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PPC-6001 - Fireye Inc.

1. N VERTICAL FLUE TOP VIEW PROBE MOUNTED ON SIDE SECTION ON E E nad eere i PREFERRED MOUNTING PROBE MOUNTED ON SIDE FLUE AS 4 E SECTION T ON D D 4 4 2 lt ___ PROBE MOUNT HOLES SHOWN F L_ Wy SEE HG220371 ee GAS GAS FLUE EE 2 RE Ll J PROBE MOUNT HOLES SHOWN MJ SIDE VIEW 30 SEE HG220371 HOLE ORIENTATION SECTION ONG SECTION ON F F RELATIVE TO FLUE GAS FLOW TOP VIEW PROBE MOUNT HOLES SEE HG220371 SECTION ON A A NOTE ORIENTATION RELATIVE TO FEUEGASTEON UNACCEPTABLE MOUNTING ZA Ll SIDE VIEW HORIZONTAL FLUE FLUE gt PROBE MOUNTED UNDERNEATH XZ B B t Z Ee _ 7 SN 1 E ape NON PREFERRED MOUNTING BL HORIZONTAL FLUE 2 PROBE MOUNTED ON Seas DO NOT FIT PROBE IN THIS POSITION SECTION ON B B SIDE VIEW There are two types of flange available see the drawing over the page With either flange the vertical center line of the flange shown on the drawing should correspond to the gas flow direction 6 stainless steel M6 x 20mm socket cap screws are provided for probe attachment The probe flange temperature must be maintained at the temperature of the flue wall by repacking or adding lagging which may h
2. Terminal Number Location Function Voltage Range PR7 Display Unit Relay output 3 common 0 250V PR8 Display Unit Relay output 3 normally closed 0 250V PR9 Display Unit Relay output 3 normally open 0 250V PR10 Display Unit Relay output 9 common TSD104 0 250V only PR11 Display Unit Relay output 9 normally closed 0 250V TSD104 only PR12 Display Unit Relay output 9 normally open 0 250V TSD104 only PT1 Display Unit 24Vac Suppl 24 40Vac PT2 Display Unit 24Vac Suppl 24 40Vac PT3 Display Unit CAN 0 5V PT4 Display Unit CAN 0 5V STUD Display Unit Screen connection Not applicable PZ1 Daughter Board Channel 1 output 4 20m4A 0 20V PZ2 Daughter Board Channel 1 output 4 20mA 0 20V PZ3 Daughter Board Channel 2 output 4 20mA 0 20V PZ4 Daughter Board Channel 2 output 4 20mA 0 20V PZ5 Daughter Board Channel 3 output 4 20mA 0 20V PZ6 Daughter Board Channel 3 output 4 20mA 0 20V PZ7 Daughter Board Encoder proximity counter 0 12V Feedback 1 PZ8 Daughter Board Encoder Supply 12Vdc PZ9 Daughter Board Encoder proximity counter 0 12V Feedback 2 PZ10 Daughter Board Encoder Supply 12Vdc PZ11 Daughter Board Encoder Feedback 3 0 12V PZ12 Daughter Board Channel 1 Feedback 4 20mA 0 5Vdc 213 Daughter Channel 1 amp Channel 2 0
3. d A A oO DIO l3 ok l ce LB o O O1 o a d repe S NNOO my Option 35 0 Inlet temperature sensor serial number LV3 2 Each CANbus device connected to the system has unique serial number allocated to it during production testing This number cannot be changed and is used to uniquely identify each device When the system is in commissioning mode the serial number of all the connected devices is read by the PPC6000 and displayed as a list to allow the selection of the relevant serial number unit to be made Scrolling the list in an upward direction will scroll through all temperature sensor options available until 0 nothing is displayed Enter this value to disconnect the specified device from any hardware Scrolling the list downward direction will stop when the currently selected item is displayed and the value will stop flashing The display will show type information for each device present such as air temp but the commissioning engineer should be aware of which serial number device is being used for which function 02 EB Options 35 1 to 35 4 Hydrocarbon ratios of each fuel respectively 0 00 9 99 LV3 If a display of calculated burner efficiency or automatic trim commissioning is required the hydrocarbon ratios for the required fuels must be entered These may be set b
4. Z gt ve 4 z 2 SIDE VIEW a ow a E W E o Eb CASE MATERIAL CORROSION RESISTING STEEL 3 u FINISH SELF uz 02 ata rs TOTAL ASSEMBLY WEIGHTS MODEL NXO2PKA 2 95kg 6 516 25 PROBE T c o Y UN MODEL NXO2PK6 3 40kg 7 516 gt PROBE 9 s Wa MODEL 2 4 24kg 9 416 E LUE TG o CUSTOMER uu INTERNAL 0 CONNECTIONS A CONNECTIONS HEATER o e HEATER e TO MOUNT ON FLAT WALL FLUES STACKS SEE DRG No HG220371E PART TO MOUNT ON CYLINDRICAL WALL FLUES SEE DRG No HG220371E PART B COMPONENT SIDE VIEW OF INTERNAL FLUE FOR PROBE MOUNTING POSITIONS SEE DRG HG220559E ELECTRICAL INTERCONNECTION PCB GAS ALL DIMENSIONS IN MILLIMETRES NOTE 02 CONNECTED TO PROBE BODY ie GROUND INCH EQUIVALENTS ARE IN 22 my The probe must be mounted in a manner that ensures that the flue gases pass into the gas tube at its open end and out of the tube at the flange end Furthermore if possible the flange should be vertical with the gas tube angled downwards to ensure that particulates do not build up within the sample tube Probe mounting with the flange horizontal is acceptable Inverted probe mounting is not acceptable 2 243 Mounting the oxygen probe P dius FTN VERTICAL FLUE TOPVI
5. NA e d 178 8 INXDBVSD 217 218 Low voltage 50V AC DC 200m 17 9 Available on NXTSD104 display ONLY PR10 Common PR11 Normally Closed PR12 Normally Open Option 18 1 to 18 4 Low Voltage Fail safe Alarm Lockout Inputs 0 460 LV3 These functions are all fail safe and may be used to lockout or shutdown the burner The fault number generated always relates directly to the input that caused the fault by going open circuit Thus F1 references input 1 F4 references input 4 The lockout functions themselves are activated by putting a number into option parameters 18 1 to 18 4 for inputs 1 to 4 The number is a one two or three digit number defined as follows zero gives no function 91 Gary NOTE In order to enable any Digital Input a value greater than 0 MUST be entered in one of the three columns HUNDREDS TENS fault type fuel type 0 This alarm will lockout the 0 or 1 Fault will be active for burner and shows on the display any fuel selection including as FXX Manual intervention no fuel selected at all fault mute is required to restart the burner once the fault condition has cleared The burner will lockout within one second UNITS burner status type 0 or 1 Fault will be active regardless of the current burner status i e all the time 2 Fault will be active after the fan has started the air pressure switch has made and the driv
6. SIDE VIEW in NC CASE MATERIAL CORROSION RESISTING STEEL FINISH SELF TOTAL ASSEMBLY WEIGHTS MODEL NXO2PKA 2 95kg 6 516 i MODEL NXO2PK6 _ 3 40kg 7 5lb MODEL 2 4 24kg 9 416 ER SEE DIM A N TO MOUNT ON CYLINDRICAL WALL FLUES SEE DRG No HG220371E PART B FOR PROBE MOUNTING POSITIONS SEE DRG HG220559E TO MOUNT ON FLAT WALL FLUES STACKS SEE DRG No HG220371E PART FLUE GAS ALL DIMENSIONS IN MILLIMETRES INCH EQUIVALENTS ARE IN 160 CLEARANCE REQUIRED TO amp e Os A 2 a m gt 5 CALIBRATION GAS CONNECTION 3 l 5 02 o PROBE T C o 3 PROBE T C 910 CUSTOMER INTERNAL RET S CONNECTIONS aj CONNECTIONS HEATER o HEATER COMPONENT SIDE VIEW OF INTERNAL ELECTRICAL INTERCONNECTION PCB NOTE 02 CONNECTED TO PROBE BODY ie GROUND Cary The probe must be mounted in a manner that ensures that the flue gases pass into the gas tube at its open end and out of the tube at the flange end Furthermore if possible the flange should be vertical with the gas tube angled downwards to ensure that particulates do not build up within the sample tube Probe mounting with the flange horizontal is acceptable Inverted probe mounting is not acceptable C gt 2
7. 1 3 7 Linking and uploading your program In order to upload the program to the Fireye PPC6000 or NX6100 control Fireye s Comfire 2 version 2 0 or above must be running on your PC For a complete description of Comfire 2 capabilities refer to Fireye bulletin NEX 1502 Before uploading it may be a good idea to save the project file Click on the top toolbar or choose File Save project from the menu 192 Cary If Fireye Comfire 2 is not already running on your system start it up You can do this from the A Start menu You ll find it under programs Comfire 2 After Comfire 2 starts it should see the units connected to it if it has been connected Click the Scan Units button The unit address should be the same as that used for your program Switching back to abacus ensure that the schematic page is open and selected click within the schematic and choose Project program Link schematics from the menu Abacus will now open all the schematic pages in your project that contain programs for the same unit as the current schematic page one in this case When the compile link process has finished almost immediately in this case this message will appear telling you how much memory see Program size limits has been used Click Yes to send the program to the control or No if this was just a dry run NOTE THE CONTROL MUST BE IN FULL COMMISSION MODE TO ACCEPT PROGRAM UPLOAD Abacus
8. 60 C 20 to 140 F ENSORS FOR PPC6000 PXMS 15 Steam Pressure Sensor 0 15 PSI 0 1 bar 4 20mA output 1 2 NPT non elf check for use with PPC6000 PXMS 200 Steam Pressure Sensor 0 200 PSI 0 14 bar 4 20mA output 1 2 NPT non elf check for use with PPC6000 PXMS 300 Steam Pressure Sensor 0 300 PSI 0 21 bar 4 20mA output 1 2 NPT non elf check for use with PPC6000 BLPS 15 Steam Pressure Sensor 0 15 PSI 0 1 bar 4 20mA output 1 2 NPT non self check for use with PPC5000 PPC6000 NX3100 NX4100 NX6100 BLPS 30 Steam Pressure Sensor 0 30 PSI 0 1 bar 4 20mA output 1 2 NPT non self check for use with PPC5000 PPC6000 NX3100 NX4100 NX6100 BLPS 200 Steam Pressure Sensor 0 200 PSI 0 14 bar 4 20mA output 1 2 NPT non self check for use with PPC5000 PPC6000 NX3100 NX4100 NX6100 Bsao Pressure Sensor 0 300 PSI 0 21 bar 4 20mA output 1 2 NPT non self check for use with PPC5000 PPC6000 NX3100 NX4100 NX6100 emperature Sensor Range 32 F 350 F 0 176 C 4 20mA linear TS350 2 4 8 output includes 1 2 14 NPT well See bulletin BLZPTS 1 for complete description emperature Sensor Range 32 F 752 F 0 400 C 4 20mA linear TS752 2 4 8 output includes 1 2 14 NPT well See bulletin BLZPTS 1 for complete description OFTWARE NXAM ComFire communications software on CD for Nexus and PPC controls OMMUNICAT
9. Flue Limits assigned to relay 4 PPC6000 PE1 COM PE4 NO Low voltage or line voltage 5 Reserved for future expansion NA 6 R eserved for future expansion Flue Limits assigned to relay 7 Daughterboard PZ15 PZ16 MA scant BSCE LOW VOLTAGE AND CURRENT ONLY Flue Limits assigned to relay 8 Daughterboard PZ17 PZ18 LOW VOLTAGE AND CURRENT ONLY 83 E gt A relay can be used to indicate any combination of fault conditions from 14 0 14 1 and 14 2 this means that one relay could be used for all faults When used for an alarm function the relay will de energize when in the fault condition so an alarm bell would be wired in series with the normally closed contacts H IJ 15 0 Modulation sensor input type 0 3 LV3 The modulation sensor input caters for connection to a standard 0 5V 4 20mA signal or a Fireye fail safe pressure temperature sensor When using a Fireye fail safe sensor the control may be used to monitor the boiler high safety limit and perform a non volatile lockout if it is exceeded Ensure that the links on the circuit board are set to correspond with the requirements of the sensor signal being used If a 4 20mA sensor Fireye PXMSxxx is used it is still possible to set a safety limit but an external limit device must be fitted to protect the boiler Option parameter Meaning 15 0 value 0 5V operation Set the JP1 link to OUT Set the link as required This option
10. See Option 14 1 14 2 and 17 x for important details voltage Alternatively all relays may operate at the same voltage The relay functions can be set via the option parameter or via the programmable blocks See Option 17 x for important details regarding these relays 2 6 11 Fuel Select Profile Select Input Purge and Ignition Prove Outputs PPC6000 The four fuel profile select inputs are designed for operation at between 120 amp 230Vac relevant Engineer s Keys EK11 EK14 section 6 6 2 1 2 za These inputs must be connected using multi strand single core PVC insulated 16 AWG 19 0 3mm wire Since this cable is to be run adjacent to and or in the same conduit as high voltage wiring its voltage rating must exceed the maximum voltage carried by any other cable connected to the control or run in the same conduit 3 4 56 IGNITION PROVE N PURGE PROVE FUEL PROFILE 1 FUEL PROFILE 2 FUEL PROFILE 3 FUEL PROFILE 4 Note and PE8 provide purge and low fire position signals to the flame safeguard control These outputs MUST NOT have a load greater than 30mA i e relays lamp etc damage to the PPC6000 will result READ THIS FIRST There are numerous mentions of overall braided shielded screened wire throughout this manual This is an important aspect to reliable operation Table 2 6 1 A lists THE ONLY APPROVED WIRE for this control While one of the specifications r
11. 9 Link Successful Program Bytes used 34 DataBytes used 7 Send new program to unit 0 1 If the download completes with no errors your program is now installed the control as the user program There can only be one user program installed in a control When you upload your program you will overwrite any existing user program See Choosing the Running Program to make your new program the active program i e to run it 1 4 The schematic toolbar The function block toolbar can be used whenever a schematic page is open and active If you are unsure what a button does hold the mouse pointer over it and wait for the tip to come up as shown here The top section of buttons will place selected function blocks on your schematic The actual buttons shown may vary from those shown here but the idea is the same This button jd is the other block button This will open up a dialog window allowing you to select any function block from the database See Place Function blocks These line buttons are used when editing the positions of the lines that link the blocks on the screen The next link to be drawn will be in the style selected here Also you can use these to change the style of a currently selected link 193 SS T When the El button is clicked on the schematic toolbar this window will open 1 5 Place Function blocks 1 ij Choose Function Block x Close PatID 1 03 Option P
12. Be Dedicated buttons at the lower edge of the screen perform the following functions Mute Reset used to reset a burner lockout mute alarms or to test audible alarms If an alarm is present the button is yellow and the text on the button changes to Alarm Mute Burner Start Stop starts the burner grayed out if the burner is already operating Fuel allows selection of which fuel profile is to be used from a list of fuels profiles available Control used to enable selection of modulation mode Menu used to access configuration adjustment modes Overview returns screen to burner overview mode The following table shows the Icons that are displayed on the touchscreen above the information panels and their details Description Details State of CANbus Displays when CANbus communication is faulty connection State of Oxygen Interface Displays when Oxygen Interface related fault is present 64 Description Details COM Indicates commissioning Displays when the control is operating in mode commissioning mode MAN Indicates HAND Displays when the control is operating in HAND modulation mode modulation mode AUTO Indicates AUTO Displays when the control is operating in AUTO modulation mode modulation mode R Indicates Boiler Setpoint Displays Boiler setpoint selected remote local L 1 L 2 mode setpoint 1 or local setpoint 2 1 2
13. Guy This is the derivative time used in the PID control loop for setpoint 1 It may be set to any value from 0 to 999 A value of zero will disable the derivative function A non zero value will have the effect of advancing the modulation rate change caused by a constantly changing measured value by the number of seconds given A low value will have little effect a large value will cause a large effect Option 21 4 Set point 1 derivative time 0 999 seconds LV1 Derivative control is seldom needed for boilers but can improve the response of the modulation system to sudden load changes Too much can cause control instability EE option 21 5 Setpoint 1 control limit type 0 2 LV3 This option parameter defines the control limit type for setpoint 1 The control limits are used to automatically turn the burner off when it is not needed and bring it back on when it is needed Option parameter Meaning 21 5 value p No limits The burner will run until another method is used to switch it off Absolute limit The values entered in option parameters 21 6 and 21 7 are the actual limit values Deviation limit The values entered in option parameters 21 6 and 21 7 represent a deviation i e offset from the setpoint 1 control value This means that if the setpoint control value is changed the limits are automatically changed correspondingly Option 21 6 Setpoint 1 low limit control value Cut In 0 999 00 0 9
14. Option 14 0 Primary Fault Relay 0 8 LV3 DEFAULT Relay 4 PD5 This option parameter assigns the primary faults to a specific relay Relays 2 amp 3 share a common connection on the NX610 display NXTSD104 relays are independent Option parameter 14 0 Meaning Connection Details NX610 es Primary faults not assigned to relay N A NA _ _ _ _ _ O PR2 NO Low voltage or line voltage PR6 NO Low voltage or line voltage PR8 NO Low voltage or line voltage Primary faults assigned to relay 4 PPC6000 PE1 COM PE4 NO Low voltage or line voltage 5 Reserved for future expansion INA 6 eserved for future expansion aera OLTAGE AND CURRENT ONLY Sa OLTAGE AND CURRENT ONLY These relays MUST NOT be used to provide a safety function A relay can be used to indicate any combination of fault conditions from 14 0 14 1 and 14 2 this means that one relay could be used for all faults When used for an alarm function the relay will de energize when in the fault condition so an alarm bell would be wired in series with the normally closed contacts 82 Tes Option 14 1 Limit Relay 0 8 LV3 DEFAULT Relay 4 PD5 This option parameter assigns the limits to a specific relay Relays 2 amp 3 share a common connection on the NX610 display NXTSD104 relays are independent value net assigned to any relay PR2 NO Low voltage or line
15. once This will give up a digital output block Move On the toolbar click the OR gate symbol once to create an OR function block Move this to the middle of the other blocks roughly as on the example To connect the blocks together Move the mouse pointer over the output pin of the block the signal is to originate from The output pins are those which have a description shown in blue They are always on the right hand side of a block The term output pin refers to the output from this block to the next one not an output from the control itself Press and hold the left mouse button Move the mouse pointer over an input pin of the block the signal is to arrive at keeping the left mouse button pushed Release the mouse button A link should be drawn Links must always be drawn like this starting from an output finishing at an input Note Some of the blocks have a sloped top left corner and some do not These blocks require parameters 190 eS Some function blocks require parameters to be entered to work The sloped top left corner can easily identify these blocks The digital input and output blocks on the previous page are examples of this 1 3 5 Entering Parameters Double click one of the digital input blocks on the left hand side of the schematic power New schematic Block x2 DI x2 PL Comment 1 Pump 1 Fault Digital Input Number 1to12 1 The parameters window should
16. 99 9 0 00 9 99 LV1 100 Option 22 8 Maximum modulation rate 100 Option 22 9 Heserved 100 Option 23 0 Warming Enable 0 or 1 LV1 100 Option 23 1 Warming Limit 0 999 00 0 99 9 0 00 9 99 LV1 100 Option 23 2 Warming Time 0 to 999 minutes LV1 100 Options 24 x Sequencing 101 Option 24 0 Sequence Slaves number of boilers 0 3 LV1 102 Option 24 1 24 3 Priority Number s LV1 102 Option 24 4 Lead OFF Time LV1 103 Option 24 5 Lead master Boiler Select Method LV1 103 Option 24 6 lag slave On Rate 0 100 LV1 104 Option 24 7 lag slave On Delay 0 999 minutes LV1 104 Option 24 8 lag slave Off Rate 0 100 LV3 104 Option 24 9 lag slave Off Delay 0 999 minutes LV3 104 Option 25 0 Banking based on temperature water temperature standby for steam boiler LV3104 Option 25 1 Water temperature zero value LV3 105 Option 25 2 Water temperature span value LV3 105 Option 25 3 Water temperature cut in LV1 105 Option 25 4 Water temperature cut out LV1 105 Option 25 5 Temperature based warming limit LV1 105 Option 25 6 Lag wait time LV1 105 Option 28 0 Analog Input decimals 0 2 LV3 105 Option 28 1 Analog Input 1 zero 0 999 LV3 105 Option 28 2 Analog Input 1 span 0 999 LV3 105 Option 28 3 Analog Input 2 decimals 0 2 LV3 105 Option 28 4 Analog Input 2 zero 0 999 LV3 105 Option 28 5 Analog Input 2 span 0 999 LV3 105 Option 28
17. DESCRIPTION PPC 6001 OCTOBER 7 2015 PPC6000 SERIES FUEL AIR RATIO CONTROLLER The Fireye PPC6000 is a state of the art stand alone parallel positioning system for all types of liquid or gaseous fuel fired combustion systems When combined with a Fireye flame safeguard system such as the Fireye BurnerLogix control the PPC6000 offers the most compact and advanced parallel positioning system available Four fuel profiles allow the PPC6000 to accommodate a variety of applications such as two fuels with and without the optional variable speed drive VSD With each profile having up to 24 points entered to assure a smooth curve the microprocessor interpolates points between entered values and precisely positions fuel and air to within 1 degree This eliminates hysteresis for improved efficiency The PPC6000 is capable of powering up to ten 24volt servomotors supplied from the integral transformer All servomotors and displays operate on a secure CANbus communications protocol and can be daisy chained together for simplified wiring Two independent PID control loops for temperature or pressure control provide precise accurate control of firing rate for unmatched response to load changes Four safety rated user definable digital inputs are standard and can be configured for functions such as lead lag night setback thermal shock warm up etc Digital inputs can also be configured as analog inputs via the optional programmable fun
18. max error LV3 123 Option 43 0 Water level expansion unit LV3 Reserved 123 Option 43 1 Water level expansion unit LV3 Reserved 123 Option 44 0 Set real time clock 0 1 LV1 123 Option 44 1 Set Year 00 99 LV1 123 Option 44 2 Set Month 1 12 LV1 123 Option 44 3 Set Day of Month 1 31 LV1 123 Option 44 4 Set Day of Week 1 7 LV1 124 Option 44 5 Set Hours 0 23 LV1 124 Option 44 6 Set Minutes 0 59 LV1 124 Option 44 7 Set Seconds 0 59 LV1 124 Option 44 9 Reset Fault Log 0 1 LV3 124 Option 45 0 Erase Restore enable 0 1 LV3 124 Option 45 1 Erase command 0 5 LV3 125 Option 45 2 Restore command 0 999 LV3 125 5 6 Commission ratio mode 126 5 6 1 Description 126 5 6 2 Using commission ratio mode 126 5 6 3 Leaving commission ratio mode 128 5 7 Adjust ratio mode 128 5 7 1 Description 128 5 7 2 Entering adjust ratio mode 128 5 7 3 Using adjust ratio mode 129 5 7 4 Leaving adjust ratio mode 130 5 8 interrogating the software issue 130 6 Faults and fault finding 131 6 1 Thefault display 131 6 2 What to do when a fault occurs 131 6 3 Non volatile lockout 132 6 4 Fault subsets 132 6 5 Faultlisting 132 6 6 The engineer s key 139 6 6 1 Fault history 140 6 6 2 Engineer s key parameter list 140 6 7 Troubleshooting 150 6 7 1 Display General 150 6 7 2 Startup 151 6 7 3 Commissioning 151 6 7 4 Modulation 152 6 7 5 Inverters 153 6 8 YB110 TSD
19. 1 6 Moving and editing the link lines 194 11 Circuit board connections 196 11 1 Inlet Air Temperature Sensor Optional 196 11 2 PPC6000 Variable Speed Drive Daughter Board P N NXDBVSD 197 11 3 Oxygen probe connection optional Oxygen Probe Interface unit 198 11 4 PPC6000 199 10 1 Technical specification 1 1 General Supply voltage 120 230Vac 10 15 Power consumption Approx 60VA Supply frequency 50 60 Hz 5 Ambient temperature range 0 to 60 C 32 to 140 F Control unit protection category IP20 The control must be situated in a clean environment according to EN6730 1 Indoor Control must be mounted NEMA1 IP40 enclosure Outdoor Control must be mounted in an NEMAS IP54 enclosure Unit dimensions Control unit 176 x 115 x 92mm 6 93 x 4 53 x 3 62 in deep Display 132 x132 x 36mm 5 20 x 5 20 x 1 42 in deep Weight Control unit 1 55kg 3 42 Ibs Display 0 90Kg 1 98 Ibs Type of display 2 lines x 20 characters vacuum fluorescent display with membrane keypad 1 2 Servo motor control IMPORTANT See Section 3 2 Type CANbus Maximum total number of servo motors 10 see section 3 regarding servo motors Maximum number of fuel profiles 4 Max number of setpoints per profile 24 including close purge and ignition Positioning accuracy 0 1 Response time to positioning error 15s for 1 0 1s for 5 0 Number of fuel motors Not Limited by profile e g 2 or 3 fuel motors All non mo
20. 7 81 NProbe diameter Conduit connection 6mm M16 2 Conduit Adaptor PN 35 336 24 eS The temperature sensor has a protection level of NEMA4 providing suitable conduit glands are used and can be mounted in any attitude It has been designed for mounting into a well or pocket that has been inserted into the boiler shell When choosing the position of the well care should be taken to ensure that the sensor operates within its environmental specifications and that the position will allow measurements and subsequent control actions to be correlated to other devices e g auxiliary safety stats The ambient operating temperature range is 0 to 60 C 0 to 140 F The unit MUST be grounded earthed to maintain electrical safety and ensure reliable operation 2 4 6 Steam pressure sensors 44mm When fitting the sensor care should be taken to ensure that the sensor lt gt operates within its environmental specifications An important issue is the heating effect of the steam Also the sensor should be connected to the process in such a way that readings and subsequent control actions can be correlated to other devices e g the boiler pressure dial gauge and any auxiliary safety stats Steam Pressure sensors must be mounted in a vertical attitude to ensure water vapor does not collect inside the sensor Additional devices e g a pig tail feed pipe may be required to reduce the possibility of moisture reachi
21. Burner Settings button 68 5 4 11 Touchscreen Fault Event Log button 70 5 4 12 Touchscreen Screen Configuration button 70 5 4 13 Cleaning the Touchscreen 71 5 4 14 Touchscreen Commission mode 72 5 5 Using option set mode 74 5 5 1 Option parameter list 74 Option 00 1 Site passcode 0 999 DEFAULT VALUE is 154 LV3 74 Option 00 2 Serial communications control address 0 15 LV3 74 Option 00 3 Reset hours run 0 1 LV3 75 Option 00 4 User program select 0 1 LV1 75 Option 00 6 Reserved 75 Option 00 7 Modbus device address 1 99 75 Option 00 8 Modbus communications speed 0 3 LV3 76 Option 01 0 Power Up Option 0 30 LV3 76 Option 01 1 Keyboard Auto Manual enable 0 1 LV3 Engineer s Key 33 76 Option 01 2 Mute Reset Input enable 0 2 LV3 76 Option 02 x Drive Name LV3 77 Option 03 x Drive Serial Number LV3 78 Option 04 x Drive Usage Information LV3 78 Option 05 x Drive Options LV3 79 Options 06 1 06 4 Profile Naming LV3 80 Options 07 x 08 x RESERVED 80 Option 09 0 Inverter control accuracy 0 1 LV3 80 Option 09 1 Inverter error tolerance 0 1 LV3 80 Option 09 2 Inverter closed loop gain 15 12596 LV3 81 Option 09 3 Inverter stop time 0 100 seconds LV3 81 Option 09 4 Inverter acceleration time 0 100 seconds 60 seconds max recommended LV381 Option 09 6 VSD2 Speed Encoder Scaler 255 999 LV3 82 Opti
22. Drive Usage Information LV3 The system will allow a maximum of four fuel air profiles to be entered Each drive servo or VSD can be selected to operate for any all or none of these profiles For example The system can be programmed to use the gas servo on a gas profile but not an oil profile When the control is firing a profile that doesn t use a specific drive that drive can be disconnected or faulty and the control will carry on working For example if the gas servo is broken the burner can be run on oil 78 The number to be entered is a binary code 1 if the drive is used for profile 1 2 if the drive is used for profile 2 4 if the drive is used for profile 3 8 if the drive is used for profile 4 This means that the number entered is from 0 to 15 see chart below Number entered in parameter 4 X Drive X used for profile s NONE 3 1 4 4 0 4 3 2 4434200 4 3 2 1 ALL If these parameters are changed after the burner has been commissioned any profiles affected will need to be re commissioned A profile invalid fault see FAULT 64 will lock the burner out on an attempt to fire a profile which has had a previously commissioned drive removed If a drive has been added removed form a profile it is recommended that the specified profile is erased using option parameter 45 X before an attempt is made to re commission it Example of use Option parameter 4 0 4 drive 0 used fo
23. The SCROLL keys are used to view boiler and Engineer s Key Used to view status INTEGRATED BURNER CONTROL burner status data during of inputs outputs normal running conditions NOTE Pressing both the left and right scroll keys In commission mode these keys select option parameters which are simultaneously adjusted by the UP DOWN will reveal the AP keys serial number of g SEES The UP DOWN keys the display as are used to adjust well as the J the fire rate in status of a manual modulation backup The mode letters CDBKP E In commission mode will appear on they are used for the bottom line if MUTE AUTO RESET MAN COM data value selection a valid backup is stored MODE NEXT RUN ENTER Alternate key C functions when in commission mode MUTE RESET Press this key to mute open the alarm relays then hold the key down for three seconds to remove any cleared faults AUTO MAN Selects auto or manual burner modulation In manual mode the UP DOWN keys are used to alter the firing rate DATA Toggles the display between normal run mode and servo motor position In COMmissioning mode this key is used to return to run mode Selects different data types on the display window Holding the DATA key down for 5 seconds allows for selection of operating modes NORM normal remote used for
24. and checking the pressure drop The pressure drop can be found by connecting a manometer or similar in the flow line to the calibration gas connection as shown below Calibration air pump See NOTE 350cc min below 150mm 6ins max If the pressure is 150mm 6ins water gauge or more the filter must be replaced NOTE Fireye offers a calibration pump kit part number CAP 1 See your local Fireye Distributor for details 9 1 3 Removing the oxygen probe from the flue CAUTION e Before attempting to remove the probe switch off the system and the boiler It is essential to switch the burner off since dangerous levels of carbon monoxide may be present in the flue Since the body of the probe will be hot it will be necessary to use heat resistant gloves to hold the probe Do not operate the boiler without the probe or blanking plate fitted since dangerous levels of carbon monoxide may be present in the flue The Fireye Oxygen Probe is retained in the flue by six 6mm stainless steel socket head cap screws e Loosen the 3 screws securing the probe end cap and slide the cap down the flexible conduit Use caution the end cap unit may be hot 164 e Access is now available to the electrical terminations Remove the plug from the printed circuit board allowing the flexible conduit fitting to slide out of the probe body complete with the plug Since the body of the probe will be hot it will be necessary to use heat resi
25. determine which direction you need to go Bear in mind the burner should not continuously hunt or swing to 183 E gt maintain the desired setpoint It is normal for a slight over and undershoots of setpoint during serious load changes The values for the PID s are found at option parameters 21 2 21 3 and 21 4 for setpoint 1 PID1 and 22 2 22 3 and 22 4 for setpoint 2 PID2 These values are adjustable using the Site Passcode 154 9 7 11 The startup shutdown stages are as follows Stage Stage name Description no Non volatile The burner is held in this state until all faults are removed lockout safety shutdown The safety shutdown output PE5 PE6 will be open The controlled shutdown output on PE3 will also be OFF during this time however if the burner was running when the fault occurred the safety shutdown output will have opened first Burner off The burner is checked to make sure that it has switched off completely The fuel profile select inputs must all go OFF when the burner is switched off or at the end of post purge This provides a EK18 feedback to confirm that the burner is off and ensures that this control is always synchronized with the burner controller The controlled shutdown output on PE3 will be OFF during this time however the safety shutdown output PE5 PE6 will be closed during this time The control will advance to status 2 when All fuel profile select
