of the PF3100 FARC system features, commissioning procedures and

operation.

APPLICABLE FIRMWARE VERSIONS

The information provided in this document applies only to PF3100 systems configured for FARC applications

running NA-43 firmware.

ADDITIONAL DOCUMENTATION

This document outlines information specific to FARC applications only. Visit the Profire Documentation Website to

access additional PF3100 documentation.

PF3100 FARC User Guide

DOC-001065 v8.0

855.PRO.FIRE | PROFIREENERGY.COM

3HARDWARE REQUIREMENTS

The following sections specify the PF3100 components and peripheral equipment required to commission a FARC

system with a PF3100. The items listed below do not include standard fuel train components required in accordance

with local safety codes and heater manufacturer specifications.

PF3100 COMPONENTS

At a minimum, A PF3100 system configured for FARC applications must include: one PF3100-00 User Interface card,

one PF3101-00 BMS Controller card, one PF3102-00 Ion Pilot card, one PF3103-00 Temperature card and one

PF3113-00 I/O Expansion card. This will accommodate a single pilot FARC system controlling fuel and air position

and up to 2 additional I/O Expansion inputs.

Additional Network cards, Pilot cards, temperature cards, and I/O Expansion cards can be added as required to

accommodate more complex FARC applications in accordance with the diagram below:

User Interface (UI)

card

Modbus card

PFRN Contro ller Network

Use for applications that do not require

Modbus functionality

Use for applications that require Modbus

functionality

BMS card

C D

Netw ork card(s)

Pilot card 4Pilot card 1

Temperature

card 1

Temperature

card 5

I/O Expansion

card 1

I/O Expansion

card 5

Connect up to 4 Pilot car ds per

controller

Connect up to 5 Temperature cards

per controller

Connect up to 5 I/O Expansion

cards per controller

PFRN I/O Network

CUse for controllers that require no

more than 4 I/O cards

DUse for controllers that require more

than 4 I/O cards

Required

Hardware

Optional

Hardware

Netw ork

Configuration

Options

PF3100 FARC User Guide

DOC-001065 v8.0

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PERIPHERAL EQUIPMENT REQUIREMENTS

The following peripheral equipment is required to satisfy the input and output requirements of a PF3100 FARC

system:

Item Input Requirements Output Requirements Application Requirements

Fuel Gas Control Valve

Position must be

controlled by a 4-20mA

input signal.

Current position must be

represented by a 4-20mA

position feedback signal.

Required for all FARC

applications

Air damper or VFD

blower

Position/speed must be

controlled by a 4-20mA

input signal.

Current position/speed

must be represented by a

4-20mA position feedback

signal

Required for all FARC

applications

Auxiliary FARC channel

actuator

Position must be

controlled by a 4-20mA

input signal.

Current position must be

represented by a 4-20mA

position feedback signal

only if the channel is to be

used for cross limiting.

Required for FARC

application with control

channels beyond Fuel and

Air.

Proof of Airflow device N/A Must be an airflow switch

or 4-20mA transmitter.

Required for all FARC

applications

Oxygen sensor N/A Must be a 4-20mA

transmitter.

Required for FARC

applications utilizing

PF3100 O2trim

functionality.

Additional safety

interlocks and sensors N/A

Can be switches or 4-

20mA transmitters and

can be configured as

alarms, waits, warnings or

main permissives.

Can be added as required

in accordance with local

safety codes and heater

manufacturer

specifications.

PF3100 FARC User Guide

DOC-001065 v8.0

855.PRO.FIRE | PROFIREENERGY.COM

4INSTALLATION

The diagram below shows the expected configuration for all FARC inputs and outputs only. Refer to the PF3100

Product Manual for detailed installation instructions and wiring diagrams. Note that a single I/O Expansion card is

required for basic FARC applications, but a network card and additional I/O Expansion cards are required for

multichannel FARC applications or those requiring additional instrumentation.

Gree n

Ora ng e

Power

CAT 5/6

Link

1 L EL IN -

2 L EL IN +

3 VALVE -

4 VALVE +

5 MA IN IO N +

LEL

COIL

MAI N

PI LO T

FAU LT

v2.2

ION+ EGND --COI L+

6 7 8 9

PF3102-00 Io n Pilot Module

PF3102-00

XX: 00: 00 :0 0: XX :XX

139750

2021-12-31

v2.2.x

Gree n

Ora ng e

Pwr

9 – PFR N IO B us

Link

PF3103-00

XX: 00: 00 :0 0: XX :X X

139750

2021-12-31

v1.4.x

TC1A

TC1B

TC2A

TC1B

Faul t

Red

TC1A

Red

TC1B

PF3103-00

TC Temp. Module

v1 .x

PF3106-00

XX00 -00 00 -XX XX

139750

2021-12-31

v2.1.x

Reset

Gree n

Ora ng e

Por t 1

Pwr

Link

Gree n

Ora ng e

Por t 2

Pwr

Link

Gree n

Ora ng e

Por t 3

Pwr

Link

Gree n

Ora ng e

Por t 4

Pwr

Link

Gree n

Ora ng e

Por t 5

Pwr

Link

6. 3A

Fus e S pare

PF3106-00

Net work Sw itch M odule

v2 .x

12-24 VDC

+ Vin -

1 2 3

Gree n

Ora ng e

Pwr

Link

PF3113-00

XX: 00: 00 :0 0: XX :XX

139750

2021-12-31

v2.0.x

6 7 8 9 10 11 12 13 14 15 16 17 18 19

6 7 8 9 10

PWR O ut

Signal In

Signal Out

Input 1

11 12 13

PWR O ut

Signal In

Signal Out

Input 2

14 15 16

PWR O ut

Signal In

Signal Out

Input 3

17 18 19

PWR O ut

Signal In

Signal Out

Input 4

GND R etu rn

Signal Out

4-20 mA

Ou t

Signal Out T ermination

Gro u nd

Floatin g

Input #

1 2 3 4

12V

24V

PWR Ou t

Mode

20 - P FRN

PF3113-00

IO Expansion Card

V2. 0

SPS T 120 VAC / DC, 80mA max

Eart h GND

N .O . D ry

Contact

Ou t

N .C. D r y

Contact

Ou t

Reset

Gree n

Ora ng e

Pwr

Link

PF3113-00

XX: 00: 00 :0 0: XX :XX

139750

2021-12-31

v2.0.x

678 9 10 11 12 13 14 15 16 17 18 19

6 7 8 9 10

PWR O ut

Signal In

Signal Out

Input 1

11 12 13

PWR O ut

Signal In

Signal Out

Input 2

14 15 16

PWR O ut

Signal In

Signal Out

Input 3

17 18 19

PWR O ut

Signal In

Signal Out

Input 4

GND R etu rn

Signal Out

4-20 mA

Ou t

Signal Out T ermination

Gro u nd

Floatin g

Input #

1 2 3 4

12V

24V

PWR Ou t

Mode

20 - P FRN

PF3113-00

IO Expansion Card

V2. 0

SPS T 120 VAC / DC, 80mA max

Eart h GND

N .O . D ry

Contact

Ou t

N .C. D r y

Contact

Ou t

Reset

Gree n

Ora ng e

Pwr

Link

PF3113-00

XX: 00: 00 :0 0: XX :XX

139750

2021-12-31

v2.0.x

6 7 8 9 10 11 12 13 14 15 16 17 18 19

6 7 8 9 10

PWR O ut

Signal In

Signal Out

Input 1

11 12 13

PWR O ut

Signal In

Signal Out

Input 2

14 15 16

PWR O ut

Signal In

Signal Out

Input 3

17 18 19

PWR O ut

Signal In

Signal Out

Input 4

GND R etu rn

Signal Out

4-20 mA

Ou t

Signal Out T ermination

Gro u nd

Floatin g

Input #

1 2 3 4

12V

24V

PWR Ou t

Mode

20 - P FRN

PF3113-00

IO Expansion Card

V2. 0

SPS T 120 VAC / DC, 80mA max

Eart h GND

N .O . D ry

Contact

Ou t

N .C. D r y

Contact

Ou t

Reset

Gree n

Ora ng e

Pwr

Link

PF3113-00

XX: 00: 00 :0 0: XX :X X

139750

2021-12-31

v2.0.x

6 7 8 9 10 11 12 13 14 15 16 17 18 19

6 7 8 9 10

PWR O ut

Signal In

Signal Out

Input 1

11 12 13

PWR O ut

Signal In

Signal Out

Input 2

14 15 16

PWR O ut

Signal In

Signal Out

Input 3

17 18 19

PWR O ut