26. required to support the load on the boiler LOW VOLTAGE EK6 This input is made by connection to PA11 If this input goes Low Voltage OFF during a normal run the motors will move to their low fire not ignition positions and stay there No feedback will be given on LFS see below See OPT 16 1 for return to pilot PROFILE PE9 PE10 PE11 PE12 Tells the fuel air ratio controller which fuel air profile to SELECT run This signal must be removed when the burner goes Line Voltage off before a new start up can begin It is common to use a EK11 14 selector switch fed from the fan contactor output of the EK31 burner controller for this input LINE VOLTAGE If this signal is removed at any time the controlled shutdown output PE3 will turn off for at least 3 seconds to ensure the burner is off See OPT 16 2 for profile swap on the fly From fuel air ratio controller to burner controller Signal Name Alternate Names Pin Description SAFETY Lockout PE5 PEG These contacts will open in the event of a lockout of the SHUTDOWN fuel air ratio controller When this happens will loose Line Voltage power a short time later These contacts MUST be in the main safety circuit of the Flame Safeguard effectively interrupting power to the fuel valves LINE VOLTAGE The installation must guarantee that if these contacts open the burner goes off IMMEDIATELY CONTROLLED Call for heat PE3 When the fuel air ratio controller
27. 0 999 LV3 121 SS This option parameter must be set to the calibration gain value that is specified with the probe supplied This option parameter is only available if option 31 0 is non zero Option 42 3 Second Oxygen probe calibrate enable 0 2 This option parameter is only available if option 31 0 is non zero This option parameter must be used when calibrating the second FIREYE oxygen probe There are three possible values as seen on the following chart Option parameter Meaning 31 3 value No calibrate This is the normal operating condition where the probe is used to measure the oxygen concentration in the flue Calibrate in air The probe will be calibrated for offset at the normal atmospheric oxygen concentration 2 Calibrate in reference gas The probe will be calibrated for gain in a reference gas with a nominal oxygen concentration the level specified in option parameter 30 3 typically 3 0 Once this calibration has been successfully completed the values in 31 1 and 31 2 will be automatically updated Option 42 4 Max oxygen variation 0 9 9 1 3 Where the second oxygen probe is being used as a cross check on the first one the maximum permitted variation between the two oxygen readings should be entered here It is suggested that a value of around 0 5 96 be used but the application may demand a higher setting if the two probes are not in exactly the same part of the flue
28. 1 alarm F02 External Alarm The fault may be prefixed by either an L or an F and may may Fault 2 not shutdown lockout the burner F03 External Alarm See Option parameters 19 1 to 19 4 Fault 3 Subset burner status F04 External Alarm Fault 4 Not enough A fuel air ratio profile has been selected which does not have at setpoints entered least four setpoints commissioned e Use commission ratio mode to enter more setpoints Subset fuel code Circuit board The circuit board has an incorrect on board reference level voltage reference fault Ensure ALL analog inputs 4 20mA 0 5v are in the range 0 to 5 0 volts It is critical that none of the inputs are higher than 5 0 volts If the problem persists even when all analog inputs are disconnected check EK37 and contact supplier Subset 1 out of range 2 zero check failed 4 span check failed See EK37 for more details 132 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F32 Drive 0 position fault Drive 1 position fault Drive 2 position fault Drive 3 position fault Drive 4 position fault Drive 5 position fault Drive 6 position fault Drive 7 position fault Drive 8 position fault Drive 9 position fault Safety input fault my A drive positioning fault has occurred which will cause a non volatile lockout of the burner This fault has occurred for one of the following reasons 1 During c
29. 10 psi then the proportional band would be from 90 to 100 psi A measured value of 90 psi would give high fire and 100 psi would give low fire assuming no integral or derivative terms were entered A value of 0 means no proportional band the burner would stay at low fire until the high limit Cut Out is reached then turn off Proportional control is therefore needed to allow the burner to modulate Option 22 3 Set point 2 integral term 0 999 seconds LV1 This is the integral time used in the PID control loop for setpoint 2 It may be set to any value from 0 to 999 seconds If a value of 0 is entered the integral function is disabled otherwise the time entered is the number of seconds the control will take to give an additional modulation change equal to that currently given by the proportional term The lower the number apart from zero the more affect the integral function has A large number will cause the integral term to act very slowly Integral control is required for the burner to accurately reach its setpoint Option 22 4 Set point 2 derivative term 0 100 LV1 This is the derivative time used in the PID control loop for setpoint 2 It may be set to any value from 0 to 999 A value of zero will disable the derivative function A non zero value will have the effect of advancing the modulation rate change caused by a constantly changing measured value by the number of seconds given A low value will have litt
30. 22 0 6 0 8 0 P6 17 0 28 0 5 0 7 0 P7 24 0 33 0 4 0 6 0 P8 29 0 38 0 4 0 6 0 P9 35 0 45 0 4 0 6 0 P10 43 0 55 0 3 5 5 0 P11 53 0 67 0 3 5 5 5 P12 66 0 79 0 3 5 5 0 P13 80 0 88 0 3 5 High Fire NOTE The angular change in the air drive position required to achieve the 1 0 to 1 596 increase in observed oxygen level may increase as the burner fires at higher rates This is normal as the air damper will not likely be linear When approaching high fire large increases in the air drive servomotor travel may be required to increase the oxygen reading by 1 0 to 1 596 As a rule this should be avoided as the burner is potentially out of air and in so doing the effective input to the boiler will be negligible This would also affect the operation of oxygen trim should this option be used 169 Gay 9 5 Fireye PPC6000 Efficiency Calculations Fireye PPC6000 controls can display calculated combustion efficiency For the displayed efficiency to be meaningful the correct values for Calorific Value and Hydro Carbon Ratio for the fuel in use must be entered in the related Fireye PPC6000 option parameters Efficiency may be displayed as Net or Gross The calorific value of a fuel is the heat given out when unit quantity of the fuel is completely burnt any fuel containing hydrogen has two calorific values these being the gross or higher calorific value and the net or lower calorific value The gross calorific value is the he
31. 3 4 Indicates profile selected Displays the profile number for the selected profile 13 07 16 Indicates Time and Date Displays Actual Time and Date used for fault 2008 05 20 history and event logging Date format is yyyy mm dd 5 4 4 Touchscreen Overview display Operating hours 109 Profile 1 GAS 50 Profile 2 OIL SELECTEC XGAS 0 Unito While the burner is changing status the bottom right one sixth of the Boller actual 6 2 Jbar Boiler setpoint EiS bar display is used to provide a graphical Modulation rate indication of changing status Flame intensity 0 The sequences displayed in this manner include burner start up burner shutdown and fuel changeover In each case there is a lamp for each stage providing a ripple through lamp system to clearly indicate the progress of the change in burner status Burner Start Sequence Gas valve proving stage 1 Q Gas valve proving stage 2 Prove air pressure Purge position reached The example shown in the picture is Purge in progress 0 08 for the burner start up sequence Q Ignition position requested display Once the sequence is complete then P a r a e 5 S e purge the display will return after a short delay to the overview screen 65 Guy The Reset Alarm Mute button on the touchscreen is multi functional In normal operation it may be used to test the alarms this is achieved
32. 3 IP54 3R IP14 3S IP54 4 and 4X IP56 5 IP52 6 and 6P IP67 12 and 12K IP52 13 IP54 Table 2 6 1 B International Wire Size Conversion Table All dimensions shown are as accurate as possible however when converting AWG SWG inches and metric dimensions round off errors do occur Wire and cable also vary depending upon manufacturer American or Nominal Nominal Cross Sectional Stranded Wire Construction Brown amp British Conductor Fractional Conductor Conductor Area Number of Strands Sharpe s Standard Diameter 0 Equivalent Diameter 0 Sq mm x Diameter of Strands AWG SWG inches inches mm inches mm 16 0 051 1 30 1 33 26 x 010 19 x 30 18 19 0 040 1 02 0 82 16 x 010 7x 4 20 21 0 032 0 81 0 52 10 x 010 16x 2 24 25 0 020 0 51 0 20 7 x 008 7x 2 Table 2 6 1 C 31 CONDUIT CONNECTOR ADAPTERS Metric to inch NPSL Female Device Fireye Part Number NXC04 Servomotor 35 321 Table 2 6 1 D 2 6 2 Grounding cable screens Two screen termination clamps are provided on the PPC6000 for termination of cable screens copper braid type where necessary if the unit is used with a daughter board the screens of these cables MUST also be terminated to the cable clamps and the screen and associated insulation left on the cable until as close as possible to the terminals to which they are connected Where screened cables are required to run through one unit to c
33. 34 1 to 34 4 Trim proportional gain 0 0 99 9 LV3 115 Option 34 5 Calculating and entering the flow values manually LV3 115 Option 35 0 Inlet temperature sensor serial number LV3 118 Options 35 5 to 35 8 Calorific values of fuels profiles 1 to 4 respectively 0 0 99 9 LV3 118 Option 35 9 Boiler radiated heat loss 0 0 9 996 LV3 119 Option 36 0 Flue temperature alarm select 0 1 V3 119 Options 36 1 to 36 4 Flue temperature low alarm values 0 999 L V3 119 Option 38 0 Oxygen alarm select 0 2 LV3 120 Options 38 1 to 38 4 Oxygen low alarm values at low fire 0 0 99 996 LV3 120 Options 39 1 to 39 4 Oxygen low alarm values at high fire 0 0 99 9 LV3 120 Options 40 1 to 40 4 Oxygen high alarm values at low fire 0 0 99 996 LV3 120 Options 41 1 to 41 4 Oxygen high alarm values at high fire 0 0 99 996 LV3 120 Option 42 0 Second Oxygen probe interface serial number LV3 121 Option 42 1 Second Oxygen probe calibration offset value 0 999 L V3 121 Option 42 2 Second Oxygen probe calibration gain value 0 999 LV3 121 Option 42 3 Second Oxygen probe calibrate enable 0 2 LV3 122 Option 42 4 Max oxygen variation 0 9 9 96 L V3 122 Option 42 5 Max flue temp variation 0 to 999 C LV3 123 Option 42 7 Air pressure monitoring input number LV3 123 Option 42 8 Air pressure monitoring Span LV3 123 Option 42 9 Air pressure monitoring
34. 5Vdc PZ14 Daughter Board Channel 2 Feedback 4 20mA 0 5Vdc PZ15 Daughter Board Relay output 7 common 0 40V PZ16 Daughter Board Relay output 7 normally open 0 40V 217 Daughter Board Relay output 8 common 0 40V 218 NXDBVSD Relay output 8 normally open 0 40V 2 6 8 LINE and NEUTRAL supply PPC6000 PE1 amp PE2 N WARNING Incorrect setting of the Supply Voltage Links WILL damage or destroy the unit PE1 NEUTRAL LIVE MAX 8A PE2 NON The LINE and NEUTRAL supplies must be connected using multi strand single conductor core PVC insulated 16 AWG 19 0 3mm wire The live connection MUST be fused with a maximum rating as shown 35 ry NOTE Line live is term PE2 If a fuse greater than 8A is fitted each relay safety shutdown and controlled shutdown output supplied via this terminal MUST be separately fused at 8A maximum to protect the relay contacts from welding It is also recommended that the alarm relay be fused at 4A maximum to protect the relay contacts from welding which may cause incorrect alarm indication 2 6 7 Safety Shutdown output PPC6000 MAX 8A The safety shutdown relay output must be connected using multi strand single conductor coNtRorten PVC insulated 16 AWG 19 0 3mm wire This output must be connected to ensure the burner will shutdown if no output is present SAFETY SHUTDOWN PE 5 SAFETY SHUTDOWN PE 6 Ed If
35. 60 C 32 to 140 F NEMAS IP54 57 x 63 x 35 mm 2 25 x 2 5 x 1 37 inches 0 15 kg 5 4 oz FIREYE specific CANbus 1 10 Variable Speed Drive VSD Daughter Board NXDBVSD optional Ambient temperature range Protection category Analog inputs 4 20mA Input impedance Analog outputs 4 20mA Maximum loop resistance Isolation voltage RS485 communications 0 to 60 C 32 to 140 F Not applicable fits inside PPC6000 unit 3 max non isolated 120ohms 3 max isolated 250 ohms 50v Modbus RTU 14 1 11 Fireye NXC04 NXC12 NXC20 NXC40 Servo Motors Interface to PPC6000 CANbus Speed 30 seconds for 90 degrees Microswitches Open amp close positions Torque Driving Holding NXC04 4Nm ft lb 2Nm NXC12 12Nm 9 ft lb 18Nm NXC20 20Nm 14 7 ft lb 18Nm NXC40 40Nm 29 ft lb 20Nm Voltage 24 30Vac supplied from control only VA rating NXC04 3VA NXC12 5VA NXC20 10VA NXC40 18VA Protection Category NXC04 IP40 NEMA 1 NXC12 NXC20 IP54 NEMA 3S NXC40 IP65 NEMA 4 Typical accuracy Accuracy as specified by EN12067 0 1 0 5 1 12 Fireye NXO2INT Oxygen Probe Interface Unit optional Supply voltage 115 230Vac 15 Power consumption Approximately 60VA Supply frequency 50 60Hz 596 Ambient temperature range 0 to 60 C 32 to 140 F Protection category NEMAA IP65 Unit dimensions 160 x 98 x 63mm 6 30 x 3 86 x 2 48 deep W
36. 7 to the desired cut out value when in stand by Oo RONA For example If the normal operating setpoint is 100 PSI and the desired stand by pressure is 75 PSI The setup would be Option Parameter Setting 22 0 1 22 1 75 22 5 1 22 6 75 cut in or minimum pressure 22 7 80 cut out or maximum pressure 101 OO STANDBY WATER TEMPERATURE FOR STEAM BOILER If a steam boiler is being banked based on boiler temperature a temperature sensor must be fitted into the boiler water jacket The temperature sensor must be a 4 20mA device If this device is to be loop powered by the PPC6000 it should be connected to the 30V output sensor supply on PA16 See option 25 0 25 5 Example Fireye Temp Sensor 75350 PPC6000 Sensor Terminal 1 4 20mA PPC6000 Terminal PB8 or PA12 Sensor Terminal 2 Current PPC6000 Terminal PA5 PA6 PA8 The blocks program needs to be 15 or higher EK200 shows the current version Option Parameters 20 7 0 If using AUX input 5 Using inputs 1 2 will allow the boiler water temperature to be displayed on the TSD104 Input 4 will NOT 25 0 1 Analog input 1 PA5 to PA12 or PB8 Input 2 3 amp 4 will also be powered from PA12 or PB8 25 1 32 Zero value of temp sensor 25 2 350 Span value of temp sensor 25 3 Cut in temp 25 4 Cut out temp No PID involved lag boiler will turn on and off on low fire Relevant Engineers Keys EK115 EK120 to EK139 and EK15
37. 908 73 7 74 4 116 D Table Flow calculation table Ex Air 100 y X 100 c a 100 0 100 Profile position High fire x A A a a Fuel flow y C4 C4 d4 17 1 99 9 91 f y c4 e Co do fo e f4 92 fo y c2 C3 d4 fo 93 y c3 MEN wa 2 c2 N 1 gt N Cc gt c o wo N 4 4 A IH 2 gt Cg dg fg eg fg 99 fo y cg 6 6 o gt c 4 E a C a C a C a C s gt o o T4 3 3 5 5 7 7 gt ag cg gt ag cg o e A 10 10 010 10 fg 910 f40 Y c49 A a 411 441 d44 f44 11 914 f41 Y c44 12 12 02 f12 642 f44 942 2 y c42 43 43 d43 f13 13 f42 943 13 414 614 014 f44 14 f13 914 f44 Y c44 e15 15 015 5 15 4 15 915 15 15 6 16 06 f16 16 15 916 16 16 EE 17 97 6 917 f17 ylc17 b18 dig b19 dig b20 d20 NOTE For the following Options 35 x see procedure in Section 9 5 3 o o o Oo X x lx Ix cx N NIA 10 lt N A o a WO C C C C A d d 14 d AB 99 I I
38. Com Isol Gnd 8 eoococococcocoocoocooe TOP SIDE VIEW FOR CONNECTORS Profile 1 Profile 2 Profile 3 Profile 4 12 Purge Prove Note All wiring to terminals PA amp PB are low voltage and must be braided shielded wire per table 2 6 1A Wiring to terminals PE are line voltage The maximum wire size is 16AWG 19 3mm for all terminals Note amp PE8 provide purge and low fire position signals to the flame safeguard control These outputs MUST NOT have a load greater than 30mA i e relays lamp etc damage to the PPC6000 will result This connection MUST be braided shielded wire 28 Ces 2 6 Wiring Typical Schematic An abbreviated typical wiring schematic diagram showing the PPC6000 Parallel Positioning Controller YB110 Flame Safeguard Control and YZ300 Expansion Module can be found in section 9 6in this manual This diagram is for reference only and may not meet all national or local codes In all cases local codes prevail with respect to the final installation of this product 2 6 4 General READ THIS FIRST There are numerous mentions of overall braided shielded screened wire throughout this manual This is an important aspect to reliable operation Table 2 6 1 A lists the only approved wire for this control While one of the specifications relating to shielded wire indicates the amount of coverage 0 100946 th
39. DC Since this cable is to be run adjacent to and or in the same conduit as high voltage wiring its voltage rating must exceed the maximum voltage carried by any other cable connected to the control or run in the same conduit See Section 2 6 1 IMPORTANT Wiring Guidelines DIGITAL INPUT 1 PA 5 DIGITAL INPUT 2 PA 6 DIGITAL INPUT 3 PA 7 DIGITAL INPUT 4 8 DIGITAL COM PA 11 These functions are all fail safe and may be used to lockout or shutdown the burner The fault number generated always relates directly to the input that caused the fault by going open circuit Thus F1 comes from input 1 F2 comes from input 2 and F4 comes from input 4 The lockout functions themselves are activated by putting a number into option parameters 18 1 to 18 4 for inputs 1 to 4 The number is a one two or three digit number See option parameter 18 1 to 18 4 for settings Under no circumstances should these input outputs be connected to mains potential Connection of any voltage above 5 volts to these terminals will damage or destroy the unit 2 6 13 Servo motor and Display Connection PPC6000 There are 2 sets of terminals available for the CANbus 24Vac PB 4 aac PA connection both sets are identical 24Vac PB 2 24Vac PA 2 3 CANbus allows several options for connecting the units together based on the actual position of each CANbus SPEM CRDI PAS unit relative to the PPC6000 and the current required by each unit The recommended cable over
40. DEFAULT 0 unlimited Range 1 100 Values represent 0 unlimited 1 100 is maximum 96 Option 22 9 Reserved Option 23 0 Warming Enable 0 or 1 LV1 This parameter allows a warming function to be applied to the boiler and makes option parameters 23 1 and 23 2 available If zero is entered no warming limit is applied Option 23 1 Warming Limit 0 999 00 0 99 9 0 00 9 99 LV1 If when the burner starts up and reaches modulation the measured pressure temperature value is lower than that specified here the control will hold the boiler at low fire until the value specified is reached The control will hold the boiler at low fire in status 15 indefinitely unless a non zero time has been entered in option parameter 23 2 Note If during normal modulation the measured value falls below this limit having once been above it the warming function will not be re applied The warming function is only applied on a burner start up Option 23 2 Warming Time 0 to 999 minutes LV1 This parameter specifies a maximum time to hold the burner at low fire for before ignoring the warming limit and allowing normal modulation Additionally when the burner goes off for any reason other than power interruption and the measured value falls below the warming limit the warming function will not be activated again until this time has passed NOTE Further parameters up to 29 9 may be available here if they are part of
41. Enter the appropriate option parameters from 30 0 to 42 6 as required With the burner off enter commission mode See section 5 To get the trim operational it is only necessary to address all option parameters with the 02 m symbol Refer to options 30 0 thru 42 6 inclusive for details of parameters that may be entered 107 Cay 2 Flow values and 2 setpoints The flow and O2 values may be entered manually by the engineer option 34 5 or the system can automatically calculate the values and enter them itself by using automatic trim commissioning option 30 9 If the automatic trim commissioning is performed the engineer MUST CHECK THAT THE VALUES ENTERED ARE VALID AND SAFE AFTER COMPLETION Additionally the oxygen probe calibration should be checked before and after the procedure since the results depend highly upon measurements taken using the probe Before proceeding to enter the oxygen setpoints for each profile a few points relating to the oxygen trim option should be considered Notrim is applied which would require a drive to move above its high fire position or below its low fire position The flow for each profile position must be entered to ensure correct operation The flow can either be measured for each profile position or calculated as a percentage with respect to the flow at high fire Using adjust ratio mode to modify and existing oxygen profile manually follow steps 1 12 listed below
42. LOW OIL TEMPERATURE 269 LOW ATOMIZING MEDIA 270 HIGH PRESSURE 271 HIGH TEMPERATURE 272 AUX 4 OPEN 273 AUX 5 OPEN 274 AUX 6 OPEN 275 AUX 7 OPEN Interlock annunciation messages THESE CAN BE MODIFIED BY THE USER Fault Description Number 241 HIGH WATER 242 LOW WATER 243 HIGH GAS PRESSURE 244 LOW GAS PRESSURE 292 AUX GAS 245 LOW OIL PRESSURE 256 HIGH OIL TEMPERATURE 246 LOW OIL TEMPERATURE 247 LOW ATOMIZING MEDIA 248 HIGH PRESSURE 249 HIGH TEMPERATURE 250 AUX 4 OPEN 251 AUX 5 OPEN 252 AUX 6 OPEN 253 AUX 7 OPEN 240 AIR FLOW OPEN 294 OP CONTROL OPEN 260 L1 3 AUX 1 OPEN 261 L1 3 AUX 2 OPEN 262 L1 3 AUX 3 OPEN 156 my 7 Inverter variable speed drives This manual may cover more than one model in the PPC6000 series Check for additional information at the end of this chapter 7 1 System configuration The PPC6000 control can control one or two inverter drive s to control a fuel and or air drive s using a daughter board fitted within the PPC6000 enclosure The daughter board controls the inverter s using 4 20mA output channel s The output s are the speed reference signal to the inverter s 4 20mA or encoder input is used to monitor the feedback signal from each inverter representing the speed of the motor s In addition to the 4 20mA signals the inverter s also require motor start signal s that can be taken fro
43. Option 28 6 Analog Input 3 decimals 0 2 LV3 Set the number of decimal places for analog input on PA7 PA11 105 Cay Option 28 7 Analog Input 3 zero 0 999 LV3 Set the number to be displayed when the input 3 current is 4mA Option 28 8 Analog Input 3 span 0 999 LV3 Set the number to be displayed when the input 3 current is 20mA Setting this parameter to a non zero value also enables this item See NOTE under Option 28 2 Option 29 0 4 20mA Output 1 function if not VSD LV3 Set this option to a value from the table below to enable an analog output to re transmit system variables as a 4 20mA signal For example if this output is to represent Flue Gas Temperature then set a value of 22 If this output has been assigned for VSD control in option 3 x then this setting will be ignored Option 29 0 29 3 and 29 6 function list Value Function Value Function 0 Drive 0 Position 20 Spare 1 Drive 1 Position 21 Boiler operating Setpoint 2 Drive 2 Position 22 Flue gas temperature 3 Drive 3 Position 23 Spare 4 Drive 4 Position 24 Spare 5 Drive 5 Position 25 Spare 6 Drive 6 Position 26 Spare 7 Drive 7 Position 27 Spare 8 Drive 8 Position 28 Spare 9 Drive 9 Position 29 Spare 10 Spare 30 Burner modulation rate 11 Spare 31 Spare 12 Measured value 32 Spare 13 Boiler Efficiency 33 Spare 14 Inlet air temperature 34 Spare 15 Flue gas oxygen level 35 Gas pressu
44. PPC6000 A back up of the data held in the PPC6000 is automatically stored in the display when the control is in modulation status NOTE You must exit commissioning mode to initiate the restore 5 6 Commission ratio mode 5 6 1 Description Commission ratio mode is used for entering a new profile or changing an existing profile Using commission ratio mode it is possible to step through each setpoint including close purge and ignition Once a setpoint has been entered it is not possible to go back and modify it again in the same commissioning session To do this adjust ratio mode must be used after all the required setpoints have been entered 5 6 2 Using commission ratio mode CAUTION Use extreme care while commissioning the system While operating in commissioning mode the safety of the system is the sole responsibility of the commissioning engineer Ensure a pre purge position is entered for the relevant drives Incorrect positioning of either fuel or air could cause a hazardous situation to occur If the servo motor positions have been up loaded it is essential that the combustion is verified at each firing position to ensure a hazardous condition cannot occur and for the data to be stored in the control It is recommended that the close position for each servo motor is re entered as part of the burner service regime to compensate for wear in the servo motor micro switch during operation Once all profile positions have been a
45. PPC6000 equipment and hand held equipment first check that the following values are the same or very close Inlet temperature Flue gas temperature Calorific value Hydro carbon ratio Oxygen value after making correction for dry to wet on the hand held Selection of net or gross If a radiated heat loss value is being included ensure the hand held equipment has corrected the value for the current firing rate of the burner NOOR WD Other points to remember In a typical package boiler radiation losses are usually in the order of 3 blow down losses typically 2 and flue gas losses 15 to 20 Giving a typical overall efficiency of 100 3 2 20 75 The major area for attention to improve boiler efficiency is the flue gas losses with the object of minimizing excess air within the bounds of safe and reliable boiler operation O2 Trim is the best tool for ensuring consistent optimum combustion and minimization of excess air The PPC6000 ensures consistent fuel air ratios The Fireye O2 Trim option continuously compensates for changes that affect efficient combustion due to such variables as viscosity of liquid fuels density of gaseous fuels changes in temperature of fuels changes in gas and oil pressures worn and damaged burners dirty burners scaling if boiler tubes ambient temperature barometric pressure and tramp air 171 IMPORTANT Low Voltage vertical terminal
46. The control will lockout within 30 seconds of the two oxygen readings being outside the specified window When this parameter is non zero the flue oxygen limits will be checked on a worst case basis This means that the low oxygen limit see options 38 X 39 X is checked against the lower of the two oxygen probe readings and the high oxygen limit see options 40 X 41 X is checked against the higher of the two oxygen probe readings If there is a fault with second oxygen probe the burner will also lockout If this parameter is left at zero 0 0 no checking will be done but the oxygen and temperatures associated with second oxygen probe will still be available on the engineers key EK75 79 Note When fail safe oxygen monitoring is employed using two probes each probe must be tested and calibrated at intervals not less frequent that once every six months 122 eme Option 42 5 Max flue temp variation 0 to 999 C If non zero the burner will lockout if the two oxygen probes vary by more that this many degrees Celsius This can be used in applications where flue temperature is especially critical Option 42 7 Air pressure monitoring input number LV3 Available on firmware version 1 3 onwards 56 Option 42 8 Air pressure monitoring Span LV3 Option 42 9 Air pressure monitoring max error LV3 For options 42 7 42 8 42 9 EK98 shows air pressure error if in RUN and MODULATION
47. VSD controlled oil pump Can be used for oil warming see option parameter 9 8 Waste fuel combined fuel firing PRI Fueldrive YES Primary flame shaping air S FUE Fueldive NO Generic fuel but not trimmed Main combustion air damper S 02 X 20 BENE BUR c3 p 266 Main combustion air fan name 13 AIR Aidive Generic Air but not trimmed Two or more drives can be allocated the same name 77 CH The number entered also tells the control information about the drive If the number entered here is less than 10 the drive is considered a fuel If the number is greater than or equal to 10 it is considered an air drive This only makes a difference when oxygen trim is enabled for a particular drive since it determines the trim direction Selection of fuel trim or air trim is made with option parameters 31 1 to 31 4 Primary air is considered a fuel drive since it is used for flame shaping and should normally track the fuel valve option 03 x Drive Serial Number CAUTION e total electrical load for all connected servo motors must not exceed 40VA e Due to the possibility of High Frequency electrical noise BOTH ends of the shielded signal wire to the VSD MUST be grounded Each Drive connected to the system has a unique serial number allocated to it during production testing This number cannot be changed and is used to uniquely identify each drive
48. a users program or non standard manufacturers program 100 my Sequencing lead lag is managed by using the setpoint select function internally to choose between Setpoint 1 and Setpoint 2 via the communications bus between PPC6000 s The lead or master boiler controls the lag or slave boiler s by switching them from setpoint 2 lag stand by or banking to the setpoint 1 values and turns on based on Option 24 6 lag slave On Rate value The lead boiler will override the modulation rate of the last lag boiler to come on and cause it to modulate in unison with the lead master boiler If both the lead master boiler and last lag slave boiler remain above the Option 24 6 value another lag slave boiler will be started after Option 24 7 lag slave on delay value has expired Other lags slaves that are on will remain at high fire until the last lag is turned off At this point the next lag boiler will begin to modulate with the lead master and so on until the lead master is carrying the load The sequence in which boilers are turned on is set in Option 24 1 24 3 via communications addresses of each PPC6000 When a lead master boiler is deselected as lead master and Option 24 0 has not been changed to 0 the boiler remains as lead master until a new lead master takes control Once the new lead master takes control the previous lead master may be turned off based on the demand and Option 24 1 24 3 set
49. address exists To exit local mode press either the Data or COM key 150 my A display can only log the faults of up to eight PPC s therefore the fault log range is selected by holding down the right arrow key and the Engineers Key Fireye logo simultaneously The ranges are as follows Fault Mode on CANbus 0 1 2 6 7 2 Startup Possible cause Control in non volatile lockout High control limit exceeded Control in commission ratio mode Burner off via serial comms Problem Burner will not start Waiting for burner controller Stored close positions do not match actual close positions Drive positioning fault occurs before drives move to purge Drive positioning fault occurs when drives reach purge Stored purge positions cannot be reached Fault Log Range No Logging Address 0 7 Address 8 15 Suggested action Hold MUTE RESET key when faults clear Check EK18 and wait for press temp to drop Press NEXT to advance to next setpoint Turn the burner ON using ComFire software if fitted Use section 4 2 and burner status EK30 to see what the control is waiting for Check feedback potentiometers and motor micro switches Reset close positions using commission ratio mode Check feedback potentiometers and motor micro switches Reset purge positions using commission ratio mode Drives stuck at ignition Drives cannot reach ignition Check motor micro switches and linkages and
50. and Fireye s program can be re selected at any time by changing this parameter back to zero Option 00 4 Meaning value Run standard manufacturer modulation program Controls PID control limits and some Input Output settings see option parameters 20 0 to 29 9 Run user program if available Option 00 5 Alternate Language select 0 1 LV1 DEFAULT 0 This parameter may not be available Where it is available it allows the user to change the language used for the display Depending on spare memory and customer requirements this option may only change the text displayed to users in RUN mode and not in COMMISSION mode or all text can be changed to a second language Table below is for basic display Language selection on the touchscreen is handled on the touchscreen directly Option 00 5 Meaning value 0 Operate with standard language usually ENGLISH 1 Operate with alternate language at least in RUN mode but possibly in other modes depending on specification of the control Option 00 6 Reserved Option 00 7 Modbus device address 1 99 LV3 Default value is 02 OFF This option sets the Modbus device address for the controller and must be unique for each device on the bus NOTE Only available with NXDBMB Modbus or NXDBVSD variable speed drive daughterboard installed 75 dem Option 00 8 Modbus communications speed 0 3 LV3 Default value 0 NOTE Only avail
51. appear allowing the relevant passcode to be entered using the soft keypad and confirmed by pressing the OK button NOTE The Supplier s Passcode LV3 is six digits Enter ALL including any zeros followed by the OK button 13 20 33 2008 05 20 OFF GAS AUTO Unito Burner Settings re Enter Passcode Drives Options Engineers Values Prot Proz Pros Pro4 tA H 1 2 3 DAIR 4 abe def 0 0 02 4 5 ghi jkl m Cancel OK Not in commission mode VIEW ONLY NEXT NTEF COM S ly Burner Off A E e 1 Reset Start Fuel Control Menu Overview 2 N CAUTION Use extreme care while commissioning the system While operating in commissioning mode the safety of the system is the sole responsibility of the commissioning engineer Ensure a pre purge position is entered for the relevant drives Incorrect positioning of either fuel or air could cause a hazardous situation to occur If the servo motor positions have been up loaded it is essential that the combustion is verified at each firing position to ensure a hazardous condition cannot occur and for the data to be stored in the control It is recommended that the close position for each servo motor is re entered as part of the burner service regime to compensate for wear in the servo motor micro switch during operation Once all profile positions have been adjusted entered it is essential that all profile points are c
52. before the selected motors will automatically move to their relevant P1 positions and stop if no change is required press NEXT Otherwise move each motor to its required pre purge position and press ENTER If the purge setpoint has not been entered before the servo motors will remain at their respective closed PO positions until each motor has been moved to its required position Once all selected motors are at the correct position press ENTER P1 purge is displayed Please note that if a purge position for a particular drive has not been entered before the drive will remain at its closed position The engineer must ensure that the main combustion air damper is set to open enough to purge the boiler 4 Wait for the pre purge time to elapse If the ignition setpoint has been entered before the drives will move to their ignition positions once all drives stop moving P2 ignition will be displayed if a change is required or the ignition setpoint has not been entered before move all the motors being used to their required ignition positions and press ENTER 5 To attempt ignition of the burner hold down the NEXT key for approximately three seconds If it is wished to change the ignition position adjust the relevant drive s and press ENTER if the position is acceptable press NEXT Once the relevant safety times have elapsed P3 will be displayed 6 If the low fire setpoint has been entered before and no change is required press NEXT Otherwise
53. boiler setpoint of 100 psi the burner would first remain at high fire until the pressure reached 90 psi and then start to modulate down If the load was equal to 50 firing rate the pressure would stall at 95 psi Adding and I value of 10 would ramp the output up to 100 high fire in 10 seconds assuming no change in the boiler pressure Setting and I value of 300 increases the output up to 100 high fire in 5 minute 300 seconds As the boiler reaches setpoint the same timing effect occurs above setpoint Therefore too much I can cause over under shoot as loads change Too little I may cause rapid hunting A good starting point for the I value in most cases is 50 Derivative Enabling the derivative has the effect of sensing the rate of change in the process variable pressure or temperature and increasing or holding up the firing rate output despite the integral term This in effect amplifies the output to anticipate the effect of a sudden change in load demand Derivative acts inversely when the setpoint is exceeded Derivative is set in seconds on the PPC6000 A good starting point for the D value in most cases is 2 Start with a P value of about 10 of setpoint and value of 50 seconds and a D value of 2 seconds After observing the operation through normal load swings adjust each value usually one at a time and observe the results When making a change it is recommended the value be doubled or halved to de
54. burner has not fired position 6 7 3 Commissioning Problem Possible cause Suggested action Cannot get past PO See burner will not start above See burner will not start above or Ax display flashes constantly and motor positions cannot be altered Drives moving to position AO A1 A2 displayed Waiting for burner controller Option parameter not be set first available Burner off in adjust ratio mode Another option parameter must Wait for drives to position Turn burner on if you need to adjust points a3 onwards Use section 4 2 and burner status EK30 to see what the control is waiting for Set option parameter usually XX 0 to a non zero value to enable other params in group Option parameter not Wrong passcode entered or Enter the supplier passcode and or turn the adjustable burner firing burner off before changing the value Not possible to enter commission ratio mode Supplier passcode incorrect Burner firing goes into adjust ratio mode Enter correct passcode Turn burner off and try again Not possible to enter Supplier passcode incorrect Enter supplier passcode with the burner on adjust ratio mode 151 6 7 4 Modulation Problem Possible cause Suggested action Sensor or modulation rate V I input setting incorrect Check option parameter inaccurate 5 24V supply setting incorrect Check SENSOR IN and SUPPLY links Intermittent positioning
55. driven UP Option parameters 5 0 to 5 9 can be used to reverse this 3 2 IMPORTANT Servo motor direction warning Servo motors are shipped with the shaft flat in the 9 12 o clock facing motor shaft position and by default rotate counter anti clockwise For applications requiring clockwise rotation the motor must be left disconnected from the device being driven until after the system is powered and the motor set for clockwise direction via Option Parameter 5 x Setting this option to 1 causes the motor to display the maximum travel degree e g 90 0 as set by the internal adjustable end switch After selecting all motors that are to travel in a clockwise direction switch to the adjust motors display by pressing the Mode key It is now possible to manually drive each of the clockwise motors to the new PO position e g 1 0 as set by the adjustable end switch The flat facing the shaft will now be in the 6 9 O clock position At this point the mechanical connection to the driven device can be made up Fireye D hole couplings should be used in order to assure a secure connection Set screws alone are not recommended as they can come loose resulting in a potentially unsafe condition Motor shafts are hardened generally preventing set screws from biting in and thus loosening after commissioning Fireye bulletin NEXBK 1000 provides information on D hole couplings Setting the option with the motor connected to the device being dri
56. green ve and white ve covered by a green PVC sheath US 2 PVC insulated cores yellow ve and red ve covered by a yellow PVC sheath e Each core consists of 24AwG 7 32AWG 300V 80 C solid conductors covered by PVC insulation EU cable may be stranded wire compensating cable NOTE Thermocouple wires polarized Failure to connect the correct color to the designated terminal will result in a temperature offset that will affect the operation CHECK TWICE to be certain 45 Oxygen Probe Wiring GROUND EARTH screw in Interface g Oxygen Probe Interface Unit GROUND EARTH OXYGEN PROBE 0 1 2 3 4 5 6 7 8 9 1 screw in Interface INTERNAL PROBE CONNECTORS Z OIO O O O O O O O O REMOVABLE 109 87654321 PIN O SPOMANOankWD OXYGEN PROBE PCB AND CABLE TYPES CONNECTION CABLE TYPE NO CONNECTION ZIRCONIA CELL OUTPUT 20AWG 16 0 2mm BRAIDED SHIELD ZIRCONIA CELL OUTPUT 20AWG 16 0 2mm BRAIDED SHIELD ZIRCONIA CELL TEMP TYPE K COMP CABLE RED or GREEN ZIRCONIA CELL TEMP TYPE K COMP CABLE YELLOW or WHITE FLUE TEMP THERMOCOUPLE TYPE K COMP CABLE RED or GREEN FLUE TEMP THERMOCOUPLE TYPE K COMP CABLE YELLOW or WHITE PROBE HEATER gt 24VAC 16AWG 19 0 3mm BRAIDED SHIELD PROBE HEATER gt 24VAC 16AWG 19 0 3mm
57. in profiles 1 to 4 These parameters are used together with the parameters entered in option parameters 2 0 to 2 9 to determine which drives are trimmed and in which direction Parameter Meaning Trim Type for profile 1 Trim Type for profile 2 Trim Type for profile 3 Trim Type for profile 4 Parameter value in Meaning 31 X ae Q MNoTfrim Do not apply oxygen trim when running on this profile Air Trim Trim Air drives when running on this profile see option parameters 2 0 to 2 9 Fuel Trim Trim Fuel drives when running on this profile see option parameters 2 0 to 2 9 oo m Option 32 0 Trim limit default 0 1 LV3 0 Default Trim Limit of 5 1 Enables options 32 1 to 32 4 O2 Ni Options 32 1 to 32 4 Trim limits 0 0 25 0 LV3 Option 32 0 is only available if option 30 5 oxygen input function has been set for closed loop oxygen trim It is possible for the system to trim the air or fuel drives up to a maximum deviation of 25 0 of the total air or fuel flow for the chosen trim drives If option 32 0 is set to 0 the default trim limit will be 5 0 for all profile selections Option parameters 32 1 to 32 4 will not be available If option 32 0 is set to 1 itis possible to individually adjust the trim limit for each profile selection using option parameters 32 1 to 32 4 The trim limit may be adjusted from 0 0 no trim up to a maximum of 25 0 maximum allowable tri
58. inputs are OFF The boiler status is equal to 1 call for heat See engineers key 18 The AUTO input PA10 PA11 is OFF open Wait for purge The controlled shutdown output on PE3 will be switched on to tell the burner controller there is a call for heat EK5 This control waits for a fuel profile select signal on one of the line EK11 14 voltage terminals PE9 PE10 PE11 or PE12 and a purge request EK31 HIGH input PA9 PA11 closed This input is low voltage This would normally come from the burner controller If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 184 Stage Stage name no 3 amp 4 N A Prove closed positions EK80 89 N A Moving to Purge Pre purge Move to ignition positions Description Not Applicable to PPC6000 Note Statuses 3 and 4 are reserved for a gas valve proving system and are not implemented on this control This control will advance directly to status 5 once the conditions above have been met The fuel and air motors are moved down until they are stopped by the closed position micro switches in the servos The final positions are compared with the closed positions stored in memory and must be within 5 of the stored values otherwise the control will lockout Variable speed drives must read zero 4 mA When all drives have stopped moving the control will adva
59. interference resulting in unreliable operation 2 6 19 Variable Speed Drive Selection The NX6100 may have an optional daughter board within the main enclosure to allow control of 1 or 2 inverter drives Optionally the daughter board is also available to allow feedback to be taken from directly from encoders measuring the speed of the relevant motor fan or pump shaft There is also an option to allow the cup speed of an additional rotary device e g atomizing cup to be monitored as an encoder input When not configured to control an inverter the 4 20mA outputs may be configured to transmit system variables as current outputs 4 20mA such as modulation rate steam pressure etc There are special wiring requirements for inverter feedback See Caution in Section 2 6 20 Important note When selecting a VSD or variable frequency drive VFD consideration must be given to the size and weight of the blower wheel While a fan application is by nature a variable torque load the inertia weight of the blower wheel must be considered Typical HVAC type drives do not speed up or slow down large blower wheels with enough control to operate within the tolerance of the PPC or NX series control Therefore a VSD VFD with some built in breaking capability such as a constant torque drive should be used At a minimum if the drive has a constant torque setting it must be enabled to minimize faults due to drive hunting Since VFD s are expected to perfor
60. inverter s connected to the 4 20mA output s on this daughter board The analog outputs are isolated but the analog inputs are not and therefore special precautions must be taken when using these inputs The inputs are for 4 20mA signals must be isolated as the second input connects on top of the first to ensure cross talks will be detected Terminal PX13 alternates to be shared with PZ12 and PZ14 This switching detects a direct link between input 1 and input 2 which is not allowed The function of relay 1 amp 2 can be set by option parameter but please note the maximum rating of these relays is 200mA at 50V Incorrect connection may damage or destroy the units being connected 197 Guy 11 3 Oxygen probe connection optional Oxygen Probe Interface unit Bussmann S504 series Bussman S504 series PN GMA 5 5 AMP Fast Acting to protects transformer primary DC circuit Alternate Source Mouser Electronics PN 504 GMA 5 P N GMD 630 TIME Delay for 115V P N GMD 315 TIME Delay for 230V to protect 24V circuit Alternate Source Mouser Electronics PM 9 PROBE HEATER gt 24VAC PM 8 PROBE HEATER 24VAC PM 7 FLUE TEMP THERMOCOUPLE PM 6 FLUE TEMP THERMOCOUPLE PM 5 CELL TEMP PM 4 CELL TEMP PM 3 CELL OUTPUT PM 2 CELL OUTPUT Termination for screens from Oxygen Probe screw IP C NBUS PL 7 Ov Common see note PL6I P2 4 20
61. master boiler and last boiler on if any exceeding the value set in Option 24 6 and the next being turned on This time may also include additional time as set in Option 25 6 Option 24 8 lag slave Off Rate 0 100926 LV3 When the lead master boiler and last boiler modulate below this modulation rate and exceed the value set in Option 24 9 the last turned on will be turned off At this point the lead master and the previous if any lag turned on will begin to modulate in unison until they together are below this setting This will continue until only the lead master boiler remains on Option 24 9 lag slave Off Delay 0 999 minutes LV3 This option sets the time delay between the modulation rate is at or below the value set in Option 24 8 and the last turned on being turned off This also sets the time delay between successive slaves lag being turned off should the modulation rate stay below the setting in Option 24 8 Option 25 0 Banking based on temperature water temperature standby for steam boiler LV3 This option sets which input will be used and the 4 20mA current input from the temperature sensor must be connected into one of the 5 possible current inputs 0 lag banking on temperature is not enabled 1 uses analog input 1 PB8 to PAS input 2 uses analog input 2 PB8 to PA6 input 3 uses analog input 3 PB8 to input 4 uses analog input 4 PB8 to PA8 input 5 uses analog input 5
62. modulate 1 Measured value below warming limit burner held at low fire if the control is in auto or sequencing mode EK18 Boiler status 0 Burner will not fire because the temperature pressure measured value has exceeded the high control value 1 Burner will fire because the temperature pressure measured value has fallen below the low control value EK19 Confirm to adjust 0 Control not in commission mode or control is in commission mode and drives moving to setpoints 1 Control in commission mode and drives may be adjusted using the UP DOWN keys EK20 Drive moved 0 Control not in commission mode or control is in commission mode and drives have not been moved using the UP DOWN keys 1 Control in commission mode and drives have been moved using the UP DOWN keys EK21 Positions proved 0 Drives have stopped moving ready for position prove test 1 Ready for position prove test but drives still moving EK22 Fault alarm 0 No alarms faults present 1 Any Un muted fault alarm present EK23 Oxygen Trim Enable 0 Oxygen trim off or not working 1 Oxygen trim on and working Note EK23 1 IF EK46 0 EK25 CAN TX Failures A count of the number of times the CANbus controller has failed to send a message since power up This should be zero unless there has been a problem EK26 Commission status Current commissioning mode where 0 Normal run mode 1 Adjust ratio mode 2 Commission ratio m
63. move each drive to the required low fire position and press ENTER P4 next profile setpoint above low fire is displayed 7 Repeat step 6 for each required profile setpoint up to a minimum of P4 and a maximum of P23 8 Leave commission ratio mode The last profile setpoint entered will become the high fire setpoint e f a controlled shutdown occurs the controller will return to step 2 The setpoints entered the current commissioning session are not lost and the NEXT key may be used to step through the start up sequence and fire the burner e f a non volatile lockout occurs the setpoints are kept in the same way as for a controlled shutdown It will be necessary to remove all faults before moving further than step 2 e f power is removed from the controller the setpoints entered in the current commissioning session will be lost 127 5 6 3 Leaving commission ratio mode Commission ratio mode __ ENTER Hun mode To leave commission ratio mode and return to run mode press the key labeled RUN followed by the key labeled ENTER e f P3 or higher has been commissioned the existing profile will be overwritten If you do not wish the existing profile to be overwritten disconnect the power to the control without pressing RUN and ENTER e Only the setpoints used in the current commissioning session will be stored For example if an existing profile has setpoints up to P15 but only the setpoints up to P10 were viewed or alt
64. not heated up yet or Check EK45 Check EK73 must be above other probe fault 600 C to work Oxygen trim will not work Trim is not operative Use EK45 and 46 to decide if trim is operative Check that option 30 5 1 Check option parameter 31 1 to 31 4 Boiler just fired up Wait for the boiler transport time after ignition Wait for modulation Probe calibration values not Re enter values options 20 1 20 2 entered correctly Check EK75 must be above 600 C to Probe not heated up yet work Probe installed incorrectly Check wiring Set to monitor only Probe in calibration Check option parameter 30 5 set to 1 Trim being reset Check option parameter 30 6 set to 0 Check option parameter 30 8 set to 0 Trim limits set to 0 0 of flow Trim integral gain set to zero Check option parameters 32 X Commissioning data missing Check option parameters 33 X are non zero Check oxygen and flow values been entered for all profile points in the firing range 154 65 6 8 YB110 TSD104 Fault Messages Due to the increased use of the Nexus Touchscreen in combination with the Burnerlogix the numbering format for fault messages is formatted as below The fault numbers are taken from table 7 in the BurnerLogix manual BL 1001 pdf but with 200 added to the message number The 200 is added because there are codes associated with the PPC6000 that utilize the lower levels codes The list of touchscreen alarm codes associated
65. of 100 psi the burner would first remain at high fire until the pressure reached 90 psi and then start to modulate down If the load was equal to 50 firing rate the pressure would stall at 95 psi Adding and I value of 10 would ramp the output up to 100 high fire in 10 seconds assuming no change in the boiler pressure Setting and I value of 300 increases the output up to 100 high fire in 5 minute 300 seconds As the boiler reaches setpoint the same timing effect occurs above setpoint Therefore too much I can cause over under shoot as loads change Too little I may cause rapid hunting A good starting point for the I value in most cases is 50 Derivative Enabling the derivative has the effect of sensing the rate of change in the process variable pressure or temperature and increasing or holding up the firing rate output despite the integral term This in effect amplifies the output to anticipate the effect of a sudden change in load demand Derivative acts inversely when the setpoint is exceeded Derivative is set in seconds on the PPC6000 A good starting point for the D value in most cases is 2 A rule of thumb is start with a P value of about 1096 of setpoint an value of 50 seconds and a D value of 2 seconds After observing the operation through normal load swings adjust each value usually one at a time and observe the results When making a change it is recommended the value be doubled or halved to
66. of a higher level Passcode Warning Should the Passcode be changed and forgotten the PPC6000 will have to be reprogrammed by using the higher level Passcode Until then no adjustments are possible Operating Pressure PID setpoint 1 or 2 NOTE Parentheses indicate setpoint 2 option parameter E g Day night To set or adjust the boiler s operating pressure follow steps 1 thru 7 Press the COM key Use the UP key to raise the value to 154 or new Site Passcode if changed Press the ENTER key This is the same key as COM If the display shows the angular positions of the servomotors press the MODE key to change to option parameters Using the up or down key move to OPTION 21 1 22 1 This is the control value the Nexus will modulate the burner to maintain PON gt 179 5 6 7 Use the left or right arrow key to move the cursor to the lower portion of the display then using the up down arrow key change the setting Press the ENTER key to accept the new setpoint To exit and return to the normal run mode press the RUN key followed by the ENTER key Note The next time you enter the site password you will return to the last option selected 9 7 4 Adjusting Cut IN and Cut OUT Follow steps 1 through 3 above 4 5 6 T If the display shows the angular positions of the servomotors press the MODE key to change to option parameters Using the up or down key move to OPTION 21 6 22 6 for Low Limi
67. only If not modulating or in a commission mode it shows the actual pressure value otherwise it can t be seen on the NX610 display in commission mode Air pressure will show as a display value on the NX610 display and on the touchscreen if updated to 1 039 or later Currently air pressure setpoints cannot be seen in the profile tables in comfire or on the touchscreen Option 43 0 Water level expansion unit LV3 Reserved Option 43 1 Water level expansion unit LV3 Reserved For options 43 0 and 43 1 Firmware 1 039 or later Option 44 0 Set real time clock 0 1 LV1 Setting this option 1 enables the user to set the clock in the control used for fault logging First set this option to 1 then adjust the options 49 1 to 49 6 When these are correct check that this option is still at 1 then press the RUN key then the ENTER key Option 44 1 Set Year 00 99 LV1 See SET CLOCK Example after Option 44 7 Option 44 2 Set Month 1 12 LV1 See SET CLOCK Example after Option 44 7 Option 44 3 Set Day of Month 1 31 LV1 See SET CLOCK Example after Option 44 7 123 ems Option 44 4 Set Day of Week 1 7 LV1 For reference 1 Sunday 2 Monday through 7 Saturday See SET CLOCK Example after Option 44 7 Option 44 5 Set Hours 0 23 LV1 Hours use 24 hour format AM 0 11 PM 12 23 For reference 0 midnight 12 noon 18 6 pm 12 46 See SET CLOCK Example afte
68. only to the Fireye products and not to any other equipment or to the combined system or its overall performance FIREYE guarantees for one year from the date of installation or 18 months from date of manufacture of its products to replace or at its option to repair any product or part thereof except lamps and photocells which is found defective in material or workmanship or which otherwise fails to conform to the description of the product on the face of its sales order THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES AND FIREYE MAKES NO WARRANTY OF MERCHANTABILITY OR ANY OTHER WARRANTY EXPRESS OR IMPLIED Except as specifically stated in these general terms and conditions of sale remedies with respect to any product or part number manufactured or sold by Fireye shall be limited exclusively to the right to replacement or repair as above provided In no event shall Fireye be liable for consequential or special damages of any nature that may arise in connection with such product or part PPC 6001 FIREYE OCTOBER 7 2015 3 Manchester Road Supersedes May 6 2014 Derry New Hampshire 03038 USA www fireye com 200
69. option set mode Look at the display for the inverter output The display should show 0 for a feedback signal of zero speed 4mA and 999 for a feedback signal of 20mA If using an encoder feedback the value displayed will depend on the frequency measured by the input on the daughterboard See note below If the display is flashing High the feedback signal is less than 3 5mA or more than 21 0mA the polarity of the wiring is reversed or the encoder is faulty In all these cases check the wiring and or the option parameters on the inverter Monitor the reference signal from the PPC6000 daughter board With the inverter drive selected the UP key should increase the current gradually up to 20mA and the DOWN key should decrease the current gradually down to 4mA For encoder feedback signals run the inverter to its maximum value normally 50Hz or 60Hz depending on motor rating local mains frequency Look at engineers key 69 or 70 depending on VSD1 or VSD2 This will give you a measured pulse frequency in Hertz Add about 2 to 5 to this value to ensure it is the maximum you would ever expect to get and enter this value into option parameter 9 5 or 9 6 The displayed value for this drive should now be 950 to 990 i e 95 to 99 For reliability it should be ensured that the feedback can t go over 99 996 999 This is why a small percentage is added to the 10096 scale value entered in the option parameter See option parameter 9 5 for a
70. should be increased a minimum of one degree or until the observed oxygen level increases approximately 1 0 to 1 5 do not press enter at this time At this point the fuel drive should be increased slowly to bring the oxygen level back down to the desired level and entered at this time Following this procedure from low to high fire will yield a relatively linear profile That is to say each position will increase the fuel and air flows by nearly equal amounts from low to high fire thus making the profile somewhat linear This will aid in setting up O2 trim NOTE On very high turndown burners the O2 increase may need to be greater in higher firing rates to avoid running out of P positions The PPC6000 s Engineers Key 44 see section 6 6 2 displays the actual O2 value of the Fireye oxygen probe when fitted It should be noted that the reading of the Fireye probe will be between 1 and 1 596 lower than most portable combustion analyzers This is normal and due to the difference between wet and dry samples Bear in mind the PPC6000 will trim to the value of the Fireye probe not to the value of a portable analyzer Also when using adjust ratio mode to re tune an existing profile do not simply charge the O2 target value Adjust the fuel or air to achieve the desired O2 setpoint then enter that value For example Position Air Drive Fuel Drive Observed 02 Increased 02 P3 5 0 15 0 7 0 9 0 P4 7 5 18 0 7 0 9 0 P5 12 0
71. strips All low voltage circuits and communication wire must be fully shielded braided 9 6 Typical Wiring Diagrams type wire of the specified gauge and number of conductors Table 2 6 1 A provides the only approved wire for this application No or equal is is provided Use of wire not approved by Fireye may VOID warranty Typical Wiring Diagram YB110 All wiring to terminal block PA amp PB as well as to any optional daughter board e g VSD and the Power CANbus wiring to the display must be fully shielded braided wire per Table 2 6 1 A Under no circumstances should these input outputs be connected to mains potential Connection of any voltage above 5 volts to these terminals will damage PPC6000 TA or destroy the unit 24 VIC Sup 24 vac Sup BurnerLogix D A Input 1 Q WA Input C D A Input 3 Q D A Input 4 O PE WDOOOOODOO ODO CABLE CLAMP PROFILE SELECT PURGE POSITION PROVE CAUTION Due to the possibility of High Frequency IGNITION POSITION L F S PROVE NON RECYCLE LIMITS electrical noise BOTH ends of the shielded N signal wire to the VSD must be grounded O RECYCLE LIMITS 5 9 BURNER SWITCH ALARM 8A FUSE Refer to bulletin BL 1001 for remaining BurnerLogix 1 0 connections A complete schematic can be found at http fireve net pdf JC 1109 pdf Note and PE8 provide purge and low fire position signals t
72. take approximately 16 seconds during this initialization period the status LED will remain red The display backlight will come on and the relays will be held in their no alarm state to avoid the possibility of nuisance alarms which may otherwise occur Five 5 seconds after power is applied the Fireye splash screen shown below will be displayed for 6 seconds after which a period of 5 seconds of a blank white screen will show Once the initialization is complete the touchscreen will show the overview screen shown in section 5 4 3 and the control will operate normally changing the LED to green and relays to operate in line with the control status 5 4 3 The Operation Mode line and Status messages The line at the top of the screen displays the current burner operating mode profile modulation mode and unit address Burner status and fault information if applicable is displayed in the bottom right corner of the display Dependent on the actual fault the audible alarm may be active and the control may move to safety shutdown 63 SS 13 07 16 2008 05 20 R GAS AUTO Unito Boiler actual 2 bar Boiler setpoint 64 Jbar Modulation rate Flame intensity 0 Burner Start Sequence Gas valve proving stage 1 Gas valve proving stage 2 Prove air pressure Operating hours 109 Profie 1 GAS SELECTED Purge position reached S0 Profie2 0IL Purge in progress 0 08 Ignition position requested EJ II Ea
73. the upper right hand corner The ENGINEERS key is hidden behind the Fireye logo on the display Pressing the logo will show the EK to the right of which will be the fault and any subset Using the up down arrow keys scrolls through the EK 5 to view other information For specific Engineer s Key listing see Section 6 6 of Fireye Bulletin PPC6001 9 7 7 Fault and Fault Finding Should the Nexus determine a fault has occurred that required the burner be shut down the bottom portion of the display will indicate the cause Pressing the ENGINEERS key will display more information which will be found in the upper right of the display See Section 6 0 of Fireye Bulletin PPC 6001 for more details Using the ENGINEERS key the last 33 faults or limits can be reviewed The fault history begins with the most recent which can be found after EK200 and will be date and time stamped There are three aspects to each record when it was reset when it changed from a fault to a cleared fault and when the fault occurred The portion of the record at the Fxx will also include the subset if any See Fault Subsets Many of the faults detected and displayed by the unit will cause a safety shutdown of the burner Other faults will be displayed as a warning but operation of the burner will not be affected All fault numbers are prefixed by a letter This letter describes the status of the fault F This means that a fault e g PSU calibration fault has occurred