Signal In

Signal Out

Input 4

GND R etu rn

Signal Out

4-20 mA

Ou t

Signal Out T ermination

Gro u nd

Floatin g

Input #

1 2 3 4

12V

24V

PWR Ou t

Mode

20 - P FRN

PF3113-00

IO Expansion Card

V2. 0

SPS T 120 VAC / DC, 80mA max

Eart h GND

N .O . D ry

Contact

Ou t

N .C. D r y

Contact

Ou t

Reset

12-24 VDC

Common

Ea rth GN D

HFV-

HF V+

SSV2+

SSV2-

SSV1+

SSV1-

Pilot+

Pilot-

Aux Out-

Aux Out+

Start-

Start+

ESD-

ESD +

POC-

POC+

Aux In-

Aux In+

Pressure-

Pressure+

Leve l-

Leve l+

4-20mA / D ry

Contact Inputs

Dry Contact Input s Powe red Outp uts Relay Output

Power Input

4-20mA 12/24V

STATUS

SPST

80m A

120VAC/

120VDC

MAX

PF3101-00

XX: 00: 00 :0 0: XX :XX

139750

2021-12-31

v1.3.x

PF3101-00

BMS Con t rol le r

V1.3

RunIgniteOn

PFRN IO Network

PFRN Controller Network

33 – Ignition

Sw it ch

35 – License Key

34 - Keypad

Push Ta bs

To Remove Key

Spare Fu se

10A

Fuse

123679 811 1013 12141516172223 1819202124252627 5 4

Gree n

Ora ng e

Pwr

Link

Gree n

Ora ng e

Pwr

Link

Gree n

Ora ng e

Pwr

Link

Gree n

Ora ng e

Pwr

Link

Gree n

Ora ng e

Pwr

Link

28 29 30 31 32

To UI Card

Network Card Pilot Card Temperature

Card

I/O Expansion 1 I/O Expansion 2 I/O Expansion 3 I/O Expansion 4

BMS Card

3 2 4 11B 56 7 8910

1211A 1

# Input/Output Signal Type PF3100 Card /

Terminal

1 Fuel actuator output 4-20mA output BMS /

Aux Out

2 Fuel position feedback input 4-20mA input Any I/O Expansion card /

Any available input

3 Air actuator output 4-20mA output I/O Expansion 1 /

-20mA Out

4 Air position feedback input 4-20mA input Any I/O Expansion card /

Any available input

5 Aux 1 channel output 4-20mA output I/O Expansion 2 /

-20mA Out

6 Aux 1 channel feedback input 4-20mA input Any I/O Expansion card /

Any available input

7 Aux 2 channel output 4-20mA output I/O Expansion 3

-20mA Out

8 Aux 2 channel feedback input 4-20mA input Any I/O Expansion card /

Any available input

9 Aux 3 channel output 4-20mA output I/O Expansion 4 /

-20mA Out

10 Aux 3 channel feedback input 4-20mA input Any I/O Expansion card /

Any available input

11A Proof of Airflow input Option 1 Digital input BMS /

Aux In

11B Proof of Airflow input Option 2 Digital or 4-20mA input Any I/O Expansion card /

Any available input

12 Oxygen sensor input 4-20mA input Any I/O Expansion card /

Any available input

PF3100 FARC User Guide

DOC-001065 v8.0

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5FARC AND O2TRIM TERMINOLOGY

FARC CHANNELS

A FARC channel is a controller output for which precise position control is required over the operating range of an

appliance.

FARC TABLE

The FARC Table specifies the output positions of each FARC channel at 5% firing rate intervals across the operating

range of the appliance (21 configurable points for each channel). Each column represents a specific firing rate for

the system and each row specifies the corresponding channel output position required at that firing rate.