74. to the control it is recommended the alarm relay output be separately fused at 4A maximum NOTE Relays 1 to 3 are optionally provided on the display board Relays 5 and 6 are reserved for future products Relays 7 and 8 are optionally provided on the daughter board 36 amp 2 6 10 Auxiliary Relay Outputs display Fuses not exceeding 4A must protect all relay outputs If a control panel fuse greater than 4A is fitted the relay common MUST be RELAY 1 NORMALLY OPEN PR 1 separately fused at 4A maximum Where the total relay current RELAY 1 NORMALLY CLOSED PR 2 exceeds 4A fit a separate fuse on each relay output to achieve this RELAY OUTPUTS 1 COMMON PR NO CONNECTION PR 4 These outputs must be connected using multi strand single core PVC insulated 16 AWG 19 0 3mm wire Since this cable may be run in conduit with high voltage wiring its voltage rating must exceed the RELAY 2 NORMALLY OPEN PR 5 maximum voltage carried by any other cable connected to the control or RELAY 2 NORMALLY CLOSED PR6 run in the same conduit RELAY 2 amp 3 COMMON PR7 The 3 auxiliary relays provide volt free change over contacts Two of the RELAY NORMALLY CLOSED PR 8 relays 2 amp 3 share a common voltage source The relays are separated on the circuit board to allow either the pair sharing the common or the RELAY NORMALLY OPEN PR9 single relay to operate at high voltage while the other s operate at low NOTE The above is for Alarm Function
75. visible on the probe rear face are there to cover the calibration gas port and the sample gas port The latter is merely a tube that passes directly into the flue to enable gas samples to be drawn or flue temperatures to be taken using other instrumentation normal operation for safety and accurate performance 162 Both ports must be kept sealed during my 9 Appendix 9 1 Calibrating and servicing the oxygen probe 9 1 1 Probe calibration WARNING Before proceeding with probe calibration ensure you have a suitable air and reference gas supply since both are required to complete the calibration procedure The calibration gas concentration must be entered as option parameter 30 3 and the oxygen trim function must be disabled using option parameter 30 5 Depending on the system configuration there may be 2 oxygen probes connected to the system in which case please ensure the calibration gas is being supplied to the correct probe If the probe calibration is to be checked while the burner is firing ensure that oxygen limits have not been set option 38 0 which may cause a burner lock out to occur while the calibration is being performed Proceed with probe calibration as follows 1 2 Enter option set mode using the site or adjust ratio passcodes see section 5 Select option parameter 30 3 and set the value to be the same as the concentration of the calibration gas to be used Select option paramet
76. voltage P Meon Lowvotageor ines PR6 NO Low voltage or line voltage PR8 NO Low voltage or line voltage Option parameter 14 1 Meaning Connection Details NX610 Limits assigned to relay 4 PPC6000 PE1 COM PE4 NO Low oltage or line voltage b Reserved for future expansion NA 6 RR eserved for future expansion een ee OLTAGE AND CURRENT ONLY VUE OLTAGE AND CURRENT ONLY These relays MUST NOT be used to provide a safety function A relay can be used to indicate any combination of fault conditions from 14 0 14 1 and 14 2 this means that one relay could be used for all faults When used for an alarm function the relay will de energize when in the fault condition so an alarm bell would be wired in series with the normally closed contacts Option 14 2 Oxygen and Flue Temperature Limit Relay 0 8 LV3 DEFAULT Relay 4 PD5 This option parameter assigns the limits to a specific relay Relays 2 amp 3 share a common connection on the NX610 display NXTSD104 relays are independent Option parameter 14 2 Meaning Connection Details NX610 value 0 Eue Limits not assigned to any relay _ N A Flue Limits assigned to relay 1 Display PR3 COM PR1 NC PR2 NO Low voltage or line voltage 2 Flue Limits assigned to relay 2 Display PR7 COM PR5 NC PR6 NO Low voltage or line voltage 3 Flue Limits assigned to relay 3 Display PR7 COM PR9 NC PR8 NO Low voltage or line voltage
77. with the BurnerLogix is listed below Fault Description Number 201 T16 M D LIMIT OPEN AUTO 202 HOLD FALSE FLAME STANDBY 203 LOW FIRE PURGE 204 HOLD M 8 LIMT OPEN PURGE 205 AIR FLOW OPEN 206 T16 M D LOW LIMIT AUTO 207 LOCKOUT FLAME FAIL PTFI 208 T16 INPUT CLOSED 209 HOLD M D LIMIT OPEN 210 IGNITION TIMING PTFI 211 CHECK FLAME SIGNAL MTFI 212 FLAME SIGNAL AUTO 213 CYCLE COMPLETE POSTPURGE 214 STANDBY L1 3 OPEN 215 T21 INPUT CLOSED 216 LOCKOUT M D LT OPEN PTFI 217 LOCKOUT LT M 8 LIMIT OPEN 218 LOCKOUT LIMIT M D OPEN 219 LOCKOUT FLAME FAIL MTFI 220 LOCKOUT FALSE FLAME 221 LOCKOUT 3 P INTLK OPEN P 222 LOCKOUT 3 PINTLK CLOSED 223 HOLD 3 P INTLK CLSED STBY 224 HIGH FIRE PURGE 225 LOCKOUT M D LT OPEN MTFI 226 LOCKOUT 3 P INTLK O AUTO 227 LOCKOUT 3 P INTLK O MTFI 228 LOCKOUT 3 P INTLK O PTFI 229 LOCKOUT T13 FVES OPEN 230 LOCKOUT 3 P INTLK O PP 231 CHECK FLAME SIGNAL PTFI 232 CHECK M 8 HI LIMIT HFP 233 CHECK M D LOW LIMIT LFS 234 FLAME SIGNAL PTFI 235 HOLD T21 OR CHK LF AUTO 236 FLAME SIGNAL MTFI 237 LOCKOUT FLAME FAIL AUTO 238 HOLD 3 P INTLK O PP 239 LOCKOUT FUELVLVE ST CH 263 HIGH WATER 264 LOW WATER 265 HIGH GAS PRESSURE 266 LOW GAS PRESSURE 295 AUX GAS 155 Fault Description Number 267 LOW OIL PRESSURE 296 HIGH OIL TEMPERATURE 268
78. 00 101 to 104 3 The selected profile has been uploaded from a PC but has not been verified on this burner Subset Invalid profile 100 101 to 104 In all cases the F74 can be cleared by switching to another good profile or by re commissioning the profile in commission ratio mode making sure all points up to and including high fire are acknowledged using the NEXT key or ENTER if the points are adjusted a The control has locked out on power up This will normally be because option parameter 1 0 is set to 1 Subset 1 See option parameter 1 0 254 Serial EEPROM write failure 255 NV Lockout verification failed Currently unassigned Secondary relay A secondary fault has occurred with the non volatile lockout relay fault A Self check is performed once an hour and two consecutive failures will cause the fault to appear and the burner to lock out immediately e Contact supplier Subset Failed relay number 138 Fault Description Number F68 Secondary A fault has occurred with the program memory in the control A program memory Self check is performed once an hour and two consecutive failures checksum fault will cause the fault to appear and the burner to lock out immediately e Contact supplier Subset Not applicable Secondary A fault has occurred with the CPU watchdog A Self check is watchdog fault performed once an hour and two consecutive failures will cause t
79. 00 therefore only CANbus signals need to be derived from the PPC6000 and not the power The recommended cable for this CANbus connection is overall screened 2 core PVC insulated minimum 24 AWG 7 0 2mm cable since this cable is to be run adjacent to and or in the same conduit as high voltage wiring its voltage rating must exceed the maximum voltage carried by any other cable connected to the control or run in the same conduit CANbus PB 3 CANbus PA 3 CANbus 4 CANbus PA 4 Connect the screen with the use of the screen termination clamp at the PPC6000 and be cut back and insulated at the Oxygen Probe Interface Incorrect connection may damage or destroy the units being connected FOR MORE DETAILS See section 2 6 18 thru 2 6 20 2 6 16 Pressure temperature sensor input PPC6000 The pressure temperature cabling must be overall LOOP POWERED screened PVC insulated minimum 24 AWG PXMSxxxx 4 20mA SENSOR 7 0 2mm number of conductors cores as or required by the relevant sensor Since this cable other 2 WIRED LOOP POWERED SENSOR may be run in conduit with high voltage wiring its voltage rating must exceed the maximum voltage carried by any other cable connected to the control or run in the same conduit SENSOR SUPPLY PB 8 OR EXT SELF POWERED The input is suitable for use with 0 5V or 4 20mA 4 20 0 5V signals externally or internally powered Refer to section 2 5 3 for details on setting the
80. 104 Fault Messages 155 7 Inverter variable speed drives 157 7 1 System configuration 157 7 2 Description of control method 158 7 3 Setting up the inverter for use with the PPC6000 series 158 7 4 Setting up the PPC6000 series for use with a inverter drive 159 8 The oxygen trim option 160 8 1 Oxygen Pro probe description 160 8 1 1 Installation of oxygen probe 160 8 1 2 Mounting the oxygen probe 160 9 Appendix 163 9 1 Calibrating and servicing the oxygen probe 163 9 1 1 Probe calibration 163 9 1 2 Oxygen Probe Filter Testing 164 9 1 3 Removing the oxygen probe from the flue 164 9 1 4 Filter replacement 165 9 1 5 Probe mounted flue thermocouple replacement 165 9 2 Troubleshooting inverter problems 167 9 3 PID Tutorial 168 9 4 Combustion Profile Setup Guideline 169 9 5 Fireye PPC6000 Efficiency Calculations 170 9 6 Typical Wiring Diagrams 172 9 7 Operator s Guide 179 9 7 1 Introduction 179 9 7 2 General 179 9 7 3 Password 179 9 7 4 Adjusting Cut IN and Cut OUT 180 9 7 5 Manual Modulation 181 9 7 6 Resetting the Control 181 9 7 7 Fault and Fault Finding 182 9 7 8 Fault subsets 182 9 7 9 Fault listing 183 9 7 10 PID Tutorial 183 9 7 11 The startup shutdown stages are as follows 184 9 7 12 Non volatile lockout 187 9 8 Fireye Nexus Combustion Curve 188 10 Function Block Programming Details 189 Introduction to Fireye s Abacus Programming Software 189 1 1 Introduction 189 1 4 The schematic toolbar 193 1 5 Place Function blocks 194
81. 139 ew 6 6 1 Fault history The PPC6000 series stores information on faults The memory in the unit will store the last 128 faults and associated status data and as an option a date and time stamp The 100 most recent faults are available via the display unit and all 128 are available through ComFire The Engineers Key gives access to the fault history To view the fault history scroll up through the EK s numbers until EK200 then by scrolling once more the most recently occurring fault is displayed indicated by 00 in the top left corner of the display For example Fault log number Date and time 400 01Jun 03 13 05 014 F04 Dig Input 4 Earlier faults are displayed by indexing using the UP key The fault log can be navigated using the UP DOWN keys 6 6 2 Engineer s key parameter list No Name Description 1 Shows the state of each input EK2 Low Voltage Digital Input 2 PAG6 PA11 Where EK3 Low Voltage Digital Input 3 PA7 PA11 0 OFF Open circuit EK4 Low Voltage Digital Input 4 PA8 PA11 1 ON 5 Low Voltage HIGH input 9 11 EK6 Low Voltage AUTO input 10 11 EK8 Profile 1 Select Line Voltage PE9 EK9 Profile 3 Select Line Voltage PE11 EK10 Profile 2 Select Line Voltage PE10 EK11 Profile 4 Select Line Voltage PE12 140 No Description EK16 Low fire hold or warming limit active 0 Measured value above warming limit burner free to
82. 16 5 16 6 value 0 AlarminputOpen O 2 ExtraLowWater O 4 High Gas Pressure J 0 0 0 O 5 Jf LowGasPresue 6 High Oil Pressure 8 HghOlTem o 9 LowOlTemp gt 4A A4 y 93 Option parameter Meaning 19 X or 16 5 16 6 Low Draft BurnerDoorSwitch Emergency Stop ExitDamperClosed The product allows for customization of various non safety critical functions including the modulation control The option parameters shown below relate to the default modulation control function programmed in the control at the factory To verify this has not been replaced by an application specific function check with the equipment supplier and or check option parameter 00 4 if available Option 20 0 Set point Select input 0 35 LV3 This option parameter allows for a digital input to be used to select between modulation setpoint sets 1 and 2 see option parameters 21 0 and 22 0 1 4 Open Setpoint 1 Closed Setpoint 2 16 or 20 Permanently Closed Setpoint 2 21 24 Closed Setpoint 1 Open Setpoint 2 NOTE Options 20 0 to 20 6 and 20 8 have two operational modes In one case a high level or voltage present as would be the case of a closed switch will result in the action specified In the other case a low level or open switch would cause the action specified For example gt If opti
83. 4 128 Air pressure input 133 Fault Number Burner input fault Primary relay fault ADC fault RAM test fault Description One or more of the high voltage profile select inputs is registering a fault Subset Failure mode One or more of the internal relays is not responding correctly Subset 1 10 Failed relay number One of the internal checks on the analog to digital converter has failed Subset Failure mode This fault occurs if the control receives more than 5 false restart requests within a 15 minute period A false restart request occurs then the fault mute key input is held for more then three seconds when there is no fault present This is to protect against a failure in an external device continually re starting the control which could cause un attended burner restarts in the event of a genuine burner problem This is important since the fault mute function can come from anywhere via a digital input or serial communications To clear the fault either enter a commission mode or cycle the power to the control The subset in not applicable for this fault The main memory in the control has malfunctioned Interrupt power to the control This could be due to high levels of electrical interference getting into the product Check all cables are correctly screened and screens are terminated correctly Ensure the mains supply is not excessively noisy e lf this fault persists t
84. 6 Analog Input 3 decimals 0 2 LV3 105 Option 28 7 Analog Input 3 zero 0 999 LV3 106 Option 28 8 Analog Input 3 span 0 999 LV3 106 Option 29 0 4 20mA Output 1 function if not VSD LV3 106 Option 29 1 Output1 zero value 4mA output LV3 106 Option 29 2 Output1 span value 20mA output LV3 106 Option 29 3 4 20mA Output 2 function if not VSD LV3 107 Option 29 4 Output2 zero value 4mA output LV3 107 Option 29 5 Output2 span value 20mA output LV3 107 Option 29 6 4 20mA Output 3 function if not VSD LV3 107 Option 29 7 Output3 zero value 4mA output LV3 107 Option 29 8 Output3 span value 20mA output LV3 107 Option 30 0 Oxygen probe interface serial number LV3 109 Option 30 1 Oxygen probe calibration offset value 0 999 LV3 109 Option 30 2 Oxygen probe calibration gain value 0 999 LV3 110 Option 30 4 Flue and inlet sensor temperature units 0 1 LV3 110 Option 30 5 Oxygen input function 0 1 LV3 110 Option 30 6 Oxygen probe calibrate enable 0 2 LV3 110 Option 30 7 Boiler transport delay 5 60 seconds LV3 111 Option 30 8 Reset oxygen trim profile 0 1 LV3 111 Option 30 9 Automatic trim commissioning 0 1 LV3 111 Options 31 1 to 31 4 Trim Type for profiles 1 to 4 0 to 2 LV3 113 Option 32 0 Trim limit default 0 1 LV3 114 Options 33 1 to 33 4 Trim integral gain Default 1096 LV3 114 Option 34 0 Trim proportional gain 0 1 LV3 115 Options
85. 9 NOTE When using sequencing setpoint 2 is unavailable for use with any digital input unless the boiler is removed from sequencing completely Option 24 0 Sequence Slaves number of boilers 0 3 LV1 This option is set to 1 2 or 3 in each PPC6000 to equal the number of lag slave boilers in the system Once set option parameters 24 1 24 2 and 24 3 will become available If the value is set to 0 the boiler will be taken out of sequencing and operate on its own PID NOTE OPTION PARAMETER 00 6 MUST BE SET TO 0 FOR SEQUENCING TO OPERATE ON NEWER PPC6000 s Option 0 6 has been moved to the NX610 display Press and hold the DATA key for 5 seconds Position the cursor to NORM for sequencing See Section 4 1 for details Option 24 1 24 3 Priority Number s LV1 The order in which boilers sequence on is entered as the communication address s of the boilers in Options 24 1 24 2 and 24 3 The first to be turned on will have a priority number one above that of the lead boiler For example If the communications address of the four boilers were 1 2 3 and 4 set in Option 0 2 boiler 1 master lead with the following entered in Options 24 1 24 3 102 Option parameter 24 x value The sequencing order would be boiler 2 3 and 4 If boiler 2 were set to lead via Option 24 5 the order would be boiler 3 4 and 1 Setting boiler 3 to master lead the order would be boiler 4 1 and 2 Other sequencing orders can be achieved by ch
86. 9 Prof e 1 GAS SELECTED 50 Profile 2 OIL The Name for each available profile will be either the default as set by the relevant option parameter or that entered via the Configuration Screen If the profile change is made while the burner is firing there are two possibilities dependent on the options set in the control If the unit does not have the option to perform an online changeover enabled switch profile without the burner going off the burner will go through a controlled shutdown on the original profile and then restart on the new profile The online changeover allows a digital input to be configured to allow a profile swap without turning the burner off If this input is ON and a fuel profile selection change is made the control will go to low fire then back to pilot ignition P2 on the original profile It will then drop the main fuel valves and run with just the pilot on and the ignition transformer if option parameter 14 6 is not set to 1 It will then move all drives to the P2 position of the new profile and open the appropriate main fuel valves To exit this operation window and return to the overview screen press the Overview button 67 Guy Once the Control button is pressed a window appears giving the user a choice of options If an option is unavailable it will be grayed out for example Manual Modulation may be disabled during commissioning 5 4 8 Touchscreen Control
87. 9 9 0 00 9 99 LV1 If the boiler is off due to a controlled shutdown this parameter defines the measured value at which the boiler will be turned on again Option 21 7 Setpoint 1 high limit control value Cut Out 0 999 00 0 99 9 0 00 9 99 LV1 If the boiler is on and firing this parameter defines the measured value at which the boiler will be turned off via a controlled shutdown Option 21 8 Remote Setpoint 1 zero 4ma value 0 999 00 0 99 9 0 00 9 99 LV1 This is the zero value for the remote setpoint function specified by option parameter 20 7 Option 21 9 Remote Setpoint 1 span 20mA value 0 999 00 0 99 9 0 00 9 99 LV1 This is the span value for the remote setpoint function specified by option parameter 20 7 Option 22 0 PID set point 2 enable 0 1 LV1 This option parameter is used to select setpoint 2 98 E Option 22 1 Set point 2 control value 0 999 00 0 99 9 0 00 9 99 LV1 This is the control value used in the PID control loop for setpoint 2 When the control is in auto mode the PID control loop will modulate the boiler to maintain the measured value at the same level as set by this parameter Option 22 2 Set point 2 proportional band 0 999 00 0 99 9 0 00 9 99 LV1 This is the width of the proportional modulation band that is used by the PID control loop for setpoint 2 For example if the setpoint was 100 psi and this term was set to
88. BRAIDED SHIELD NO CONNECTION NOTE Wire Sizes Shown are MINIMUM After ensuring all connectors are correctly fitted secure the probe cap on the probe The heater supply must be connected using screened 2 conductor core 16 AWG 19 0 3mm PVC insulated cable The oxygen cell output must be connected using screened 2 conductor core 20 AWG 16 0 2mm PVC insulated cable Both thermocouple connections must be made using type K compensating cable For screen connection detail refer to section 2 6 2 DO NOT connect the screens at the probe Incorrect connection may damage or destroy the units being connected 2 6 23 Inlet temperature sensor optional 24Vac PA PB 1 FIREYE NXIATS AIR TEMPERATURE 24Vac PA PB 2 CANbus PA PB 3 SENSOR See NOTE CANbus PA PB 4 CABLE CLAMP NOTE Insulate Shield Terminal 5 to prevent accidental shorting to pins on circuit board J1 The system allows direct connection of an FIREYE inlet temperature sensor The unit is connected via CANbus similar to the servo motors and display using overall screened 4 conductor core 24 AWG 7 0 2mm PVC insulated cable Since this cable is to be run adjacent to and or in the same conduit as high voltage wiring its voltage rating must exceed the maximum voltage carried by any other cable connected to the control or run in the same conduit See Sections 2 6 1 amp 2 6 2 Incorrect connection may damage or destroy the units being connect
89. CAUTION When using the adjust ratio mode it is not possible for the unit to check drive positions at all times It is the responsibility of the engineer to check that motors and valves are responding correctly To adjust an oxygen setpoint or enter an air flow value in the firing range use the following procedure The manual calculation of the values to be entered here is covered in the next section 1 Enter adjust ratio mode See section 5 6 2 Ensure oxygen trim is set to monitor only 30 5 0 3 Use the scroll keys to select the desired setpoint and move up and or down A4 for example The system will modulate to the selected setpoint and the number displayed will flash to indicate that the drives are modulating 4 Wait for the number in the display to be illuminated steadily This means that the drives have arrived at the selected setpoint 5 The display will allow scrolling sideways to show flow and O2 in addition to the servo motor positions to indicate that the system is expecting a flow value and an oxygen setpoint to be entered for the current profile setpoint To check the current oxygen measured value use the engineer s key EK44 6 Once the oxygen value is shown on the display use the scroll keys to position the gt pointing to the O2 value use the UP DOWN keys to adjust the oxygen setpoint as necessary The display will start flashing to indicate that a change has been made 108 eS 7 If the new ox
90. E fe O NOTE Insulate Shield 4 Cover shield to Terminal 5 to prevent prevent short accidental shorting to iis pins on circuit board J1 CANbus 24 VAC 24 VAC Oo NXIATS Inlet Air Temperature Sensor 196 my 11 2 PPC6000 Variable Speed Drive Daughter Board P N NXDBVSD SS E a FER ale OONAARWNH See Section 5 4 1 Option 03 x for setup details CAUTION Due to the possibility of High Frequency electrical noise BOTH ends of the shielded signal wire to the VSD must be grounded 4 20mA Output Channel 1 PZ 1 4 20mA Output Channel 1 PZ2 4 20mA Output Channel 2 PZ3 4 20mA Output Channel 2 PZ4 4 20mA Output Channel 3 2 5 4 20mA Output Channel 3 PZ6 Counter Input 1 PZ 7 12Vdc PZ8 Counter Input 2 PZ 9 12Vdc PZ 10 Counter Input 3 PZ 11 Input Channel 1 PZ 12 Input Channel 1 PZ13 Input Channel 2 PZ14 Relay 7 common PZ 15 Relay 7 normally open PZ 16 Relay 8 common PZ 17 Relay 8 normally open PZ 18 The cabling for all of these terminals must be 2 conductor core overall screened PVC insulated 24 AWG 7 0 2mm Since this cable may be run in conduit with high voltage wiring its voltage rating must exceed the maximum voltage carried by any other cable connected to the control or run in the same conduit The counter inputs are for use with encoder s for speed feedback from the devices being controller by the
91. EK48 Excess air Excess combustion air at the current firing position EK49 Oxygen error Error between O2 measured value and O2 setpoint 143 No Name Description EK50 Trim deviation flow Deviation in air flow imposed by trim 25 to 25 EK55 Main PCB issue The issue number of the main circuit board that the firmware is expecting This may be different to the actual PCB issue if they are compatible EK56 Software issue The current revision of the main product firmware CPU serial number low 4 digits The CPU board serial number Drives at setpoint Represents which drives are currently at their setpoints where 0 All drives are at their setpoints and are not moving Non zero One or more drives are not at their setpoint Digital relay outputs on The combination of digital outputs currently Switched on 1 Digital Output 1 ON Display PR3 COM PR1 NO PR2 NC Low voltage or line voltage 2 Digital Output 2 ON Display PR7 COM PR5 NO PR6 NC Low voltage or line voltage 4 Digital Output 3 ON Display PR7 COM PR9 NO PR8 NC Low voltage or line voltage 8 Digital Output 4 ON PPC6000 PE4 line voltage out 16 Digital Output 5 ON Not implemented 32 Digital Output 6 ON Not implemented 64 Digital Output 7 ON Daughterboard PZ15 PZ16 LOW VOLTAGE AND CURRENT ONLY 128 Digital Output 8 ON Daughterboard PZ17 PZ17 Not implemen
92. EW PROBE MOUNTED ON SIDE SECTION ON E E ACCEPTABLE MOUNTING PREFERRED MOUNTING PROBE MOUNTED ONSIDE O FLUE AS 4 i q SECTION T OND D 4 4 2 lt ___ PROBE MOUNT HOLES SHOWN F L F 2 SEE HG220371 E E NOTE ORIENTATION RELATIVE FLUE D FLUE TO FLUE GAS FLOW SCENE EM GAS GAS FLUE EQ f LI S PROBE MOUNT HOLES SHOWN p c MJ SIDEVIEW 30 SEE HG220371 HOLE ORIENTATION SECHONONGC SECTION ONFE RELATIVE TO FLUE GAS FLOW TOP VIEW PROBE MOUNT HOLES SEE HG220371 SECTION ON A A NOTE ORIENTATION RELATIVE TO OAS ETON UNACCEPTABLE MOUNTING meee E SIDE VIEW HORIZONTAL FLUE FLUE Gx PROBE MOUNTED UNDERNEATH CES B B Ne J 41 i Ep NON PREFERRED MOUNTING gt HORIZONTAL FLUE pun 2 PROBE MOUNTED ON es DO NOT FIT PROBE IN THIS POSITION SECTION ON B B SIDE VIEW There are two types of flange available see the drawing over the page With either flange the vertical center line of the flange shown on the drawing should correspond to the gas flow direction 6 stainless steel M6 x 20mm socket cap screws are provided for probe attachment The probe flange temperature must be maintained at the temperature of the flue wall by repacking or adding lagging which may have been removed to mount the probe Sulphate condensation will occur if the flue wall of an oil fired boiler fa
93. F when the burner is switched off or at the end of post purge This provides a EK18 feedback to confirm that the burner is off and ensures that this control is always synchronized with the burner controller The controlled shutdown output on PE3 will be OFF during this time however the safety shutdown output PE5 PE6 will be closed during this time The control will advance to status 2 when All fuel profile select inputs are OFF The boiler status is equal to 1 call for heat See engineers key 18 The AUTO input PA10 PA11 is OFF open 55 Stage Stage Description no 2 Wait for purge The controlled shutdown output on PE3 will be switched on to tell the burner controller there is a call for heat 5 This control waits for a fuel profile select signal on one of the line EK11 14 voltage terminals PE9 PE10 PE11 or PE12 and a purge request EK31 HIGH input PA9 PA11 closed This input is low voltage This would normally come from the burner controller If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 Note Statuses 3 and 4 are reserved for a gas valve proving system and are not implemented on this control This control will advance directly to status 5 once the conditions above have been met Not Applicable to PPC6000 Prove closed In all profiles the fuel and air motors are moved do
94. ION INTERFACE GATEWAY SD interface daughter board with two VSD channels one analog output two NXDBVSD ounter inputs two programmable relays isolated RS485 Modbus RTU ommunications NXMBIV2 Modbus RTU Communications daughter board FOR ADDITIONAL PARTS SEE FIREYE PRICE BOOK CG 14 SOME FEATURES INCLUDED ON NXTSD MANUFACTURED AFTER MAY 2011 17 Sy 2 Installation This section contains basic installation information concerning choice of control and servomotor environment wiring specification and connection details N WARNING EXPLOSION OR FIRE HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH To prevent possible hazardous burner operation verification of safety requirements must be performed each time a control is installed on a burner or the installation modified in any way This manual may cover more than one model in the PPC6000 controls Check for Additional Information at the end of this chapter This control must not be directly connected to any part of a Safety Extra Low Voltage SELV circuit WHEN INSTALLING THIS PRODUCT e Read these instructions carefully and ensure you fully understand the product requirements Failure to follow them could damage the product or cause a hazardous condition e Check the ratings given in these instructions to ensure the product is suitable for your application e After installation is complete check the product operation is as described in these in
95. If a combustion air pressure sensor is used in with firmware version 1 219 EK56 addition to the main air pressure switch in commission modes this will give the measured combustion air pressure In run mode this will give the combustion air pressure error which is the difference between the measured and expected air pressure Firmware type PT22 This shows the last four digits of the firmware part number for the PPC6000 software It is used for product variant identification The product allows for customization of various non safety critical functions including the modulation control The engineers keys shown below relate to the default modulation control function programmed in the control at the factory To verify this has not been replaced by an application specific function check with the equipment supplier and or check option parameter 00 4 if available NOTE EK101 200 shown in next table are controlled by the loaded modulation program The values given below are for the latest version 40 EK200 production version but user programs may change add to these No Name Description EK101 PID1 Active If the value is 1 Setpoint PID set 1 is active EK102 PID2 Active If the value is 1 Setpoint PID set 2 is active 147 Description No EK103 Control Limits Active If the value is 1 the control limits are active and will turn the burner on and off as the load dictates The low and high limits are shown
96. Less than 25mA 10V absolute maximum Profile Select High voltage inputs Digital OV for off 90 264Vac for on 1 6 Pressure Temperature Input PPC6000 0 5V Maximum current Less than 2mA Maximum voltage 0 to 5 0 volts maximum Input accuracy typical 0 1 Input accuracy as specified by EN12067 40 3 4 20mA 2 wire loop or ext powered Maximum current 0 to 25mA maximum Burden load resistor 220 Ohm nominal Input accuracy typical 1 0 Input accuracy as specified by EN12067 1 1 1 7 Communications interface PPC6000 2 wire RS485 plus ground with termination resistor selected using a link See Section 2 5 5 An isolated 2 wire RS485 interface is available as an option See Section 2 5 6 See MOD 6101 FIREYE serial communications protocol manual for details 13 1 8 Optional Oxygen Probe Interface Unit NXO2INT optional Supply voltage Power consumption Supply frequency Ambient temperature range Protection category Unit dimensions Weight Interface to PPC6000 series Interface to oxygen probe 115 230Vac 15 Approximately 60VA 50 60Hz 5 0 to 60 C 32 to 140 F NEMA4 IP65 160 x 98 x 63mm 6 30 x 3 86 x 2 48 deep 1 34Kg 2 95 Ibs FIREYE specific CANbus FIREYE specific or 4 20mA 1 9 Optional Ambient Air Temperature Unit NXIATS optional Type Ambient temperature range Protection category Unit dimensions Weight Interface to PPC6000 series CANbus 0 to
97. MP THERMOCOUPLE PM 6 FLUE TEMP THERMOCOUPLE PM 5 CELL TEMP PM 4 CELL TEMP PM 3 CELL OUTPUT PM 2 CELL OUTPUT Termination for screens from Oxygen Probe screw J22 PL 7 Ov Common see note PL6I P2 4 20mA see note PL5 N A future use PL 4 CANbus PL 3 CANbus PL 2 Neutral PL 1 Live 2 QQ AH221723 gt Earth screw NOTE 4 20mA input from non Fireye probe See sections 30 1 and 30 2 44 CAUTION e Disconnect the power supply before beginning installation to prevent electrical shock equipment and or control damage More than one power disconnect may be involved Wiring must comply will all applicable codes ordinances and regulations Wiring where required must comply with NEC Class 1 Line Voltage wiring The cabling between the unit and the probe consists of the following Cable Specification Probe heater cable e Max voltage in use lt 30V ac e Overall braid screened 2 core PVC insulated 16 19 0 3mm 300V 176 F 80 C e Max cable length 20 meters between units Probe cell signal cable voltage in use lt 15V dc e Overall braid screened 2 core PVC insulated 20AwG 16 0 2mm 300V 176 F 80 C e cable length 20 meters between units Heater and flue e Max voltage in use lt 15V thermocouple compensation cable e Cable Colors EU 2 PVC insulated cores
98. PA12 supply to PA13 input NOTE If a loop powered sensor is used the to the sensor is taken from PB8 PA12 sensor supply JP3 must be set to the 30V position and the from the sensor is connected to PA5 PA6 PA7 PA8 or PA13 depending on which input number is to be used If the temperature sensor gives a current feedback that is out of range i e Less than 3 5mA or greater than 21mA lag banking on temperature will be cancelled and the sequence lag boiler will bank based on steam pressure 104 Cary The following option parameters are only visible if option 25 0 is non zero Option 25 1 Water temperature zero value Sets the zero value for the 4 20mA input usually 0 for a 0 xxx degree temperature sensor Option 25 2 Water temperature span value LV3 Sets the span value for the 4 20mA input i e the sensor range xxx Option 25 3 Water temperature cut in LV1 Sets the low banking cut in temperature Option 25 4 Water temperature cut out LV1 Sets the high banking cut out temperature Option 25 5 Temperature based warming limit LV1 This works independently and in addition to the normal warming limit If a non zero value is entered in 25 5 the burner will also hold at low fire if the temperature drops below this limit Option 25 6 Lag wait time LV1 This option allows for additional time to be added before a second or third lag is started This allows the previous lag time to contribute to t
99. PR2 close when this is true Warming Limit Exceeded Abbreviations Com Common N C normally closed N O or N Open normally Open C For NXTSD104 if set as Alarm no alarm present at power up relays change state as follows 90 Option Relay ALARM Function Connection Detail for NXTSD104 Only Parameter Output ai 17 3 1 Display Low or Line voltage PR1 Common PR2 Normally Open PR3 Normally Closed 2 Display Low or Line voltage PR4 Common PR5 Normally Open PR6 Normally Closed 3 Display Low or Line voltage PR7 Common PR8 Normally Open PR9 Normally Closed 17 4 4 JPPC6000 PE1PEA4 Line voltage output ONLY 175 5 LE LB eee ee ee ME E 17 9 Available on NXTSD104 display ONLY PR10 Common EU PR11 Normally Open PR12 Normally Closed D For NXTSD104 if set as General Purpose relay connections are as follows NOTE If any relay has been previously selected for alarm purpose power MUST be recycled to reset the relay AFTER changing that relay to general purpose Option Relay GENERAL PURPOSE Connection Detail for NXTSD104 Only Parameter Output 17 1 1 Display LoworLine voltage PR1 Common PR2 Normally Closed Display Low or Line voltage PR4 Common PR5 Normally Closed PR6 Normally Open PR8 Normally Closed PR9 Normally Open PR3 Normally Open 17 2 2 17 3 3 Display Low or Line voltage PR7 Common 4 174 4 000 4 Linevoltageouput ONLY
100. Profile too close to micro switch Move end points further away from high low faults Poor Ground earth or Check wiring screening Move motor across range and check the Feedback potentiometer faulty feedback in commission ratio mode with the burner off Communication to servo Check wiring motor s Control stuck at low fire Meas value exceeds setpoint No fault Warming limit active Wait for boiler to warm up Check EK16 Control in manual Press the AUTO key to change to auto mode External low fire hold or missing Remove feed from Aux inputs if selected AUTO input from burner Check EK 6 controller In manual mode Increase the mod rate using UP key Check PID proportional band must be greater than zero to modulate Control stuck at a Serial communications Disable or change modulation slider in modulation rate Computer software Control in commission mode Press RUN then ENTER to enter run mode 152 6 7 5 Inverters CAUTION Due to the possibility of High Frequency electrical noise BOTH ends of the shielded signal wire to the VSD must be grounded Solution Ensure that the inverter receives a RUN signal from the burner fan motor output on the PPC6000 series control Possible Cause e Inverter does not start because it does not receive RUN signal Problem SPEED TIME Inverter has a slow start e Ensure that the inverter s slow start feature is disabled Late RUN signal
101. RS485 Communications status Toggles between 1 and 0 when RS485 is active on the local interface not the Modbus interface 142 Description If non zero the control is in the process of performing a fuel profile swap without turning the burner off EK40 Shutdown setpoint The nearest setpoint EK36 when the burner last locked out EK42 Adjust ratio counter The number of times adjust ratio mode has been used EK43 Commission ratio counter The number of times commission ratio mode has been used EK44 Oxygen measured value The current flue oxygen value as measured by the ETC Oxygen probe if fitted EK45 Oxygen probe status 0 Probe OK 1 Internal fault 2 Internal fault 4 Heater fault Causes F50 8 Cell temperature out of range 16 Cell millivolts out of range 32 CANbus error 64 Probe calibrating in reference gas See option parameter 30 6 128 Probe calibrating in air See option parameter 30 6 Oxygen trim status 0 O2 trim working or 1 no oxygen interface connected 2 no oxygen probe serial number entered or option 30 5 not 1 or option 30 8 not 0 or trim not selected via aux input or trim not selected via serial comms 4 O2 setpoints or flow values incorrect 8 Option 20 6 not 0 16 Not modulating 32 In commission mode 64 Probe faulty see EK45 EK47 Oxygen setpoint 96 Current oxygen setpoint This is only available if trim is enabled and working
102. T to ensure burden resistor s not connected 2 5 5 RS485 serial communications termination resistor PPC6000 Please note that the RS485 serial communications supplied as part of the basic JP4 control is non isolated the termination resistor is selected by JP4 The two OUT OUT controls at the end of the communications bus should have this link set to the IN position All other controls should have the link set to the OUT position If only two controls are on the communications bus set the links on both controls to the IN position IN IN 2 5 6 RS485 serial communications termination resistor daughter board The optional daughter board provides an isolated RS485 serial communication function the termination resistor is selected by the RS485 JP2 jumpers on the daughter board but the terminals are provided as part of the in PPC6000 The two controls at the end of the communications bus should have N IN both of the RS485 JP2 links set to the IN position All other controls should have the links set to the OUT position If only two controls are on the communications bus set the links on both controls to the IN position 27 24Vac Supply 24Vac Supply CAN CAN Digital i p 1 Digital i p 2 Digital i p 3 Digital i p 4 H HIGH A AUTO Digital COM Analogue i p 0Vdc JUMPER amp FUSE 2 Supply DETAIL SHOWN ON 7 UNIT BACKPLATE CAN RS485 A Sensor Supply Sensor Input 0v Isol Com Isol
103. TION Use extreme care while commissioning the system While operating in adjust ratio mode the safety of the system is the sole responsibility of the commissioning engineer Incorrect positioning of any drive could cause a hazardous situation to occur e To adjust the position of a servo motor or inverter select the relevant drive and use the UP DOWN keys e To change the setpoint being modified using the scroll key select the setpoint and then use the UP DOWN keys Each setpoint in the profile is referred to with a letter and number No Name Comments AO Close The close setpoint cannot be altered in adjust ratio mode A1 Purge The purge setpoint cannot be altered in adjust ratio mode A2 Ignition The ignition setpoint cannot be altered in adjust ratio mode A3 Low fire Low fire setpoint Ax High fire High fire setpoint which was the last setpoint entered max P24 The procedure for modifying a setpoint is as follows 1 Enter adjust ratio mode A n is displayed in the window where n is the number of the setpoint that is closest to the current firing position 2 Use the scroll key to select the setpoint and use the UP DOWN keys to move to the setpoint in the firing range to be altered 3 Wait for the A n display to stop flashing and modify the drive s as required 4 If the modified positions are not required press the NEXT key to return the drive s to their original positions or use the scroll key to move to a di
104. UN signal from the burner controller at the same time as the PPC6000 Check that the inverters output is selected to be linear and that the inverters own PID loop is disabled Slow down the inverter by increasing its acceleration deceleration time settings Check cable screens Slow down the inverter by increasing its acceleration deceleration time settings Check that the inverters output is selected to be linear and that the inverters own PID loop is disabled Increase the inverter stop time by increasing option parameter 9 3 on the PPC6000 Adjust option parameters 9 0 9 2 and 9 3 on the PPC6000 control to reduce accuracy amp slow down control response Check Option parameter 9 4 matches the acceleration deceleration time programmed into the VSD VSD is current limiting Increase acceleration deceleration time in VSD and option parameter 9 4 In extreme cases it may be necessary to increase the inverter error tolerance to prevent safety shutdowns caused by positioning faults set option 9 1 1 This must only be done if an inverter error of 55 will not cause unsafe combustion 167 CH 9 3 PID Tutorial PID Adjustment The PPC6000 utilizes and advanced algorithm in order to maintain setpoint over a variety of load conditions This three term PID can be infinitely adjusted to suit almost any application The operator should have a basic understanding of the relationship between the three terms pr
105. When the system is in commissioning mode the serial number of all the connected drives is read by the PPC6000 and displayed as a list to allow the selection of the relevant serial number unit for each drive 0 9 to be made Scrolling the list in an upward direction will scroll through all drive options available until O No Drive is displayed Enter this value to disconnect the specified drive from any hardware Scrolling the list in a downward direction will stop when the currently selected item is displayed and the value will stop flashing The display will show type information for each drive present such as the torque rating of a servo but the commissioning engineer should be aware of which serial number servo is connected to which item on the burner If the optional VSD daughterboard is fitted four additional options are present reference section 2 6 18 Displayed Option Meaning c VSD2 mA VSD channel 2 is used with a 4 20mA feedback d VSD2 Hz VSD channel 2 is used with an encoder pulse frequency feedback If a drive serial number is changed any profiles using that drive will require re commissioning A profile invalid fault see FAULT 64 will lock the burner out on an attempt to fire a profile which has had a previously commissioned drive removed The profile can be re commissioned by using the NEXT ENTER keys in commission ratio mode to verify all points on the combustion curve Ea option 04 x
106. a control panel fuse greater than 8A is fitted the safety shutdown output terminal MUST be separately fused at 8A maximum 2 6 8 Controlled Shutdown Relay Output PPC6000 WARNING Any external limit device if fitted must be connected into the controlled shutdown circuit unless connected into the auxiliary inputs and the correct function selected If a limit device is fitted into the controlled shutdown circuit it must be capable of supplying the total current required by devices connected to this circuit Any limit device connected to the PPC6000 series control must be approved for the specific purpose for which it is being used Wiring must comply with all applicable codes ordinances and regulations The controlled shutdown relay output must be CONTROLLER Connected using multi strand single conductor core PVC insulated 16 AWG 19 0 3mm wire If a control panel fuse greater than 8A is fitted the controlled shutdown circuit MUST be separately fused at 8A maximum to protect the relay contacts from welding 2 6 9 Alarm Relay output RELAY 4 on the PPC6000 See option parameter 14 7 for further programming options The alarm relay output must be connected NEUTRAL N PE 1 8 using multi strand single PVC BUNTE El FAULT insulated 16 AWG 19 0 3mm wire This line voltage output must only be used for indication as it is not fail safe If a fuse greater than 4A is fitted in the supply
107. able of contents This manual describes the installation commissioning operation and maintenance of the PPC6000 series fuel air ratio controls It may be used in conjunction with the following other manuals e NEX 1502 ComFire combustion analysis tool user manual Please read the safety information at the front of this manual before proceeding 1 Technical specification 11 1 4 General 11 1 2 Servo motor control IMPORTANT See Section 3 2 11 1 3 Digital outputs PPC6000 12 1 4 Alarm output PPC6000 12 1 5 Digital inputs PPC6000 13 1 6 Pressure Temperature Input PPC6000 13 1 7 Communications interface PPC6000 13 1 8 Optional Oxygen Probe Interface Unit NXO2INT optional 14 1 9 Optional Ambient Air Temperature Unit NXIATS optional 14 1 10 Variable Speed Drive VSD Daughter Board NXDBVSD optional 14 1 11 Fireye NXC04 NXC12 NXC20 NXC40 Servo Motors 15 1 12 Fireye NXO2INT Oxygen Probe Interface Unit optional 15 1 13 Fireye NXIATS Ambient Air Temperature Sensor optional 16 1 14 Approvals 16 1 15 Parts List with Description 16 2 Installation 18 2 1 Mounting details for the PPC6000 control 19 2 2 Mounting details for the display module 20 2 3 Mounting details for optional Oxygen Probe Interface unit NXO2INT 21 2 4 The oxygen trim option 22 2 4 1 Oxygen Probe description 22 2 4 2 Installation of oxygen probe 22 2 4 3 Mounting the oxygen probe 23 2 44 Mounting arrangements for Temperature and Steam pressure sens
108. able with NXDBMB Modbus or NXDBVSD variable speed drive daughterboard installed This option sets the Modbus communications speed in each controller as follows Option 00 8 Speed value bits s 0 9600 1 4800 2 9600 3 19200 Option 01 0 Power Up Option 0 30 LV3 DEFAULT 15 after Sept 2011 This option can be used to modify the behavior of the control at power up Option 01 0 Meaning value Normal power up If no faults and fuel burner selected the burner will start Lockout The burner will always lockout after a power up An F75 will be generated which will require manual intervention to clear digital inputs for fault conditions This may be useful to prevent nuisance lockouts at power up due to water levels and plant interlocks The control will remain in safety shutdown but not locked out for this time 0 The control will power up as normal but wait for 2 to 30 seconds before checking the Option 01 1 Keyboard Auto Manual enable 0 1 LV3 Engineer s Key 33 DEFAULT 1 It is possible to enable disable the auto man facility from the keyboard Selecting 0 will disable the operation of the auto man function from the keyboard Selecting a 1 will enable the operation of the auto man function from the keyboard Option 01 2 Mute Reset Input enable 0 2 LV3 The Mute Reset function is available via Comfire 2 on the keyboard and can also be selected to be from a digi
109. al is applied the control will modulate so as to track this input 4mA Low fire 20mA High fire If the signal goes below 3 5mA or above 21mA this mode will be cancelled and normal PID modulation will resume Remote Setpoint 1 Input If the control is in AUTO modulation mode accepting remote inputs the value of setpoint 1 can be overridden when a valid 4 20mA signal is applied to this input The zero and span are set in option parameters 21 8 and 21 9 If deviation limits are set see option parameter 21 5 then the high and low control limits will also move with the setpoint If the signal goes below 3 5mA or above 21mA this mode will be cancelled and normal setpoint 1 value will be applied 96 0 Option 20 8 Digital Input Lead Boiler Select 0 35 LV3 1 4 A high level on the input specified here will select the lead boiler when closed 16 or 20 Should NOT be used 21 24 A low level on the input specified here will select the lead boiler when open The input numbers are as specified in Option Table 20 0 A above NOTE For the following Options 21 x and 22 x see Section 9 7 10 for PID Tutorial LE option 21 0 Set point 1 enable 0 1 LV1 This option parameter is used to select setpoint 1 LE option 21 1 Set point 1 control value 0 999 00 0 99 9 0 00 9 99 LV1 This is the desired pressure or temperature control value used in the PID control loop for setpoint 1 When the contr
110. all screened 4 core PVC insulated minimum 24 AWG 7 0 2mm wire has a maximum current capability at 60 C 140 F of 600mA Belden 7895A or equal which will limit the maximum number of units which can be connected via a single bus Since this cable is to be run adjacent to and or in the same conduit as high voltage wiring its voltage rating must exceed the maximum voltage carried by any other cable connected to the control or run in the same conduit See Table Section 2 6 1 Once the location of each unit is defined usually by the mechanics of the burner boiler the best cable route to each device can be selected If required several cables can be run directly from the PPC6000 or a single cable can be looped through daisy chain all the connected units providing the maximum current capability of the cable is not exceeded Where the maximum current required on the cable exceeds 600mA for example when using 50Nm servo motors which are rated at 15VA suitable overall screened 4 conductor core cable must be substituted Use of 2 overall screened cables one for the CAN and one for the power is not recommended since this would increase the number of screens to be connected in each device for which there is no provision Connect the screen with the use of the screen termination clamp at the PPC6000 If wiring is being looped through units ensure that the screen of the cable is connected to the terminals provided to ensure continu
111. also occur if the AUTO input stays ON for three seconds after this control has opened the controlled shutdown relay i e tried to turn the burner off Subset burner status 135 Fault Number EEPROM memory CRC fault F50 Oxygen probe heater fault Oxygen low limit alarm Oxygen high limit alarm Oxygen probes mismatch fault Description The EEPROM memory in the control has been corrupted This memory is used to store the option parameters Interrupt power to the control Erase the system using option parameter 45 1 5 and re commission or restore with option parameter 45 2 This could be due to high levels of electrical interference getting into the product Check all cables are correctly Screened and screens are terminated correctly Ensure the mains supply is not excessively noisy If this fault persists the control must be returned to the supplier Subset Failed Page The probe heater has failed to heat to the correct temperature after 30 minutes of system power up e 5 the probe heater wiring correct e sthe probe cell thermocouple wiring correct Once the fault is rectified it will be necessary to interrupt the power to the oxygen probe interface to make it attempt to heat the probe once more Subset O2 probe status The oxygen level measured value is below the oxygen setpoint low alarm value for the current profile Subset 0 Limit violation 1 2 Probe Failed The oxygen l
112. and is still present The fault may be internal or external to the unit L This means that an alarm limit fault e g smoke level exceeding the high limit has occurred and is still present C This means that a fault or alarm limit did occur but has been cleared For example F60 Means fault 60 has occurred and still exists L75 Means alarm limit 75 has been exceeded and is still being exceeded C73 Means fault or alarm limit 73 has occurred but has subsequently been cleared When the unit is in a safety shutdown state both the controlled shutdown triac and safety shutdown relay will be turned off to prevent the burner from firing 9 7 8 Fault subsets As an aid to fault finding most faults have a fault subset that gives additional information about the type of fault or what the burner was doing when the fault occurred Where applicable the subsets are given in the fault listing in section 0 of Fireye Bulletin PPC6001 For details of how to view a subset refer to Section 6 0 of Fireye Bulletin PPC6001 182 ey 9 7 9 Fault listing For specific Fault listing see Section 6 5 of Fireye Bulletin PPC 6001 9 7 10 PID Tutorial PID Adjustment The PPC6000 utilizes and advanced algorithm in order to maintain setpoint over a variety of load conditions This three term PID can be infinitely adjusted to suit almost any application The operator should have a basic understanding of the relationship between the three terms proportional
113. and shaft moving it is recommended that the device used to link the two items is pinned together It is essential that the motor and valve remain securely connected to ensure safe operation of the equipment since feedback is only taken from the servomotor Servomotor shafts are hardened set screws alone are NOT sufficient to guard against slippage A variety of D hole couplings are available Contact your Fireye Distributor or Fireye Inc for assistance 3 4 Feedback potentiometer WARNING The servo motor internal feedback potentiometer must be secured within the servo motor to ensure that there is no possibility that the potentiometer can become disconnected from the motor output shaft For direct drive servo motor potentiometers NXC40 only ensure the potentiometer body is secured to the flexible mounting to prevent any movement between output shaft and potentiometer Do not adjust the nuts retaining the flexible mounting to the metalwork For gear driven servo motor potentiometers 4Nm NXC04 NXc12 NXC20 servo motor ensure the potentiometer is secured to its mounting bracket and that the bracket is correctly attached to the servo motor body to prevent any backlash between the potentiometer and the output shaft DO NOT ADJUST 50 my For each motor it is necessary to adjust the servo motor position relative to the shaft it is driving e g gas valve in order to obtain the correct open and closed positi
114. anging the communications address entered in Options 24 1 24 3 Note Communications addresses should be changed while the boilers are not in sequencing more than one boiler on so as not to disrupt operation Option 24 4 Lead OFF Time LV1 DEFAULT 0 after June 2011 NOTE MUST BE SET TO 3 MINUTES 3 OR GREATER FOR PROPER OPERATION This option allows the lead boiler to remain in control of all lags up to 999 minutes after the lead is turned off This may be useful during low water testing or if the burner is recycled for some reason This is especially useful on low pressure steam boilers Option 24 5 Lead master Boiler Select Method LV1 This option parameter selects the lead master boiler via the keypad digital input or communications Comfire 2 The values are 0 Not lead operates on own PID or as commanded by master lead 1 to 3 makes lag boilers modulate to their own setpoint 1 PID when commanded to be ON as follows 1 lead master via Keypad NOTE On newer NX610 Keypads press and hold the Data key for 5 seconds then move cursor to for right The word lead in lower case indicates the keypad has this boiler set to lag Pressing the Com key will cause the lead to switch to upper case LEAD This indicates the boiler is now Lead via Keypad Pressing the Data key return you to the normal screen 2 lead master via digital input Digital Input Selected via Option 20 8 3 lead master via communi
115. aram Register DI Register DO Register Al By clicking in the list you can preview all available function blocks Click Add to add the currently shown block to your schematic To get help on the currently selected block press F1 1 6 Moving and editing the link lines You can click on a link to select it It will turn pink and handles will appear on the corners of that link like this x2 Pump 1 Fault 1 DI a x3 Pump Alarm INPUT D 1 x1 Pump 2 Fault 2 You can drag these handles to move the middle section of the link 1 x1 Pump 2 Fault 2 194 x3 Pump Alarm 1 x1 Pump 2 Fault 2 In this case block x2 has been moved to the right and now the link goes backwards through the block itself There is nothing wrong the program is the same however the appearance is unclear If you grab and drag the line handles in this case you will not be able to improve the appearance It is here that you need to use the line style buttons on the schematic toolbar With the link selected i e pink click the button on the schematic tool bar The schematic will change to the following 1 x1 Pump 2 Fault 2 While not much clearer you now have more handles to drag and can make the schematic look sensible once more The finished article may look like this x3 Pump Alarm 4 x1 Pump 2 Fault 2 195 11 Circuit board connections 11 1 Inlet Air Temperature Sensor Optional QU
116. are both below 300 the PPC6000will utilize the analog input on the NXOZ2INT terminals PL6 PL7 to determine the O2 signal Option 30 3 Oxygen probe calibration gas concentration 0 00 9 99 LV3 This option parameter is only available if option 30 0 is non zero This option parameter must be set to the percentage oxygen concentration of the calibration gas used if the probe is to be calibrated using a reference gas see option parameter 30 6 The range of this parameter is 0 00 9 99 02 Option 30 4 Flue and inlet sensor temperature units 0 1 LV3 This option parameter is only available if option 30 0 is non zero This option parameter must be set to select the units for display of both temperatures on either C or F Option parameter Meaning 30 4 value C The temperature value will be displayed in C F The temperature value will be displayed in F Please note that temperature limits MUST be set in the correct units If a 4 20mA input is used for O2 signal a NXIATS is required to calculate efficiency in conjunction with a K type thermocouple measuring flue temperature connected to the appropriate inputs in the NXO2INT 2 Option 30 5 Oxygen input function 0 1 LV3 This option parameter can only be set above 1 if option 30 0 is non zero Using this option parameter it is possible to configure the oxygen input for a monitoring function or trim funct
117. at given out when unit quantity of fuel at 15 6 C 60 F is completely burnt and the products of combustion are cooled to 15 6 C 60 F as such any steam present in the products of combustion due to the burning of the hydrogen will be condensed to water giving up its latent heat of vaporization and some of its sensible heat loss This heat recovery is not possible under practical conditions and the net value is approximately the gross value less this quantity of heat which is usually taken at 2 45 MJ Kg of steam formed Therefore if gross efficiency is required gross calorific value is used and the latent heat of vaporization due to any steam present in the products of combustion is taken as a loss in the efficiency calculation However if net efficiency is required net calorific value is used and therefore the latent heat of vaporization due to any steam present in the products of combustion is already taken into account so the latent heat loss in the efficiency equation is set to zero In addition when considering gross efficiency it is normal to also take account to the boiler radiated heat loss This will be a fixed heat loss from the boiler shell in the order of 1 to 3 of the boiler high fire output which if the burner is operating with say a 6 to 1 turn down would equate to a 696 to 1896 loss at low fire Comparison of Fireye PPC6000 with Hand Held Equipment When comparing the efficiency as displayed by the PPC6000 control and
118. ave been removed to mount the probe Sulfate condensation will occur if the flue wall of oil fired boiler falls below approximately 130 C The sulfate problem does not occur in gas fired installations but vapor may cause problems due to condensation if the temperature of the flue gas falls below 100 C The maximum flue gas temperature is 1004 F 540 C 161 FLUE WALL DIRECTION OF FLUE GAS FLOW PART A MOUNTING BE220069 SCREW TAP FLUE WALL IN 6 POS NS ON 80 FLUE APERTURE 3 15 PCD TO SUIT COVER BE220059 63 5 2 5 CUT OUT IN FLUE PROBE MOUNT SYSTEM FLAT WALL FLUE MOUNT HOLES VIEW OF MOUNTING PLATE WITH COVER REMOVED GASKET BE220060 IN 2 POS NS M6x25 ST STL FLUE WALL DIRECTION OF FLUE GAS FLOW PART B 3 1 8 FILLET WELD ALL ROUND 30 FLUE APERTURE COVER BE220059 6 PROBE P MOUNT HOLES gt Eg be z GASKET BE220060 3 5 20 5 VIEW OF MOUNTING PLATE o 0 78 WITH COVER WELD FLANGE PROBE MOUNT BE220345 ALL DIMENSIONS IN MILLIMETRES MATERIAL MILD STEEL FINISH ZINC PLATE INCH EQUIVALENTS ARE IN PROBE MOUNT SYSTEM CYLINDRICAL OR FLAT WALL FLUE The probe end cap carries a removable 20mm 3 4 flexible conduit fitting to enable probe replacement without wiring The 2 hexagonal caps
119. b site at www Fireye com Search bulletins for NXOG 6001 under the Nexus products family As an operator there are generally only a few items of interest as far as operating the Nexus PPC6000 They are Setting the system s operating pressure or temperature Adjusting the cut in or cut out value Manually modulating the boiler Resetting the control after a safety shut down Finding the Fault that caused the shut down All of the other options and adjustments should be done by the combustion technician as changes to certain parameters could result in an unsafe operating mode 9 7 2 General The Nexus display and keypad allows the operator or combustion technician access to all setpoints and option parameters for commissioning and operating the Nexus PPC6000 The keys are labeled with their primary function on the key their secondary function under the key E g COM ENTER Several levels of passwords protect the integrity of the control These passwords are numbers entered by using the up down arrow keys after pressing the COM commissioning key To enter the password start by pressing the COM commissioning key You will have 30 seconds to reach the password value and press the ENTER COM key 9 7 3 Password The only password an operator should require is the site Passcode This can be set as a number from 0 999 The factory default number is 154 The site Passcode can be changed if desired however this requires the use
120. be read and fully understood If in doubt about any requirements consult Fireye Installation commissioning or adjustment of this product MUST be carried out by suitably trained engineers or personnel qualified by training and experience After installation or modifications to the installation all functions of the equipment MUST be checked to ensure safe and reliable operation of the control The manufacturer of this equipment accepts no liability for any consequences resulting from inappropriate negligent or incorrect installation commissioning or adjustment of operating parameters of the equipment Control panels must not be left uncovered while power is on If it is essential to do so while rectifying faults only personnel qualified by training and experience should be involved The time any covers are off must be kept to a minimum and warning notices must be posted Before attempting any work on this equipment or any equipment controlled by or connected to this equipment all related electrical supplies must be isolated Safety interlocks must not be removed or over ridden Any faults once detected must be corrected before the control is operated CAUTION SOME VERSIONS OF THIS EQUIPMENT CONTAIN A LITHIUM BATTERY IN THE DISPLAY UNIT NOTE The manufacturer of this equipment has a policy of continual product improvement and reserves the right to change the specification of the equipment and the contents of this manual without notice T