Table View

Curve View

MANUAL MODE

The Manual Mode setting on the FARC Status Screen must be enabled to make any changes to the FARC Table.

Manual Mode holds the system firing rate at the configured Manual Firing Rate setting during the Process Control

state and must only be enabled during commissioning. A warning is displayed on the Alerts Screen when Manual

Mode is enabled – ensure that Manual Mode is disabled when commissioning is complete.

ADJUSTING POINTS

Use and to incrementally adjust a configured point or press to access the numerical entry dialog.

ADDING POINTS

Press on an unconfigured point to activate its FARC Table column.

REMOVING POINTS

Press on a configured point to de-activate its FARC Table column. Configured points in the deleted column are

removed and replaced with interpolated values.

INTERPOLATION

Configured columns are shown in black, while unconfigured columns are shown in gray. A FARC Table with a single

configured column remains flat (i.e., Every point in the table row matches the value in the configured column).

Unconfigured points between configured points are linearly interpolated and treated as configured points.

PF3100 FARC User Guide

DOC-001065 v8.0

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CURVE SWITCHING

The system allows for two separate FARC curves to be configured to account for varying demand profiles. The

curves can be switched by configuring the Selected Curve setting in the FARC/O2Trim Wizard or the FARC status

screen. Note: If the Selected Curve setting is changed while the system is in a main fuel state the system remains

running but first transitions out of the main fuel state to reinitiate the light off sequence with the new curve

configuration.

LEADING VS. LAGGING CHANNELS

Leading channels are those that can increase above their expected positions without creating a dangerous fuel

mixture. For this reason, leading channels always move before lagging channels upon firing rate increase and after

lagging channels upon firing rate decrease ensuring that the leading channels are always in excess while

transitioning. The air channel is a leading FARC channel, the fuel channel is a lagging FARC channel, and auxiliary

channels can be configured as (1) leading, (2) lagging, or (3) neither.

CHANNEL LIMITATIONS

The curves for the fuel and air channels must not have any sections with a negative slope. The curves for leading

or lagging auxiliary channels must have no inflection points. Auxiliary channels configured as neither a leading nor

lagging channel have no slope and inflection point limitations.

Acceptable Cross Limited Auxiliary

Channel Curves

Unacceptable Cross Limited

Auxiliary Channel Curves

PF3100 FARC User Guide

DOC-001065 v8.0

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O2 TRIM

O2 Trim is designed to fine-tune either the fuel or air channel output to maintain appliance efficiency across a variety

of environmental conditions without having to recommission the FARC Table.

TABLE CONFIGURATION

The Manual Mode setting on the O2 Trim Status Screen must be enabled to make any changes to the O2Trim curves.

Manual Mode holds both (1) the system firing rate at the configured Manual Firing Rate setting and (2) the Trim

Offset at the configured Manual Offset setting during the Process Control state and must only be enabled during

commissioning. A warning is displayed on the Alerts Screen when Manual Mode is enabled – ensure that Manual

Mode is disabled when commissioning is complete.

TARGET O2CURVE

The Target O2curve specifies the optimal stack O2reading in 5% firing rate intervals across the entire operating

range of the appliance. The Target O2 values must be configured between the High and Low O2 setpoints – they are

displayed on the Target O2curve when in curve view. An O2reading below the Low Setpoint results in a Lockout,

while an O2reading above the High Setpoint displays a warning on the Alerts Screen but has no effect on system

operation. (Note: The lower boundary of the Target O2Trim curve is the higher of the configured Low O2 Setpoint

and 0.5%)

High O

Setpoint

Low O

Setpoint

Target O

MAX/MIN TRIM CURVE (OFFSET CURVE)

The Max/Min Trim curve specifies the maximum and minimum offset percentage that can be applied to a FARC

channel output (up to a maximum of +10% and a minimum of -10% as specified by the configured Trim Channel

setting on the O2Trim Tab of the FARC/O2Trim Wizard) while trimming. The current applied O2Offset is displayed

on the Status Screen (e.g., A displayed O2Offset of -3.5% means the system has decreased the trimmed channel

output 3.5% below its configured FARC Table value).

2 x

Max Offset

Min Offset

Trimmed FARC Channel

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