121. bers are as specified in Option Table 20 0 A above Option 20 5 Purge Hold input 0 35 LV3 1 4 A high level on the input specified here will prevent the burner moving on past pre purge The drives stay at their purge positions until this input is removed 160r20 Should NOT be used 21 24 A low level on the input specified here will prevent the burner moving on past pre purge The drives stay at their purge positions until this input is switched high ON The input numbers are as specified in Option Table 20 0 A above Option 20 6 Purge Time Start input 0 35 LV3 1 4 A high level on the input specified here will prevent the pre purge time from starting The drives stay at their purge positions until this input is removed and the specified pre purge time has elapsed 16 or 20 Should NOT be used 21 24 A low level on the input specified here will prevent the pre purge time from starting The drives stay at their purge positions until this input is switched high ON and the specified pre purge time has elapsed The input numbers are as specified in Option Table 20 0 A above Option 20 7 Analog Input 5 function 0 2 LV3 This parameter allows analog input 5 the second modulation input PA12 and PA13 to perform specific functions Option parameter Digital input used 20 7 Value 1 Remote tracking input If the control is in AUTO modulation mode accepting remote inputs and a valid 4 20mA sign
122. by holding the button for in excess of 10 seconds after which the alarm relays will activate 5 4 5 Touchscreen Lockout Reset Alarm Mute Function The Reset Alarm Mute button is also used to mute alarms and reset the control following a safety shutdown If the alarm is sounding the button will show the text Mute pressing the button will mute silence the alarm and then the text in the button will change to Reset holding the button for greater than 3 seconds will allow the burner to restart if the faults have cleared Further details of the functionality of this button are defined below There are three types of fault alarm Alarm Only This will allow the burner to continue to operate while the alarm is sounding If the Reset Alarm Mute button is pressed while the control is in this mode and the alarm is sounding the alarm will be muted and the burner will continue to operate Controlled Shutdown This will cause the burner to perform a controlled shutdown and the alarm will sound once the fault clears the burner will restart without the requirement for manual intervention If the Mute Reset button is pressed while the control is in this mode the alarm will be muted and the burner will remain in controlled shutdown If the Mute Reset button is pressed after the control has restarted following a controlled shutdown the alarm will be muted and the burner will continue to operate Safety Shutdown This will cause the burner to per
123. by providing line voltage to terminal PE8 high fire switch The control will remain in this status until the burner controller signals the end of pre purge by breaking PA9 PA11 HIGH input or the fuel profile select input is removed PES 10 11 or 12 In either case the control will immediately move to status 1 Non Volatile lockouts cannot be cleared without operator intervention and are remembered in the event of power being removed from the control A non volatile lockout will occur under the following conditions e In any stage the interface signals are incorrect e In stages 5 7 and 8 stages 10 16 inclusive and stage 18 if a motor is not in the correct position e In any stage if an internal or external fault not previously mentioned occurs which may affect the safe operation of the burner see section 0 of Fireye Bulletin PPC6001 187 9 8 Fireye Nexus Combustion Curve Site Date Profile Fuel NAM Drive 0 Drive Drive Drive Drive Drive Drive Drive Drive Drive 02 co NOx PO P1 P2 P3 P4 P5 P6 P7 P8 P9 P 10 P 11 P 12 P 13 14 P 15 P 16 P 17 P 18 P 19 P 20 P 21 P 22 P23 Notes PID Setup P 188 my 10 Function Block Programming Details Below is an overview of the capabilities o
124. cations such as Comfire 2 4 Not a lead boiler lag only Same as setting 5 to 7 makes lag boilers modulate in unison with the lead when commanded to be ON as follows 5 lead master via Keypad as above 6 lead master via digital input Digital Input Selected via Option 20 8 7 lead master via communications such as Comfire 2 Note When a lead master boiler is deselected as lead master and Option 24 0 has not been changed to O the boiler remains as lead master until a new lead master takes control Once the new lead master takes control the previous lead master may be turned off based on the demand and Option 24 1 24 3 settings 103 Guy This value determines the firing rate of the lead master boiler at which the first and all subsequent slave s lag boilers come on The slave s lag boiler s will be delayed in coming on by the time set in Option parameter 24 7 At this point the lead master and the last lag on will begin to modulate in unison If the lead master and modulate above this point the next as determined by priority number Option 24 1 24 2 24 3 will be turned on When more than one boiler is on the master and last slave will modulate in unison while the other slaves modulate on their own PID Option 24 6 lag slave On Rate 0 100956 LV1 Option 24 7 lag slave On Delay 0 999 minutes LV1 This option sets the time delay between the modulation rate of the lead
125. control to modulate down to low fire if not already there and then move to the ignition position P2 and close the main fuel valves When at P2 the ignition prove output LFS comes on The burner will continue to run with only the pilot on in status 12 until the digital input is removed The ignition transformer will not come on during the time that the go back to pilot input is on however it may come on briefly when the input is removed as part of the normal start up procedure as determined by option parameter 14 6 This function can be used to prevent the burner from having to go off when the demand is low meaning that it is ready to immediately respond to a sudden increase in demand no pre purge required The digital input number to use for this function is entered as the option parameter value NOTE This option should only be used if the pilot is designed for continuous operation Consult the burner manufacturer national state and local codes 86 Number entered in parameter 16 1 Digital input used None Input 1 PAS to PA11 Low Voltage supplied from PA11 ONLY Input 2 PA6 to PA11 Low Voltage supplied from PA11 ONLY Input 3 PA7 to PA11 Low Voltage supplied from PA11 ONLY Input 4 PA8 to PA11 Low Voltage supplied from PA11 ONLY Do not use Do not use Not a real input Used for custom applications Not a real input Used for custom applications Not a real input Used for custom applications Not a real input Used for
126. ction blocks using Fireye Abacus software Built in lead lag sequencing for up to four boilers is included in every PPC6000 More elaborate lead lag schemes may be possible using the programmable function blocks Two variations of multifunction displays are available e NXTSD104 10 4 Color Touchscreen display with Ethernet Modbus TCPIP 4 programmable relays and backup e NX610 display provides automatic storage of operating parameters and profiles for upload download to the PPC6000 In addition three line voltage fully programmable relays are mounted inside the display Ue Other options include two Variable speed drive VSD outputs via daughter board Oxygen Trim using Fireye s proven heated zirconia oxide probe and optional interface a wide variety of communications platforms such as Modbus is also available An optional internal freely programmable logic section of the PPC6000 means that external PLC s and expensive stand alone sequencing controls may no longer be needed Easy to program and protect this new feature will make the PPC6000 suitable for many unique or unusual applications Functions such as lead lag sequencing feedwater control and draft control are just some of the ways this feature can be used Optional ComFire software allows the user to view and control all aspects of the burner system provides real time trending and logging upload and download of profiles and options The user can build custom screen
127. custom applications Option 16 2 Allow profile swap 0 to 16 LV3 This option allows a digital input to be configured to allow a profile swap without turning the burner off If this input is ON and a fuel profile selection change is made the control will go to low fire then back to pilot ignition P2 on the original profile It will then close the main fuel valves and run with just the pilot on and the ignition transformer if option parameter 14 6 is not set to 1 It will then move all drives to the P2 position of the new profile and open the appropriate main fuel valves The digital input number to use for this function is entered as the option parameter value Number entered in parameter 16 1 Digital input used None a Do not use Do not use 87 Option 17 0 Relay output function LV3 This option parameter assigns events to the relay outputs Set option parameter 17 1 to select the function for relay output 1 option 17 2 to select the function for relay 2 etc Option parameter Meaning 17 No function set from this option parameter Digital Input 1 PB9 to PB10 Low Voltage Digital Input 2 PB9 to PB11 Low Voltage Digital Input 3 PB9 to PB12 Low Voltage Digital Input 4 PB9 to PB13 Low Voltage Digital Input 5 PB14 to PB15 Low Voltage Digital Input 6 PB14 to PB16 Low Voltage Digital Input 7 PB14 to PB17 Low Voltage 38 Burner Available ON unless locked out or held OFF by
128. d by Fireye may VOID warranty All wiring to terminal block amp PB as well as to any optional daughter board e g VSD and the Power CANbus wiring to the display must be fully shielded braided wire per Table 2 6 1 A Under no circumstances should these input outputs be connected to mains potential Connection of any voltage above 5 volts to these terminals will damage or destroy the unit 30 my Alpha Carol Belden conductors conductors conductors 4 2 4 2 4 2 300V 25164 25162 9940 600V 25524 25522 C2688 7895A NOTE If Belden 7895A wire is used it will be necessary to use 2 conduit adapters per device if wired as a daisy chain See Table 2 6 1 D Table 2 6 1 A IMPORTANT Line Voltage horizontal terminal bottom PE must NOT be shielded wire All line voltage wiring must be no greater than 16 AWG 19 0 3mm THHN TFFN or equal The following table provides a guide for converting from NEMA Enclosure Type Numbers of IEC Enclosure Classification Designations The NEMA Types meet or exceed the test requirements for the associated IEC Classifications for this reason the table should not be used to convert from IEC classifications to NEMA Types and the NEMA to IEC conversion should be verified by test NEMA Enclosure Type IEC Enclosure Number Designation 1 IP10 IP40 IP20 2 IP 11
129. djust ratio mode See section 5 Enable automatic trim commissioning by setting option parameter 30 9 to 1 Wait for procedure to finish Check that the 02 flow and transport delay values are sensible Use EK44 for O2 value Check calibration of the oxygen probe 112 my NOTE Ifthe boiler shuts off for any reason during automatic commissioning the sequence will continue when the boiler re starts T Confirm setup using adjust ratio mode Option parameter Meaning 30 9 value 0 Not selected 1 Perform automatic trim characterization The control will attempt to characterize the burner profile by calculating flow values and selecting oxygen setpoints to match the currently commissioned points Automatic trim commissioning will be performed under the following conditions An oxygen probe is fitted and fully operational The control is in adjust ratio mode A hydrocarbon ratio has been entered for the current fuel see option parameters 35 1 35 4 Option 31 0 Limit Modulation Range 0 to 1 LV3 By default the control modulates the burner between the set points low fire and Ph high fire where Pj is the last set point entered in commission ratio mode If oxygen trim is fitted it is not possible for any drive position to be trimmed lower than point low fire or higher than point P high fire Basically you can t take fuel or air off at low fire and you can t add fuel or air at high fire This
130. djusted entered it is essential that all profile points are checked to verify that the fuel air ratio is acceptable for the appliance being controlled To adjust the position of a servo motor or inverter select the motor using the scroll keys then use the UP DOWN kevs to chanae the value 126 eS Each setpoint in the profile is referred to with a letter and number refer to the table below No Name Comments PO Close This defines the positions the motors will move to when the burner is off and must be set to the lowest position each motor can reach P1 Purge This defines the positions the motor will move to when the burner is purging and can be set as required for each servo motor P2 Ignition Position during ignition May be outside the normal firing range P3 Low fire Low fire setpoint unless limited modulation range is selected Px High fire High fire setpoint unless limited modulation range is selected which is the last setpoint entered max P24 The procedure for entering or modifying a profile is as follows 1 Enter commission ratio mode see section 5 3 1 PO close is displayed 2 If the close setpoint has recently been entered and no change is required press NEXT If servicing the burner or the position has not been entered before move each motor to its lowest position and press ENTER P1 purge is displayed flashing 3 Select the burner and the required profile If the purge position has been set
131. e 6 Move air dampers 1 and 2 if fitted up until they stop so that they are at the setpoint immediately above the current position Do not press enter 7 Wait until the oxygen reading has stabilized then record the excess air value at location b in the table relating to the current profile position 115 8 Repeat the above for all other profile positions including low fire profile position A3 recording each time the values at locations a and b in the table When extra air is added at P3 the time taken before the flue oxygen reading starts to increase should be measured and entered into option parameter 30 7 9 After completing the table for all Excess Air values a and b complete the Excess Air 100 column by adding 100 i e 100 c a 100 and d b 100 10 Complete the Ratio column by dividing c by d i e e c d 11 Complete the Airflow column by multiplying by the previous value of f i e f e f 12 If the system will be applying trim to the fuel the fuel flow column must be completed This is achieved by multiplying the airflow at each point by the ratio of excess air 100 at high fire divided by the excess air 100 at the actual point i e gx f y c Example of table completed for A10 high fire to A8 In practice the table must be filled out down to A3 low fire Profile Ex Air 100 position 100 100 High fire x y A10 10 2 A8 b 20 d 120 0
132. e 0 120 seconds LV3 This option parameter sets the minimum time the burner will take to modulate from low to high fire or vice versa Note only the modulation speed in AUTO mode is affected The burner may modulate slower than this setting if the drive speeds dictate this at any point in the range 85 Guy This parameter affects the burner operation while in MANUAL mode only Option 15 7 Bumpless Transfer 0 or 1 LV3 Option parameter Meaning IWATE hen the burner comes back on after going off it will remain at low fire 0 hen the burner comes back on after going off it will go to the last modulation rate that it was set to in manual mode and stay there Option 15 8 Low before Off 0 or 1 LV3 When set to 1 this parameter will change the way a normal controlled shutdown works Option parameter Meaning 15 8 value 0 The burner will turn off immediately when it is expected required to 1 he burner will modulate down for up to 30 seconds or until low fire is reached and then turn off Note This function works for shutdowns caused by control limits for the currently selected setpoint and for shutdowns caused by option parameter 20 1 aux shutdown only Lockouts shutdowns caused by the alarm inputs in parameters 18 X will always work immediately Option 15 9 reserved Option 16 1 Go back to pilot 0 to 15 This option allows a digital input to be configured to force the
133. e Disconnect the internal connections to the thermocouple e Unscrew the 2 thermocouple mounting blocks from the probe snout to allow the thermocouple to be straightened e Remove the hexagonal nut securing the thermocouple into the probe and withdraw the thermocouple through the probe body e Refitting is the reverse of the removal procedure The electrical connection and polarity of the thermocouple are detailed on the following page 165 Fireye O2 Probe Connector 02 02 PROBE T C PROBE T C EXTERNAL FLUE T C INTERNAL FLUE TIC S e CONNECTIONS CONNECTIONS HEATER HEATER COMPONENT SIDE VIEW OF INTERNAL ELECTRICAL INTERCONNECTION PCB 166 9 2 Troubleshooting inverter problems Problem SPEED TIME SPEED TIME SPEED TIME SPEED TIME SPEED TIME SPEED TIME Possible Cause Inverter does not start because it does not receive a RUN signal Inverter has a slow start Late RUN signal Non linear output from inverter or inverter s PID is enabled Current limit reached Noise Current limit reached Non linear output from inverter or inverter s PID is enabled Fan failed to stop before restart Control is unstable my Solution Ensure that the inverter receives a RUN signal from the burner controller at the same time as the PPC6000 Ensure that the inverter s slow start feature is disabled Ensure that the inverter receives a R
134. e Ensure that the inverter receives a RUN signal from the burner controller at the same time as the TIME PPC6000 SPEED e SPEED N SPEED n Non linear output from inverter or inverter s PID is enabled Current limit reached Noise Current limit reached Non linear output from inverter or inverter s PID is enabled Fan failed to stop before restart Check that the inverter s output is selected to be linear and that the inverter s own PID loop is disabled Slow down the inverter by increasing its acceleration deceleration time settings Check cable screens Slow down the inverter by increasing its acceleration deceleration time settings Check that the inverter s output is selected to be linear and that the inverters own PID loop is disabled Increase the inverter stop time by increasing option parameter 9 3 on the PPC6000 series control SPEED TIME e Control is unstable e Adjust option parameters 9 0 9 2 and 9 3 on the PPC6000 series control to reduce accuracy amp slow down control response Check Option parameter 9 4 matches the acceleration deceleration time TIME programmed into the VSD e VSD is current limiting Increase acceleration deceleration time in VSD and option parameter 9 4 SPEED e 153 In extreme cases it may be necessary to increase the inverter error tolerance to prevent non volatile lockouts caused by positioning faults set option 9 1 1 T
135. e covered in Fireye Bulletin NXAB 1001 WARNING ON NO ACCOUNT MUST THE PROGRAMMABLE BLOCKS BE USED FOR ANY SAFETY CRITICAL FUNCTION The operation of the burner management drive positioning system in the basic control is fail safe however the programmable blocks system is not If the programmable blocks are used to control a safety related item such as water level then appropriate external limit checking must be provided to maintain safety if the user program should fail to operate After loading and executing the Abacus software and following the required steps a blank schematic page will appear The toolbar on the right hand side of the main abacus window is used to place blocks on the screen 189 S 0 Test Unit New Schematic First draw the blocks then connect them i Using the toolbar click the top button z twice to bring up two digital input blocks You will notice that the blocks always appear in the middle of the visible window In this case one is on top of the other Move these to the left hand side of the screen by dragging with the mouse To do this you must click within the block area not on one of the pins square nodes You will also notice that each block has an x number by its bottom left corner This is simply a reference number for the block Each block on a page will have a unique x number E On the toolbar click the second button from the top this towards the right hand side of the screen
136. e mounted within a burner cabinet or similar and MUST be grounded earthed to the overall enclosure to ensure safe and reliable operation Do not use a green or green yellow conductor for any purpose other than ground earth The metal body of all component parts MUST be connected to ground earth using a green or green yellow conductor 29 Gay The screen of the signal cable MUST not be used to provide the safety ground earth a separate connection using the largest cross sectional area green or green yellow ground earth wire possible MUST be made The screen termination clamps on the control are only provided to allow connection of the cable screens to the PPC6000 they do not provide strain relief The signal cable screens MUST be connected at the screen termination clamps only unless stated otherwise Screened cables MUST be of the copper braid shield type and not foil with drain wire the cross section of the drain wire is insufficient to provide correct screening of the signals and there is also no provision to connect the foil or drain at the PPC6000 Secure all cables carried in conduit at both ends using a suitable anchorage method in the cabinet All cabling that is required to operate at above 50v must be multi strand single conductor core PVC insulated 16 AWG 19 0 3mm and should meet the requirements of I E C 227 or I E C 225 NEC To comply with EMC requirements wire the control and any optional units
137. e temperature low alarm values 0 999 LV3 Using option parameters 36 1 to 36 4 it is possible to set a different flue temperature low alarm value for each profile combination Each option parameter may be set to any value between 0 and 999 inclusive The temperature units should be set with respect to option parameter 30 4 If the burner is firing it is only possible to make an adjustment to the option parameter that relates to the selected profile If the burner is not firing the low alarm value for any profile selection may be adjusted When the flue temperature drops below the low alarm value for the selected profile a fault number will appear Options 37 1 to 37 4 Flue temperature high alarm values 0 999 LV3 Using option parameters 37 1 to 37 4 it is possible to set a different flue temperature high alarm value for each profile selection Each option parameter may be set to any value between 0 and 999 inclusive The temperature units should be set with respect to option parameter 30 4 If the burner is firing it is only possible to make an adjustment to the option parameter that relates to the selected profile If the burner is not firing the high alarm value for any profile selection may be adjusted When the flue temperature rises above the high alarm value for the selected profile combination a fault number will appear 119 2 Option 38 0 Oxygen alarm select 0 2 LV3 CAUTION This para
138. e to 60 psi NEW RESULTS from Setpoint Change Boiler OFF Cut Out 115 psi Boiler ON Cut In at 95 psi Boiler maintains Setpoint 60 psi via PID NOTE NEW Cut In and Cut Out values as well as new I integral time and D derivative time values Option Parameters 21 3 22 3 and 21 4 22 4 may be required to achieve desired results In BOTH examples represents PID2 9 7 5 Manual Modulation Pressing AUTO MAN key toggles the burner in and out of manual or automatic modulation To place the boiler in manual from automatic no password is required 1 Press the AUTO MAN key 2 Usethe up down arrow keys to set the firing rate 3 Press the AUTO MAN key again to place in automatic Note The firing rate will be shown on the display This function can be disabled via option parameter 1 1 To do so requires the suppliers highest passcode 9 7 6 Resetting the Control 181 Cay To reset the Nexus the MUTE RESET key will have to be pressed and held for three seconds to first silence mute the alarm and then a second press for three seconds to clear the fault A prolonged key press will do both If for some reason the Nexus detects a fault the cause of the fault will be displayed if still present If not displayed pressing the ENGINEERS key once will reveal the fault a second press will reveal the fault and subset in
139. e values should be entered as zero The following table shows the calorific values and hydrocarbon ratios of several common fuels These values should be used as a guide only If the display is required to show gross efficiency in addition to entering the gross calorific values a non zero value for the boiler radiated heat loss MUST be entered See Option Table 35 x A on page 119 118 Option Table 35 x A Fuel Gross calorific value Net calorific value Hydrocarbon ratio x10 Light oil 2 Option 35 9 Boiler radiated heat loss 0 0 9 9 LV3 This option parameter is only available if option 35 0 inlet temperature sensor is not set to zero If this option parameter is set to zero the unit will calculate the net efficiency if non zero it will calculate gross efficiency For accurate calculation of boiler gross efficiency this option parameter must be set to the value of the heat lost through the shell of the boiler at high fire as a percentage of the burner s output at high fire The range of this parameter is 0 0 to 9 996 Option 36 0 Flue temperature alarm select 0 1 LV3 This option parameter is only available if option 30 0 is non zero If option 36 0 is set to 0 the flue temperature high and low alarms are disabled If option 36 0 is set to 1 the flue temperature high and low alarms are enabled and option parameters 36 1 to 36 4 and 37 1 to 37 4 become available Options 36 1 to 36 4 Flu
140. ed 46 J1 NOTE Insulate Shield suas 4 Cover shield to Terminal 5 to prevent prevent short accidental shorting to pins on circuit board J1 CANbus CANbus 24 VAC 24 VAC OO NXIATS Inlet Air Temperature Sensor 2 7 Final checks N WARNING Incorrect setting of the Supply Voltage Links WILL damage or destroy the unit Before applying power make the following checks e The control s supply voltage is correctly set incorrect setting will destroy the unit s e All other jumper link positions are correct e The fuse s are of the correct type and value incorrect type or value may damage or destroy the units e All wiring and connections have been made according to the specifications detailed in this chapter e Before applying power to the control ensure that the probe heater output is not attempting to drive into a short circuit by checking between terminals PM8 and PM9 using a resistance meter The expected resistance with an oxygen probe fitted should be greater than 15ohms e Enclosure lid s are fitted before applying power to the control s 47 3 Servo motor selection and calibration CAUTION All servo motors connected to the PPC6000 control system must be approved as part of system The total electrical load for all connected servo motors must not exceed 40VA Valve and motor alignment and calibration must be set in commission ratio mode prior to commissioning any profile s
141. eight 1 34Kg 2 95 Ibs Interface to PPC6000 NX6100 FIREYE specific CANbus Interface to oxygen probe FIREYE specific or 4 20mA 15 1 13 Fireye NXIATS Ambient Air Temperature Sensor optional Type CANbus Ambient temperature range 29 C to 60 C 20 F to 140 F NOTE Accuracy below 0 C 32 F may vary slightly Agency testing conducted to 0 C only Protection category IP54 Unit dimensions Weight Interface to PPC6000 NX6100 FIREYE specific CANbus 14 Approvals Tested in accordance with the Gas Appliance Directive GAD 90 396 EEC encompassing the following standards SIL Level 3 Kiwa Gastec Report 123836 ANSI UL 462 Heat Reclaimers for Gas Oil or Solid Fuel Fired Appliances ANSI UL 1995 Heating and Cooling Equipment ANSI UL 1998 Software in Programmable Components CAN CSA C22 2 No 236 Heating and Cooling Equipment FM ENV 1954 Internal and external behavior of safety related electronic parts EN60730 1 Automatic electrical controls for household and similar use prEN12067 Gas air ratio controls for gas burners as gas burning appliances SIL level 3 per Kiwa report 123836 1 15 Parts List with Description PART NO DESCRIPTION PPC6000 FUEL AIR RATIO CONTROLLER Stand alone parallel positioning controller with up to ten 10 selectable function PPC6000 CANbus servo motor outputs Includes user configurable function blocks for custom applications Display ordered sepa
142. elating to shielded wire indicates the amount of coverage 0 100 this is not the only factor in selecting wire While it is true foil and drain shielded wire specifications indicate 100 coverage as compared to approximately 85 for braided type the cross sectional area of the braid provides the required noise immunity Also the special grounding clamp bars on this control do not provide adequate connection to foil shield In fact most foil shields do not conduct on the surface Using the drain wire to a ground stud does not properly protect the control NOTE If wire entrances to terminals face inward under the cover then these wires require braided shielded wire If the terminals face outward NO braided wire is to be used 37 E 2 6 12 Low Voltage Digital Inputs PPC6000 relevant Engineer s Keys EK1 EK4 Sec 6 6 2 See option parameter 16 1 and 18 1 18 4 for further details These inputs must be connected using multi strand overall screened two conductor PVC insulated 24 AWG 7 0 2mm wire See Table 2 6 1 A Section 2 6 1 Note that these inputs are dynamic low voltage 0 5V signals and must NOTE All digital inputs be connected between the relevant MUST BE BELDEN 9940 cut terminals provided Measuring the GROUND CLAMP unused conductors off voltage between any input and PA11 will indicate O volts with input closed up to 5V with input open As it is a dynamic input the voltage will not be a steady 5V
143. en the door and the main cabinet in addition to a good electrical contact between the display unit and the door 2 6 5 Terminal Designation All terminals within the system have unique terminal designations to reduce the possibility of wiring errors This information is tabulated below Terminal Number Location Function Voltage Range PA1 PPC6000 24Vac Supply for Servos Display etc 24 40Vac PA2 PPC6000 24Vac Supply for Servos Display etc 24 40Vac PA3 PPC6000 CAN CANbus 0 5V PA4 PPC6000 CAN CANbus 0 5V PA5 PPC6000 Digital Input 1 0 5Vdc PA6 PPC6000 Digital Input 2 0 5Vdc PPC6000 Digital Input 3 0 5Vdc PA8 PPC6000 Digital Input 4 0 5Vdc PA9 PPC6000 High purge request 0 5Vdc PA10 PPC6000 Auto 0 30Vdc PA11 PPC6000 Digital Input Common 0 5V PA12 PPC6000 Analog Input 5 Aux mod remote 0 5Vdc Setpoint PA13 PPC6000 Sensor Supply 30Vdc 0 30Vdc PB1 PPC6000 24Vac Supply for Servos Display etc 24 40Vac PB2 PPC6000 24Vac Supply for Servos Display etc 24 40Vac PB3 PPC6000 CAN CANbus 0 5V PB4 PPC6000 CAN CANbus 0 5V PBS PPC6000 RS485 comms A 0 5V PB6 PPC6000 RS485 comms B 0 5V PB7 PPC6000 RS485 comms 0 Volt not shield 0 5V PB8 PPC6000 Sensor Supply 30V 0 5V PB9 PPC6000 Sensor Input 0 5V PB10 PPC6000 Sensor 0 Volt not shield 0 5V PB11 PPC6000 I
144. er 30 5 in the display and ensure it is set to O Select option parameter 30 6 and change the value of the parameter to 1 and then press ENTER The oxygen trim function will be disabled and the system is in calibrate air mode Apply the calibration air supply to the oxygen probe calibration port Once this has been connected select option parameter 30 1 and view the probe offset value Allow the offset value to settle and then select option 30 6 and increment the value to 2 and then press ENTER The oxygen trim function will remain disabled and the system will be in calibrate reference gas mode Apply the calibration gas to the oxygen probe calibration port Once this has been connected select option parameter 30 2 and view the probe gain value Once this has been connected select option parameter 30 2 and view the probe gain value Before enabling the oxygen trim function using option parameter 30 5 ensure that the calibration gas supply is removed from the probe and that the probe calibration port end cap is fitted to prevent incorrect oxygen measurements 163 E 9 1 2 Oxygen Probe Filter Testing The filter can be tested without removing the probe from the flue Before proceeding ensure the oxygen trim function is disabled using option parameter 30 5 The check is carried out by passing air at 350cc min 22cu ins min into the calibration gas connection on the rear of the probe adjacent to the flexible conduit fitting
145. er connected to the unit Option Meaning parameter 09 0 value Low accuracy normal setting Control will be performed to within approximately 9 display units 0 54Hz for a 0 60Hz system 1 High accuracy Control will be performed to within approximately 3 display units 0 18Hz for a 0 60Hz system Note When using the high accuracy setting the control may have difficulty with controlling the speed of the inverter If this occurs use the low accuracy setting for reliable operation vso NB This option parameter affects the inverter connected to the unit Option 09 1 Inverter error tolerance 0 1 LV3 Option parameter 09 1 Meaning value Small tolerance normal setting The control will perform a non volatile lockout if the inverter positioning error exceeds 30 for 15 seconds or 55 for 3 second units conform to those seen on the display 1 Large tolerance The control will perform a non volatile lockout if the inverter positioning error exceeds 55 for 3 seconds units conform to those seen on the display Note Only use the large tolerance setting if an inverter error of up to 55 will not cause an unsafe combustion condition to occur at any firing position 80 my Option 09 2 Inverter closed loop gain 15 125 LV3 VSD DEFAULT 100 This option parameter affects all inverters connected to the control For normal operation use 100 If the inverter control is
146. ered then only the setpoints up to P10 will be stored Therefore it is vital that NEXT is pressed to get to the last setpoint in the profile before leaving commission ratio mode This does not apply if only the close purge or ignition setpoints PO P1 or P2 are altered 5 7 Adjust ratio mode 5 7 1 Description Adjust ratio mode is used only for changing an existing profile e Using adjust ratio mode it is possible to modify the motor positions for any setpoint in the firing range from low to high fire P3 and higher e The setpoints may be chosen in any order e Itis not possible to modify any motor position so that it is higher than the high fire setpoint e tis not possible to modify the close purge or ignition positions PO P1 or P2 respectively For this commission ratio mode must be used 5 7 2 Entering adjust ratio mode Run mode burner on j vA Supplier passcode ENTER To enter adjust ratio mode turn the burner on Once the burner begun its startup sequence press the key labeled COM and obtain the adjust ratio passcode value using the UP DOWN keys Once the correct passcode value has been obtained press the key labeled ENTER If the entered passcode was correct A n will be seen on the display where n is the number of the setpoint currently under adjustment Entering the commission ration passcode wile the burner is ON enters Adjust Ratio mode 128 5 7 3 Using adjust ratio mode CAU
147. erface PPC6000 41 2 6 19 Variable Speed Drive Selection 42 2 6 20 PPC6000 Variable Speed Drive Daughter Board P N NXDBVSD 43 2 6 21 LIVE and NEUTRAL supply optional Oxygen Probe Interface unit 44 2 6 22 Oxygen probe connection optional Oxygen Probe Interface unit NXO2INT 44 2 6 23 Inlet temperature sensor optional 46 2 7 Final checks 47 3 Servo motor selection and calibration 48 3 4 Servo motor selection 48 3 1 1 Motor requirements 48 3 2 IMPORTANT Servo motor direction warning 49 3 3 Locking the servo motor to the valve shaft 50 3 4 Feedback potentiometer 50 3 5 Adjusting microswitch positions 51 3 6 Servomotor Replacement 52 4 Description of operation 53 4 1 TheDisplay Keypad 53 4 2 Start up sequence 54 4 3 Non volatile lockout 59 4 4 Modulation 59 4 4 1 Normal Remote mode 59 4 4 2 Local mode LOC 1 LOC 2 59 5 Commissioning the control 60 5 1 General 60 5 2 Commissioning data 61 5 2 1 Option parameters 61 5 2 2 Setpoints 61 5 3 The Commissioning process 61 5 3 1 Navigation 61 5 4 Description of Touchscreen operation 63 5 4 1 The Touchscreen 63 5 4 2 Touchscreen Power on 63 5 4 83 Operation Mode line and Status messages 63 5 4 4 Touchscreen Overview display 65 5 4 5 Touchscreen Lockout Reset Alarm Mute Function 66 5 4 6 Touchscreen LED Indication 66 5 4 7 Touchscreen Fuel Profile Select 67 5 4 8 Touchscreen Control screen 68 5 4 9 Touchscreen Menu button 68 5 4 10 Touchscreen
148. ers may be found later in this chapter Many of the faults detected and displayed by the control will cause a non volatile lockout of the burner that is to say that removing the power to the control will not cancel a fault Other faults will be displayed as a warning but operation of the burner will not be affected Each fault number is prefixed on the display by a letter as follows F This means that a fault has occurred and is still present The fault may be internal or external to the control C This means that a fault did occur but has now cleared L This means a programmed limit has been exceeded For example 217 PSI Actual AUTO F23 Drive 3 Fault Many of the faults detected and displayed by the control will cause a non volatile lockout of the burner Other faults will be displayed as a warning but operation of the burner will not be affected A complete list of faults may be found later in this chapter A fault history is available through the Engineers Key the standard fault history is lost if the power is removed from the unit but as an option the fault history may be displayed with a date and time stamp and retained in the unit memory in the event of a power loss to the control For further information see section 6 6 1 NOTE LED on PPC6000 STATUS LED Flashing LED indicates the control is OK OFF possible open fuse 2 2 see Section 2 6 1 Also OFF possible fatal processor fault 6 2 What to do when a fault occ
149. es have made their purge positions i e once pre purge starts Not active during post purge 1 This alarm will shutdown the 2 Fault will be active only burner and show on the display when the currently selected as FXX When the fault profile fires GAS condition clears this fault will change to CXX and the burner will restart without manual intervention The burner will shutdown within one second 2 This alarm is for indication 3 Fault will be active only only It will appear on the when the currently selected display as LXX but will not stop profile fires OIL the burner operating The limit will operate within three seconds 3 This operates the same as 4 Fault will be active only selection 1 in this column but when there is a fuel profile the fault will be generated when currently selected either the input closes This should not firing GAS or OIL be used for any safety function because if the wire breaks it cannot be detected 4 This alarm will shutdown the All other values will work like burner and show on the display selection 1 including zero 5 as FXX When the fault to 9 are spare so new condition clears this fault will functions can be added later change to CXX and the burner will restart without manual intervention The burner will shutdown within three seconds 5 to 9 are spare and can t be selected 3 Fault will be active after pre purge has finished
150. etpoints 3 4 Servo motor selection 3 1 14 Motor requirements Only servo motors supplied by FIREYE may be used with this equipment various servo motors are available to suit differing applications The information below is intended as a general guide only ensure that when installing or adjusting the servo motors fitted to the appliance that reference is made to the correct instruction manual e All servo motors must be connected via CANbus no other possibility exists e All 24V servo motors operate at 24Vac and are supplied from the PPC6000 main unit e All have a 90 maximum movement with an operating time of approximately 30 seconds for 90 travel e All have internal limit switches which must be adjusted during commissioning to allow the close position check to be performed and to protect the burner boiler against damage should a failure of the electronics occur NOTE Any profile must NOT exceed 40VA PPC6000 Servomotor Guide Model Rating FT LB Nm Voltage NXC04 3 0 4Nm 24 NXC12 24 NXC20 i 24 NXC40A 24 Table 3 1 1 A Example The profile requires 1 NXC20 1 NXC40 2 NXC04 Motor VA NXC04 6 NXC20 10 NXC40 18 Total 34 48 my It is necessary to ensure that each motor travels in the correct direction to match the mechanical configuration of the burner The default setting is for a servo to move counter clockwise looking at the output shaft as the motor is
151. etween 0 0 and 9 99 inclusive where the value entered is the hydrocarbon ratio x 10 For example for a hydrocarbon ratio of 0 157 a value of 1 57 should be entered Note When firing multiple fuels the mixture between the fuels fired may vary across the firing range of the burner When this happens the effective hydrocarbon ratio and calorific value of the fuel combination will change The accuracy of the calculated efficiency and the automatic trim commissioning procedure will be adversely affected by this It maybe that these functions should not be used in which case these values should be entered as zero See Option Table 35 x A on page 119 02 EI Options 35 5 to 35 8 Calorific values of fuels profiles 1 to 4 respectively 0 0 99 9 LV3 These option parameters are only available if option 35 0 inlet temperature sensor is not set to zero If a display of calculated burner efficiency is required the calorific value of the required fuels must be entered May be set between 0 0 and 99 9 MJkg inclusive Note When firing multiple fuels the mixture between the fuels fired may vary across the firing range of the burner When this happens the effective hydrocarbon ratio and calorific value of the fuel combination will change The accuracy of the calculated efficiency and the automatic trim commissioning procedure will be adversely affected by this It maybe that these functions should not be used in which case thes
152. evel measured value has exceeded the oxygen setpoint high alarm value for the current profile Subset 0 Limit violation 1 2 Probe Failed This fault occurs when two oxygen probes are used to give fail safe oxygen monitoring If this fault occurs check and calibrate both oxygen probes It may be necessary to increase option parameter 42 4 or 42 5 within safe limits if the oxygen probes are in different parts of the flue Subset 1 Oxygen values don t match 2 Flue temperatures don t match 3 Neither flue temperature or oxygen levels match 255 Second oxygen probe is faulty not ready See EK 76 136 Fault Number Cause Trim limit alarm Auto trim commissioning fault Flue temperature low alarm value exceeded Flue temperature high alarm value exceeded Combustion air pressure fault Option parameters uploaded eS The trim drive has reached the allowed maximum deviation limit Description e Change trim limit e Re commission fuel air ratio Subset Not applicable The measured oxygen level exceeded 15 0 during auto trim commissioning The burner is shutdown Subset Last auto trim commission setpoint 32 if adding air The measured flue temperature is below the low alarm value for the current profile or the flue thermocouple is faulty Subset Not applicable The measured flue temperature has exceeded the high alarm value for the current profile Subset No
153. evious downloads using Comfire 2 software all data and combustion curves will need to be entered by hand Please refer to Fireye bulletin NEX 1502 Comfire 2 available at www Fireye com Comfire 2 will not restore the servomotor serial numbers which will need to be hand entered in Option 3 0 to 3 9 BEFORE restarting the PPC6000 A valid backup is achieved after the burner has been running in AUTO for approximately 20 minutes 125 E When erase restore enable option 45 0 is set to 1 this option parameter allows the back up data held in the display to be loaded into the PPC6000 this may take up to 5 minutes to complete during which time the control will not allow the burner to operate IMPORTANT In order for the restore command to function the new control must have the same communications address Option Parameter 0 2 as the original control That is if option 0 2 was set to 2 boiler 2 for example the commissioning engineer must set options 0 2 of the new control to 2 BEFORE setting option 45 2 to 100 The default communications address of the control is 0 If multiple PPC6000 s have been connected together for sequencing it is likely that the communications address has been changed to match the boiler number To restore the data from the back up held in the NX610 or the NXTSD104 display set this option parameter to 100 If 100 is selected the data from the back up data held in the display will be loaded into the
154. f the drive Eg 5 3 is drive 3 If the device being driven rotates clockwise to increase firing rate then the servomotor must drive counter clockwise as viewed from the servomotor shaft and vise versa DO NOT COUPLE THE MOTOR TO THE DRIVEN SHAFT UNTIL AFTER THE DIRECTION HAS BEEN SET SEE SECTION 3 OF THIS MANUAL Deselect the original servomotor serial number using Option Parameter 3 x Select the new servomotor serial number from Option 3 x The serial number appears on the servomotor label but will also appear as unreserved in the list The burner will have to be started in full commissioning mode and each position PO though PX high fire must be verified by using the next key on the display This is covered in the commissioning section of the manual Bulletin PPC 6001 Combustion should be checked while doing this so as to assure a safe operation 52 my 4 Description of operation 4 1 The Display Keypad The display is a 2 line 20 character per line dot matrix vacuum fluorescent type allowing the use of plain text messages for most display parameters The keypad is a membrane construction with tactile keys to give a positive feedback of the actuation NOTE The display can be attached to more than one PPC6000 via CANbus The display must be interrogating the address of the desired PPC6000 if not a fault message will be displayed See the troubleshooting section Section 6 7 1 for details
155. f the function block program Abacus This overview is intended to give the user insight into what can be accomplished with function block programming NOTE For a more complete description on Abacus see Fireye Bulletin NXAB 1001 Introduction to Fireye s Abacus Programming Software 1 1 Introduction Abacus is a powerful software package that is used to program Fireye PPC6000 and NX6100 series controls The software allows the user to define special functions such as draft or feed water control to be implemented within the control using standard or optional inputs and outputs The designer can assign option parameters and engineer s key s as well as levels of password protection to the custom options After the program is completed it is then uploaded to the control via optional Fireye Comfire software The user can run the optional program by selection in option parameter 00 4 The factory default program is always available as a back up by deselecting the user program The programs are entered graphically by drawing and connecting blocks on schematic pages These schematics are then sent to the controls where they operate as a program Here is a preview of a simple program Briefly this program will give a relay closure digital output DO if either of the digital inputs DI 1 or DI 2 is activated These inputs could come from relay closures on other equipment The details of which inputs are read which output is activated ar
156. fault or burner select or keypad is off 43 Relay on if in normal mode inverse of 23 Relay off if in local mode or control powered off 44 Relay on if control is powered up 88 i 13 PES to live High Voltage i Option parameter Meaning 17 x value 45 Relay ON status 2 onwards and during lockout post purge Fan on if burner on or aiting for burner select 4 Burner available Relay on status 2 to 16 inclusive 47 Low fire output 48 High fire output 49 100 p Fault numbers 1 99 control the relay Relay de energized EK101 EK150 control the relay Details of the relay connection details are shown below Relays 2 amp 3 on the display share a common connection and 4 amp 5 on the PPC6000ler share a common connection When used to indicate a fault or limit the N O contacts will be closed when NO alarm is present to ensure the alarm indication is fail safe therefore alarm devices should be wired to the normally closed contacts Abbreviations Com Common N C normally closed Open normally Open A For NX610 9 key keypad if set as Alarm no alarm present at power up relays change state as follows NOTE No connection to terminal 4 on NX610 display Option Relay ALARM Function Connection Detail for NX610 Only Parameter Output 17 1 1 Display Low or Line voltage PR1 Normally Closed PR2 Normally Open PR3 Common 17 2 Display Low or L
157. fferent setpoint 5 Press the ENTER key to store the new drive positions for the current setpoint 6 Repeat steps 2 5 as required Each time step 5 is completed the new positions will be stored permanently 7 Leave adjust ratio mode If the A n display is flashing it will not be possible to adjust the position of any of the drives This may be for one of the following reasons e The burner is not firing Switch the burner on and wait for the control to begin modulating e The current setpoint is AO A1 or A2 Use commission ratio mode to adjust these setpoints e The drive s are moving to the required positions Wait for the drive s to stop moving 129 Gies 5 7 4 Leaving adjust ratio mode Adjust ratio mode Run mode To leave adjust ratio mode and return to run mode press the key labeled RUN followed by the key labeled ENTER 5 8 Interrogating the software issue There are two methods for finding the software issue 1 From run mode press the COM key The Fireye version number will appear 2 Use the engineer s key refer to section 6 6 for details and scroll up to EK200 for the current Fireye operating version 130 my 6 Faults and fault finding 6 1 The fault display The PPC6000 series carry out a number of internal and external checks during operation If a fault is found a fault number displayed with a text description is used to identify the type of problem A list of fault numb
158. fireve net pdf JC 1109 pdf potential Connection of any voltage above 5 volts to these terminals will damage CAUTION Due to the possibility of High Frequency electrical noise BOTH ends of the shielded signal wire to the VSD must be grounded Note and PE8 provide purge and low fire position signals to the flame safeguard control These outputs MUST NOT have a load greater than 30mA i e relays lamp etc damage to the PPC6000 will result NOTE These templates should be measured for accuracy as distortion from printing may occur See section 2 0 for details PPC 6000 6 26 159mm A 3 15 80 mm 0905999999399 _ if 174 175 NX600 NX610 3 7 16 87 mm 4 1 8 105 mm 9 KEY DISPLAY PANEL CUI OUT TEMPLATE Remove to use NOTE These templates should be measured for accuracy as distortion from printing may occur See section 2 0 for details 176 177 NXO2INT 4 925 125 1mm 188 4 8mm CONDUIT ENTRY 5 50 139 7mm 4 058 103 1mm O2 INTERFACE MOUNTING TEMPLATE E Ps m TEMPLATE Remove use NOTE These templates should be measured for accuracy as distortion from printing may occur See section 2 0 for details 178 Cay 9 7 Operator s Guide 9 7 1 Introduction This guide can be downloaded from the Fireye we
159. form a safety shutdown and the alarm will sound once the fault has cleared the burner will remain in safety shutdown until a Mute Reset is performed If the Mute Reset button is pressed while the control is in safety shutdown and the fault is still present the alarm will be muted and the burner will remain in safety shutdown When the fault clears the alarm will sound once more If the Mute Reset button is pressed while the control is in safety shutdown and the fault has cleared the alarm will be muted and if the button is held for in excess of 3 seconds the burner will re start 5 4 6 Touchscreen LED Indication The Touchscreen also houses a multi functional LED for indication of current status The LED will be green permanently on if no faults or limits are present The LED will be red flashing if there is a limit or an alarm condition present which does not cause a lockout The LED will be red permanently on if there is a fault present even if the fault has been muted which causes a lockout 66 eS 5 4 7 Touchscreen Fuel Profile Select Once the Fuel soft button is pressed a pop up window appears on the right giving the user a choice of available fuels profiles The PPC6000 allows for a maximum of four profiles Any profiles which are not programmed and therefore not available will be grayed out 13 09 40 OFF GAS AUTO Unito 2008 05 20 Profile 1 GAS Profile 2 OIL Operating hours 10
160. from the new block In this case they are all blank Enter something for the comment field Pump 2 Failed for example and a value of 2 for the digital input number Click Apply once more Leaving the parameters window open click on the digital output block and enter a comment field Pump Alarm for example and a digital output number of 1 Click OK to apply the parameters and close the window The schematic should now look similar to this st Unit E 1 New Schematic Note that the parameters are listed by the function block in the order that they appear in the parameters window The look can be a bit unusual but is vital for documentation and debugging purposes 1 3 6 Checking your schematic text compiling With your schematic page active choose Project Test compile schematic from the menu This will perform a test compile of your page The result will tell you if everything s okay or if you ve not entered a parameter or if there is some other problem with your schematic Hopefully all is ok If not check the block concerned The error message will tell you the block x number of any erroneous blocks Checking your schematic Usage While your schematic may compile ok you may wish to check a few more things For example you may have used the same output twice or the same input for multiple unrelated items For additional information see The IO usage window when actually working in Abacus
161. g this value causes a non volatile lockout Opt 21 1 22 1 Set 1 100 psi Opt 21 5 ees set 0 2 Opt 21 6 22 6 1 15 Opt 21 7 22 7 Set to iie 5 RESULTS Boiler OFF Cut Out at 115 psi Boiler ON Cut In at 95 psi Boiler maintains Setpoint 100 psi via PID Changing ONLY the Setpoint Opt 21 1 22 2 change to 60 psi NEW RESULTS from Setpoint Change 180 Boiler OFF Cut Out 75 psi Boiler ON Cut In at 55 psi Boiler maintains Setpoint 60 psi via PID NOTE NEW integral time and D derivative time values Option Parameters 21 3 22 3 and 21 4 22 4 may be required to achieve desired results Absolute Example setting Opt 21 5 to 1 Opt 21 1 22 1 set to 100 psi Opt 21 5 cse temen set to 1 Opt 21 6 22 6 SOttO iius 115 Opt 21 7 22 7 Set to 95 RESULTS Boiler OFF Cut Out 115 psi Boiler ON Cut In at 95 psi Boiler maintains Setpoint 100 psi via PID Changing ONLY the Setpoint Opt 21 1 22 2 chang
162. ge 16 Modulation EK33 17 Move to post purge 18 Post purge 9 7 12 Non volatile lockout my Once the fuel and air motors reach their low fire positions they are modulated according to the demand placed on the burner Description In this burner status the high fire switch and low fire switch outputs PE8 amp PE7 will come on at high and low fire respectively and may be used for indication purposes If a HIGH input is provided by closing PA9 PA11 this control will move to status 17 If the AUTO input is removed by opening PA10 PA11 this control will modulate down to low fire then jump to status 15 Note Terminal PE7 will not be energized in this case This may be used to provide a low fire post purge or a low fire hold function If the fuel profile select input is removed PE9 10 11 or 12 the control will immediately move to status 1 If this control wishes to turn the burner off there is no call for heat for example it will open the controlled shutdown relay removing power from PE3 It will remain in modulation status however until one of the conditions above is met The selected motor s are moved to their purge positions all others are moved to their closed positions When the drives have all stopped the control will move to status 18 The controller confirms all required drives are at their purge positions and gives a purge proved signal
163. gnals the end of pre purge by breaking PA11 PA9 HIGH input If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 The selected motors are moved to their ignition positions The purge proved signal is switched off When the drives have all stopped moving the control advances to status 10 If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 The controller confirms all required drives are at their ignition positions and gives an ignition proved signal by supplying line voltage to terminal PE7 low fire switch The controller will hold the drives at their respective ignition positions until the signal to modulate is received from the burner controller This is performed by closing the circuit on PA10 PA11 AUTO input If the fuel profile select input is removed PE9 10 11 or 12 the control will immediately move to status 1 NOTE Statuses 11 to 14 control the light up sequence of the burner and are provided by the burner controller device used for the application This control will jump from status 10 to status 15 when the light up is completed Not Applicable to PPC6000 57 Stage no 15 Stage Moving to low fire Modulation EK33 Move to post purge Description Once the AUTO signal is received the fuel and air motors are moved from their ignition positio
164. he control must be returned to the supplier Subset Failed Page 134 Fault Cause Number Program memory CRC fault Boiler safety limit exceeded Reserved Reserved Burner not OFF Reserved F39 Profile table CRC fault ey The program memory in the control has been corrupted Description e Interrupt power to the control e This could be due to high levels of electrical interference getting into the product Check all cables are correctly screened and screens are terminated correctly Ensure the mains supply is not excessively noisy e lf this fault persists the control must be returned to the supplier Subset Failed Page The profile table memory in the control has been corrupted e Interrupt power to the control e Erase the system using option parameter 45 1 5 and re commission or restore with option parameter 45 2 e This could be due to high levels of electrical interference getting into the product Check all cables are correctly screened and Screens are terminated correctly Ensure the mains supply is not excessively noisy e lf this fault persists the control must be returned to the supplier Subset Failed Page N A The boiler s measured value has exceeded the pressure temperature safety limit Subset 4 safety limit exceeded This fault will lock the burner out if the AUTO input PA10 PA11 is made when the control thinks the burner should not be firing It will
165. he fault to appear and the burner to lock out immediately e Contact supplier Subset 1 Late test failed 2 Early test failed F70 F79 User Faults These fault numbers are generated by the user programmable section of the control and will vary with the application 6 6 The engineer s key By selecting the engineer s key it is possible to read the values of internal system variables and external input and output states Itis also possible to see the values of fault subsets in order to obtain more detailed information about a fault that has occurred When using the engineer s key it is not possible to change any parameters Therefore it is not possible to affect the operation of the burner After pressing the Engineer s Key e top line of the display will show an EK data register number and the value of the register e The bottom line of the display will show the EK description For example 25 2 Burner Status e If there is a fault present this will be shown on the right hand side of the top line in the format Fnn sss where nn fault number and sss fault subset value Note this fault information will only be shown when viewing EK numbers 1 to 100 e Use the UP DOWN keys to change the EK number and view its corresponding data e Press the EK to index back to the normal display The control will revert automatically to the normal run display if a key has not been pressed for one minute
166. he lead before adding another lag Option 28 0 Analog Input decimals 0 2 LV3 Option 28 x is available on Firmware Version 1 204 and above EK56 Set the number of decimal places for analog input 1 on PA5 PA11 Option 28 1 Analog Input 1 zero 0 999 LV3 Set the number to be displayed when the input 1 current is 4mA Option 28 2 Analog Input 1 span 0 999 LV3 Set the number to be displayed when the input 1 current is 20mA Setting this parameter to a non zero value also enables this item NOTE Setting the span value enables the item On the 2 line display the values can then be seen by scrolling with the keys in RUN mode They will always show up as Analog Input 1 or Analog Input 2 or Analog Input 3 On the touchscreen the analog inputs appear on the right hand side list and can be added to the trends chart etc Also the touchscreen gives us the flexibility to type in text to name these inputs like the profiles can be see screen configuration page on the touchscreen Option 28 3 Analog Input 2 decimals 0 2 LV3 Set the number of decimal places for analog input 2 on PA6 PA11 Option 28 4 Analog Input 2 zero 0 999 LV3 Set the number to be displayed when the input 2 current is 4mA Option 28 5 Analog Input 2 span 0 999 Set the number to be displayed when the input 2 current is 20mA Setting this parameter to a non zero value also enables this item See NOTE under Option 28 2
167. hecked to verify that the fuel air ration is acceptable for the appliance being controlled Once the correct passcode is entered the unit will enter commissioning mode and allow the option parameters and profile points to be adjusted the text on the COM button will change to RUN To warn the user that the unit is in commissioning mode the overall display background changes to red and COM is displayed top center on the screen Drives Options Engineers Values Pro1 Pro3 Proa Modulation rate set Burner Settings Boiler actual Boiler setpoint F t t Fine Adjust Po Burner Shut down Sequence Shutdown signal Drive burner to low fire Lowfirereached Shutfuel valves ZN a Jl Burner Off e Reset Fuel Control Overview Moveto post purge Move a drive now to modify this setpoint NEXT ENTER RUN Post purge 0 00 To enter or adjust Drive positions it is necessary to select the relevant Drive to be set and then use the up down arrows to move the drive to the required position Set all the drive positions for each profile point before using the ENTER button to store the values and move to the next profile point if already entered then repeat the procedure for this point and any others required up to high fire 73 NOTE When adjusting servo motor positions it may require the use of the Fine Adjust button to get the motor to the exact spot
168. hile the control is operating in commissioning mode certain safety checks cannot be performed by the control and therefore the safety of the system operation is the sole responsibility of the commissioning engineer Do not allow fuel to accumulate in the combustion chamber If fuel is allowed to enter the chamber for longer than a few seconds without igniting an explosive mixture could result If a flame failure occurs at any point the control will not attempt a re start until the fault is cleared unless the option to allow recycling is enabled Before moving to the ignition position to attempt a re start the system will perform any selected pre purge Where operating times are adjustable ensure that those selected are acceptable for the appliance being controlled Ensure that a purge position is entered for each drive as required failure to enter a purge position will mean all drives remain at their closed positions Once all safety times have been selected it is the responsibility of the commissioning engineer to verify that the times entered are correct for the appliance being controlled After entering and or adjusting any profile points for any profile it is the responsibility of the commissioning engineer to verify that the resulting fuel air ratio is acceptable for the appliance being controlled 5 1 General If any settings in the control are to be changed it is necessary to enter a commission mode Three passcodes are avai
169. his must only be changed if an inverter error of 55 will not cause unsafe combustion Variable Speed Drive Selection Important Note When selecting a VSD or variable frequency drive VFD consideration must be given to the size and weight of the blower wheel While a fan application is by nature a variable torque load the inertia weight of the blower wheel must be considered Typical HVAC type drives do not speed up or slow down large blower wheels with enough control to operate within the tolerance of the PPC or NX series control Therefore a VSD VFD with some built in breaking capability such as a constant torque drive should be used At a minimum if the drive has a constant torque setting it must be enabled to minimize faults due to drive hunting Problem Possible cause Suggested action Oxygen display not No oxygen probe interface unit available serial number entered 30 0 No inlet temperature No inlet temperature unit serial Enter serial number into option parameter display number entered 35 0 Inlet or flue temperature Inlet air temperature sensor O2 Check wiring display flashes Hi probe not installed and wired correctly No efficiency display or No oxygen display See No oxygen display efficiency incorrect No inlet temperature display See No inlet temperature display No calorific value for the current fuel been entered into 35 X Enter the value for the fuel in use Oxygen display shows Probe
170. i e drives moving to the ignition position Not active during post purge 4 Fault will be active after pilot ignition has started status 11 onwards Not active during post purge 5 Fault will be active after main ignition has started status 13 onwards Not active during post purge 6 Fault will be active after the drives have reached their low fire positions and the burner is ready to modulate status 16 Not active during post purge 7 fault activates at ignition only status 10 to 14 inclusive continued on next page 92 HUNDREDS TENS UNITS fault type fuel type burner status type only status 8 All other values will work like selection 1 including zero 7 to 9 are spare so new functions can be added later NOTE In order to enable any Digital Input a value greater than 0 MUST be entered in one of the three columns Digital Input Number Terminals Fault number parameter number Option 19 1 to 19 4 Fail safe Alarm Lockout Display Messages The lockout functions are completely separate from the lockout messages The messages are chosen from a list of 32 possible items using option parameters 19 1 to 19 4 for inputs 1 to 4 and option parameters 16 5 amp 16 6 for the high voltage inputs 12 amp 13 These are the default messages but at least some of them can be modified using serial communications and a PC Option parameter Meaning 19 X or
171. ill be detected Terminal PX13 alternates to be shared with PZ12 and PZ14 This switching detects a direct link between input 1 and input 2 which is not allowed Counter Input 3 PZ 11 Input Channel 1 PZ 12 Input Channel 1 PZ13 Input Channel 2 PZ14 Relay 7 common PZ 15 The function of relay 1 amp 2 can be set by option parameter but please ilies MC MEAM note the maximum rating of these relays is 200mA at 50V Relay 8 common PZ 17 Incorrect connection may damage or destroy the units being connected Relay 8 normally open PZ 18 43 Sy 2 6 24 LIVE and NEUTRAL supply optional Oxygen Probe Interface unit WARNING Incorrect setting of the Supply Voltage Links WILL damage or destroy the unit MAX 3A The LIVE and NEUTRAL supplies must be connected using multi strand single conductor core PVC insulated 16 AWG 19 0 3mm wire The live connection should be fused with a maximum rating of 3A LIVE PL 1 LIVE NEUTRAL PL2 NEUTRAL 2 6 22 Oxygen probe connection optional Oxygen Probe Interface unit NXO2INT Bussmann S504 series Bussman 504 series PN GMA 5 5 AMP Fast Acting to protects transformer primary DC circuit Alternate Source Mouser Electronics PN 504 GMA 5 P N GMD 630 TIME Delay for 115V P N GMD 315 TIME Delay for 230V to protect 24V circuit Alternate Source Mouser Electronics PM 9 PROBE HEATER 24VAC PM 8 PROBE HEATER 24VAC PM 7 FLUE TE
172. imum reference frequency as required nominally 60Hz for 20mA signal e Maximum feedback frequency same as reference for 20mA signal unless using encoder e No filtering time constant 0 0 and no rate limiting Digital input The digital input i e the RUN STOP on the inverter should be configured in the following way e RUN STOP from external input NOT inverter keyboard e RUN STOP active high i e energize to start 158 my Control characteristics The control characteristics of the inverter should be configured in the following way Acceleration and deceleration time approximately 25 40 seconds must be the same Straight line linear acceleration between reference points Motor to coast to a stop when RUN signal is removed No critical frequencies DC braking may be needed if motor deceleration is not linear Motor characteristics The following motor characteristics should be entered into the inverter s option parameter list Motor nominal voltage power current and frequency see motor plate and or supplier data Motor current and temperature limits U F ratio Use the SQUARED option for fans and pumps Motor slip ratio Use drive default if unknown 7 4 Setting up the PPC6000 series for use with a inverter drive In order to use a inverter drive with a 4 20mA interface the optional inverter interface daughter board must be fitted The following steps must then be taken Enter commission mode Enter
173. in use ouchscreen Configuration Profile 1Name Profile2 Name Profile 3 Name Profile 4 Name 4 20 INiName 4 20mA Input 1 units 4 20IN2 Name 4 20mA Input 2 units 4 20 IN3 Name 4 20mA Input 3 units OFF GAS PAUTO Unito General Display Date amp Time Ethernet Unit Addr Modify i New text ENTERNAME HERE 2 amp 5 jkl BA AE Cancel 70 ry Highlight the profile for which a name is to be entered or modified and press the Modify button This will cause a window to appear allowing the required name to be entered using the button pad Once the name is displayed against the required profile the mode can be exited by pressing the X in the top right corner of the Touchscreen Configuration window To exit this configuration window and return to the overview screen press the Overview button 5 4 13 Cleaning the Touchscreen WARNING To prevent possible damage to the touchscreen ensure the correct fluid is used when cleaning the screen Before attempting to clean the screen ensure the clean screen function is enabled to ensure operation of the burner is not affected Once the Clean Screen function is selected the display keys will be unavailable for 20 seconds Before attempting to clean the screen it is essential to select the Clean Screen function to prevent any pressure applied to clean the t
174. ine voltage PR5 Normally Closed PR6 Normally Open PR7 Common Display Low or Line voltage 7 Common PR8 Normally Open PR9 Normally Closed 176 6 NA J4 J J J 178 8 NXDBVSD PZ17 PZ18 Low voltage 50V AC DC 200m 1 179 9 Available on NXTSD104 Touchscreen display ONLY common to relays 2 and 3 B For NX610 if set as General Purpose relay connections are as follows NOTE You MUST recycle power to reset relay function first 89 Option Relay GENERAL PURPOSE Connection Detail for NX610 Only Parameter Output Display Lowor Line voltage PR1 Normally Open PR2 Normally Closed PR3 Common Display LoworLine voltage PR5 Normally Open It 17 2 PR6 Normally Closed PR7 Common 17 3 1 2 3 Display Low or Line voltage 7 Common PR8 Normally Closed PR9 Normally Open 174 4 6000 4 Line voltage output ONLY 175 5 176 6 177 7 JNXDBVSD 215 PZ16 Low voltage 50V AC DC 200mA 178 8 NXDBVSD PZ17 PZ18 Low voltage 50V AC DC 200mA 179 9 Available on NXTSD104 Touchscreen display ONLY common to relays 2 and 3 For Example If you want an indicator light to illuminate when the warming limit is exceeded released to modulate 1 Use one of the three display relays for this example 1 2 Set 17 1 for relay 1 to 16 value for warming limit exceeded 3 The contacts between PR3 and
175. integral and derivative Proportional Typical older modulating systems employ only proportional control This would be similar to the slide wire type found on most steam boilers When using only a proportional control the system rarely achieves setpoint as the burner firing rate is lowered as the pressure comes up At some point the input meets the actual demand and the pressure no longer raises or lowers thus an offset between desired setpoint and actual operating pressure occurs The only time the pressure and setpoint are the same is if the actual load equals the lowest firing rate of the burner this is rare An example of proportional only set up might be Setpoint is 100 PSI proportional range is 10 PSI That is low fire is at 100 PSI high fire is at 90 PSI with a 1 1 relationship in between e g 95PSI equals 50 rate A good starting point for the P value in most cases is about 10 of setpoint Integral If the integral term is turned on the control compares the actual pressure against setpoint at an adjustable interval If there is an offset the firing rate is increased by a small percentage until the next interval This will continue until the pressure equals the setpoint The same routine occurs as the pressure rises above the setpoint Too much or too little integral will cause over and undershoot of the setpoint Integral is set in seconds per repeat in the PPC6000 For example if the P were set at 10 psi with a boiler setpoint
176. ion The two functions are explained below Option parameter 30 5 Meaning value Monitor only The oxygen value is only used to provide a display of the measured oxygen level 1 Closed loop trim The oxygen value is used to provide both a display of the measured oxygen level and a feedback signal for closed loop trim control function of the PPC6000 series control Option 30 6 Oxygen probe calibrate enable 0 2 LV3 110 eS This option parameter must be used when calibrating the oxygen probe There are three possible values This option parameter is only available if option 30 0 is non zero Option parameter 30 6 Meaning value 0 No calibrate This is the normal operating condition where the probe is used to measure the oxygen concentration in the flue 1 Calibrate in air The probe will be calibrated for offset at the normal atmospheric oxygen concentration 2 Calibrate in reference gas The probe will be calibrated for gain in a reference gas with a nominal oxygen concentration the level specified in option parameter 30 3 typically 3 0 Once this calibration has been successfully completed the values in 30 1 and 30 2 will be automatically updated 02 Option 30 7 Boiler transport delay 5 60 seconds LV3 Boiler transport delay is the time taken for gas to travel from the burner to the oxygen probe This delay varies with burner fire rate In order for the oxygen trim control loo
177. ion 20 8 Digital Input Lead Boiler Select 0 35 97 Option 21 0 Set point 1 enable 0 1 LV1 97 Option 21 1 Set point 1 control value 0 999 00 0 99 9 0 00 9 99 LV1 97 Option 21 2 Set point 1 proportional band 0 999 00 0 99 9 0 00 9 99 LV197 Option 21 3 Set point 1 integral time 0 999 seconds LV1 97 Option 21 4 Set point 1 derivative time 0 999 seconds LV1 98 Option 21 5 Setpoint 1 control limit type 0 2 LV3 98 Option 21 6 Setpoint 1 low limit control value Cut In 0 999 00 0 99 9 0 00 9 99 LV1 98 Option 21 7 Setpoint 1 high limit control value Cut Out 0 999 00 0 99 9 0 00 9 99 LV198 Option 21 8 Remote Setpoint 1 zero 4ma value 0 999 00 0 99 9 0 00 9 99 LV1 98 Option 21 9 Remote Setpoint 1 span 20mA value 0 999 00 0 99 9 0 00 9 99 LV1 98 Option 22 0 PID set point 2 enable 0 1 LV1 98 Option 22 1 Set point 2 control value 0 999 00 0 99 9 0 00 9 99 LV1 99 Option 22 2 Set point 2 proportional band 0 999 00 0 99 9 0 00 9 99 LV1 99 Option 22 3 Set point 2 integral term 0 999 seconds LV1 99 Option 22 4 Set point 2 derivative term 0 100 LV1 99 Option 22 5 Setpoint 2 control limit type 0 2 LV3 99 Option 22 6 Setpoint 2 low limit control value 0 999 00 0 99 9 0 00 9 99 LV1 100 Option 22 7 Setpoint 2 high limit control value 0 999 00 0
178. ions including Modbus and boiler sequencing This usually indicates that boiler sequencing is working EK135 AUX input in use This value 1 if option parameter 20 7 analog input 5 function is non zero 148 This value 1 if the control is currently banking based on a temperature setpoint for SP2 EK137 Remote lead selected This value 1 if the another boiler has been selected to be lead boiler instead of this one SP1 selected remotely If this value 1 the first PID modulation setpoint SP1 has been selected remotely via serial communications including sequencing and Modbus EK139 preload lag status Used internally to keep the same boilers firing when the lead boiler changes EK140 to Not used by the standard EK 150 manufacturers program May be used by a custom program EK151 Setpoint 1 control value The actual value of setpoint 1 being applied EK152 Setpoint 2 control value The actual value of setpoint 2 being applied EK153 Low control limit The actual value of the low control limit cut in point being applied EK154 High control limit The actual value of the High control limit cut out point being applied EK156 Measured Value The current boiler measured value actual value shown with increased precision EK157 AUTO modulation rate The modulation rate that the boiler will fire to if in AUTO mode providing option parameter 15 0 is not zero or 1 EK158 Not used by the standard N A manufacturers pr
179. is is not the only factor in selecting wire While it is true foil and drain shielded wire specifications indicate 10096 coverage as compared to approximately 85 for braided type the cross sectional area of the braid provides the required noise immunity Also the special grounding clamp bars on this control do not provide adequate connection to foil shield In fact most foil shields do not conduct on the surface Using the drain wire to a ground stud does not properly protect the control CAUTION e Disconnect the power supply before beginning installation to prevent electrical shock equipment and or control damage More than one power supply disconnect may be involved Wiring must comply with all applicable codes ordinances and regulations Loads connected to the PPC6000 series optional daughter board and optional oxygen probe interface must not exceed those listed in the specifications as given in this manual Ensure the maximum total load on the CANbus cabling servo motors display etc is within the specifications of the PPC6000 and for the cable being used This control MUST NOT be directly connected to any part of a Safety Extra Low Voltage SELV circuit WIRING INSTALLATION MUST BE CARRIED OUT BY A COMPETENT ELECTRICIAN AND IS SUBJECT TO I E E WIRING REGULATIONS BS 7671 1992 NEC AND OR LOCAL STANDARDS WHICH MAY PREVAIL HAZARDOUS VOLTAGES MUST BE ISOLATED BEFORE SERVICE WORK IS CARRIED OUT The PPC6000 unit MUST b
180. is used to provide a 0 to 5 volt tracking input only The burner modulation will track the voltage applied going to high fire for 5 volts There is no measured value just a tracking setpoint Option parameters 15 0 to 15 5 are unavailable 4 20mA operation Set the JP1 link to IN Set the link to 30V This option allows for connection to a 4 20mA measured value input device such as a pressure or temperature sensor The internal PID will be used if selected 1 4 20mA operation Set the JP1 link to IN Set the link to 30V This option allows for connection to a 4 to 20mA pressure or temperature sensor The burner modulation will track the current applied going to high fire for 20mA and low fire for 4mA If the current goes outside the range the burner will go to low fire There is no measured value just a tracking setpoint Option parameters 15 1 to 15 5 are unavailable Option 15 1 Modulation input decimal places 0 to 2 This parameter specified the number of decimal places to which the measured value and setpoint are displayed It also affects the scaling of the zero span and safety limit it is vital that this parameter is set before parameters 15 2 15 3 and 15 5 Option parameter Meaning 15 1 value C 5 of values is from 000 to 999 of values is from 00 0 to 99 9 2 Measure value and setpoint displayed with two decimal places Range of values is fr
181. it microswitch until the motor starts moving down Clockwise limiter Red Yellow Continue to slacken off the microswitch until the motor stops with a reading on the display of approximately 1 Move the motor up and down a few times to check that the motor stops each time at approximately 1 and re adjust the microswitch if necessary This position will allow for some tolerance in microswitch operation Hold the UP key and tighten up the high limit microswitch until the motor will no longer move up Holding the UP key gradually slacken off the high limit microswitch until the motor starts moving up Continue to slacken off the microswitch until the motor stops in the desired purge position This position does not have to be 90 but it is recommended that it is more than 45 and less than 90 Move the motor up and down a few times to check that the motor stops each time at the desired limit position Repeat steps 3 to 7 if necessary Counter clockwise limiter Counter clockwise Clockwise limiter NOTE For NXC04 NXC12 NXC20 SERVOS ONLY NOTE For NXC40 SERVO ONLY 51 SS 3 6 Servomotor Replacement After a system has been commissioned replacing an undersized or failed servomotor requires the following considerations 1 First determine the direction the motor travels as the replacement will have to be set the same way This can be found in Option Parameter 5 x x being the number o
182. ity of the screen Incorrect connection may damage or destroy the units being connected CANbus PB 3 CANbus 38 Gem Servo Motor Display Servo Motor Servo Motor PPC6000 PK PT PK PK PA or PB TER LES Ib Ti sl ft At Clamp Bar NOTE Interposing terminal blocks should be avoided when shielded cable is required Interposing terminals present a risk of electrical noise interference resulting in unreliable operation 2 6 14 Display Connection with PPC6000 and BurnerLogix YB110 Connect the touchscreen display TSD to the PPC6000 using shielded cable from positions PA1 PA4 or PB1 PB4 Terminate wires to the 4 position terminal block on the back of the touch screen display Connect the YB110 using the three terminal connector labeled B 0 volt The amp B connections connected to the Fireye ED610 terminal block purchased separately on terminals 10 amp 9 A amp B the 0 volt connection is not used The ED610 is connected to the YB110 via an ED512 4 cable purchased separately Leave in in position ter Resisto Ferrite core iN oUT 225 no ezt O52 amp 2 5 28 J1 109 8 7 65 4 3 2 1 XXXX 2 WARNING No other connections allowed on ED610 Screen Damage to YB110 will connection TSD104 setup for use with YB110 After wiring the YB110 to the TSD as shown above the TSD must be told to com
183. lable for this purpose e Supplier passcode allows entry to all commissioning modes LV3 e Adjust Ratio mode LV2 e Site passcode allows adjustment of some option parameters LV1 SUPPLIER SITE PASSCODE PASSCODE LV3 LV1 BURNER ON BURNER OFF ADJUST RATIO MODE COMMISSION RATIO MODE OPTION SET MODE 60 Cay 5 2 Commissioning data 5 2 4 Option parameters The PPC6000 series is configured by programming Option Parameters memory registers that describe the configuration of the burner and the boiler Option parameters are set and adjusted in Option Set mode but it may not be possible to adjust all of them if the burner is on 5 2 2 Setpoints Setpoints contain information about required motor positions There are four profiles or tables of setpoints available in a standard control The profiles may be represented using the diagram below CLOSE PURGE P1 IGNITION P2 LOW FIRE P3 76 8 85 6 HIGHBIRE Px Up to 24 setpoints may be entered for each profile including close purge and ignition New setpoints must be entered in commission ratio mode Existing setpoints may be modified in adjust ratio mode or commission ratio mode 5 3 The Commissioning process 5 3 1 Navigation The symbols below will be used throughout the Commissioning Process in this manual to indicate the correct application for each commissioning OPTION for use by the Commissioning Pe
184. le it will open the controlled shutdown relay removing power from PE3 It will remain in modulation status however until one of the conditions above is met The selected motor s are moved to their purge positions all others are moved to their closed positions When the drives have all stopped the control will move to status 18 58 Stage no Stage Description 18 Post purge The controller confirms all required drives are at their purge positions and gives a purge proved signal by providing line voltage to terminal PE8 high fire switch The control will remain in this status until the burner controller signals the end of pre purge by breaking PA9 PA11 HIGH input or the fuel profile select input is removed PES 10 11 or 12 In either case the control will immediately move to status 1 4 3 Non volatile lockout Non Volatile lockouts cannot be cleared without operator intervention and are remembered in the event of power being removed from the control A non volatile lockout will occur under the following conditions e In any stage the interface signals are incorrect e n stages 5 7 and 8 stages 10 16 inclusive and stage 18 if a motor is not in the correct position e In any stage if an internal or external fault not previously mentioned occurs which may affect the safe operation of the burner see section O 4 4 Modulation During stage 16 modulation the c
185. le effect a large value will cause a large effect Derivative control is seldom needed for boilers but can improve the response of the modulation system to sudden load changes Too much can cause control instability Option 22 5 Setpoint 2 control limit type 0 2 LV3 This option parameter defines the control limit type for setpoint 2 The control limits are used to automatically turn the burner off when it is not needed and bring it back on when it is needed Option parameter Meaning 22 5 value No limits The burner will run until another method is used to switch it off Deviation limit The values entered in option parameters 22 6 and 22 7 represent a deviation i e offset from the setpoint 1 control value This means that if the setpoint control value is changed the limits are automatically changed correspondingly 1 Absolute limit The values entered in option parameters 22 6 and 22 7 are the actual limit values 99 E gt Option 22 6 Setpoint 2 low limit control value 0 999 00 0 99 9 0 00 9 99 LV1 If the boiler is off due to a controlled shutdown this parameter defines the measured value at which the boiler will be turned on again Option 22 7 Setpoint 2 high limit control value 0 999 00 0 99 9 0 00 9 99 LV1 If the boiler is on and firing this parameter defines the measured value at which the boiler will be turned off via a controlled shutdown Option 22 8 Maximum modulation rate
186. lls below approximately 130 C The sulphate problem does not occur in gas fired installations but vapor may cause problems due to condensation if the temperature of the flue gas falls below 100 C The maximum flue gas temperature is 1004 F 540 C 23 CD 14220427 Assembly DIRECTION OF FLOW 3 1 8 FILLET WELD ALL ROUND FLUE WALL 4 FLUE APERTURE fF COVER MOUNT HOLES T 5 al GASKET Sr e 2 COS 20 alg saah UR VIEW OF MOUNTING PLATE 3 0 78 WITH COVER WELD FLANGE PROBE MOUNT ALL DIMENSIONS IN MILLIMETRES INCH EQUIVALENTS ARE IN MATERIAL MILD STEEL PROBE MOUNT SYSTEM CYLINDRICAL FINISH ZINC PLATE OR FLAT WALL FLUE The probe end cap carries a removable 20mm 3 4 flexible conduit fitting to enable probe replacement without wiring The 2 hexagonal caps visible on the probe rear face are there to cover the calibration gas port and the sample gas port The latter is merely a tube that passes directly into the flue to enable gas samples to be drawn or flue temperatures to be taken using other instrumentation Both ports must be kept sealed during normal operation for safety and accurate performance 2 4 4 Mounting arrangements for Temperature and Steam pressure sensors For full technical specifications of sensors see sections 2 4 5 and 2 4 6 2 4 5 Boiler temperature sensors 270mm 10 63 200mm
187. lose position prove when a drive stops at a position that is outside the close set position by more than five degrees 2 During purge position prove when a drive stops at a position that is outside the purge set position by more than five degrees 3 During pre purge ignition or post purge when a drive moves from its setpoint 4 During modulation when a drive is not at its correct setpoint as defined by the commissioned fuel air ratio for the selected profile A drive is defined as having moved from its setpoint if its positional error is more than 1 for 15s or more than 5 for 1s For positional errors between 1 and 5 the detection time is variable between 15s and 1s Note Only the selected drives are checked i e used on the current fuel air profile The other drives are ignored Subset burner status 000 016 Position fault at the status number 032 048 CAN communications error Display shows ERR1 under drive name 064 Internal servo fault Display shows ERR2 ERH7 under the drive name Note A message ERR1 ERR2 ERR3 on the display indicates a communications failure with a given servo motor This could be caused by a wiring error or an incorrectly selected serial number Verify selections in Option parameter 03 x One or more of the fail safe low voltage inputs is registering a fault Subset Combination of failed inputs Subset Input 0 N A 1 1 2 2 4 3 8
188. m It is the responsibility of the commissioning engineer to ensure the trim limit set will not allow a hazardous combustion condition to occur in the event of an oxygen probe failure Where oxygen is to be considered safety critical option parameters 31 X should be used to setup a second oxygen monitor When a second oxygen monitoring system is used the oxygen can be considered fail safe and the trim limits can be set up to 50 instead of 25 02 Options 33 1 to 33 4 Trim integral gain Default 10 LV3 Options 33 1 to 33 4 are only available if option 30 5 oxygen input function has been set for closed loop oxygen trim 114 ry In order for the oxygen trim control loop to be stable the integral gain must be set correctly Options 33 1 to 33 4 allow the integral gain to be set individually for each profile combination to any value between 0 0 and 99 9 As a general recommendation the integral gain should be initially set to 10 0 This value must be set above 0 0 for the system to apply trim If the burner is firing it is only possible to make an adjustment to the option parameter that relates to the selected profile If the burner is not firing the integral gain for any profile selection may be adjusted Option 34 0 Trim proportional gain 0 1 LV3 Options 34 1 to 34 4 Trim proportional gain 0 0 99 9 LV3 Options 34 0 to 34 4 are only available if option 30 5 oxygen input function has been set fo
189. m as if they are servomotors similar positional errors are applied to VFD s See Section 7 42 my 2 6 20 PPC6000 Variable Speed Drive Daughter Board P N NXDBVSD EAE cas qm qe T EE P OONAARWNH See Section 5 4 1 Option 03 x for setup details CAUTION Due to the possibility of High Frequency electrical noise BOTH ends of the shielded signal wire to the VSD must be grounded 4 20mA Output Channel 1 PZ 1 The cabling for all of these terminals must be 2 conductor core overall screened PVC insulated 24 AWG 7 0 2mm Since this cable may be run in conduit with high voltage wiring it s voltage rating must exceed the maximum voltage carried by any other cable connected to the control or run in the same conduit 4 20mA Output Channel 1 PZ 2 4 20mA Output Channel 2 PZ3 4 20mA Output Channel 2 PZ4 4 20mA Output Channel 3 PZ5 The counter inputs are for use with encoder s for speed feedback from the devices being controller by the inverter s connected to the 4 20mA output s on this daughter board 4 20mA Output Channel 3 PZ6 Counter Input 1 PZ 7 12Vdc PZ8 The analog outputs are isolated but the analog inputs are not and Counter Input 2 PZ 9 therefore special precautions must be taken when using these inputs 12Vdc PZ 10 The inputs are for 4 20mA signals must be isolated as the second input connects on top of the first to ensure cross talks w
190. m the volt free relay contact s on the daughter board please ensure its function is set correctly using the relevant option parameter INVERTER RUN STOP NXDBVSD SPEED Daughter REFERENCE Board SPEED FEEDBACK Relay Output Alternative speed feedback OPTIONAL 4 20mAOUT L 4 4 20mA IN 157 Guy During start up of the burner and before any drives move to purge the PPC6000 control moves all drives to their minimum positions by driving servo motors down and setting an output current of 4mA to each inverter drive The control waits for the inverter stop time Option 9 3 and then monitors the feedback signals of all drives and compares them to the values which were stored in memory at commission time If the values do not match those stored in memory a positioning fault is given and the control performs a non volatile lockout 7 2 Description of control method This test proves the feedback from each drive is operating correctly and that the potentiometer where fitted has not moved on the servo motor shaft If the test is successful the control moves all selected drives to their commissioned pre purge positions outputs 20MA to all inverters If the drives cannot achieve their pre purge positions as set during commissioning a positioning fault is given and the control performs a non volatile lockout If the burner start up is successful the control will control the frequency of the inverter du
191. mA The ADC counts from analogue input 8 0 to 999 for 4 to 20mA Terminal PZ13 alternates to detect any direct connection between Gives the measured frequency in Hz on this input If the input is not changing this value will be 0 for OFF open circuit and 1 for ON Gives the measured frequency in Hz on this input If the input is not changing this value will be 0 for OFF open circuit and 1 for ON 145 Description Daughter board Frequency input 3 Gives the measured frequency in Hz on this input If the input is not changing this value will PETI be 0 for OFF open circuit and 1 for ON Oxygen probe cell temperature The temperature of the zirconia cell inside the ETC oxygen probe if fitted This value should be very close to 650 C for accurate operation EK73 Ambient temperature The temperature measured by the inlet temperature sensor if fitted Units are C EK74 CPU utilisation The percentage utilisation of the CPU Should be less than 95 at all times EK75 Second C2 level 96 The measured flue oxygen level as measured by the second oxygen probe interface 96 EK76 Second probe status The same as EK45 but for the second oxygen probe EK77 Program size This is the length of the currently running user manufacturers program If a user program is selected this should match the program length given by the abacus software EK78 Second cell temp C The internal zirconia cell tempe
192. mA see note PL 5 N A future use PL 4 CANbus PL 3 CANbus PL 2 Neutral PL 1 Live AH221723 F c T CO BE Earth screw NOTE 4 20mA input from non Fireye probe See sections 30 1 and 30 2 NXO2INT 198 11 4 PPC6000 24Vac Supply 24Vac Supply CAN CAN Digital i p 1 Digital i p 2 Digital i p 3 Digital i p 4 H HIGH A AUTO Digital COM Analogue i p OVde JUMPER amp FUSE 2c supply DETAIL SHOWN ON UNIT BACKPLATE RS485 A RS485 B Ov Sensor Supply Sensor Input Ov Isol Com Isol Com Isol Gnd ooooooooooooQ eoococoococcococoocooe TOP SIDE VIEW FOR CONNECTORS Note All wiring to terminals PA amp PB are low voltage and must be braided shielded wire per table 2 6 1A Wiring to terminals PE is line voltage The maximum wire size is 16AWG 19 3mm Note PE7 amp PE8 provide purge and low fire position signals to the flame safeguard control These outputs MUST NOT have a load greater than 30mA i e relays lamp etc damage to the PPC6000 will result S This manual may be downloaded from the Fireye web site at www Fireye com Click on Bulletins or search by bulletin number NOTICE WARRANTIES When Fireye products are combined with equipment manufactured by other and or integrated into systems designed or manufactured by others the Fireye warranty as stated in its General Terms and Conditions of Sale pertains
193. mance of the system and may cause a hazardous condition to occur Ensure that a good electrical connection is made between both the unit and the burner panel then between the burner panel and ground earth Where necessary scrape any paint away from connection points and use shake proof washers to ensure a reliable electrical connection Always use the largest cross sectional area ground earth wire possible 32 0 2 6 4 Ground earth Connection display unit The display unit MUST be connected to ground earth the connection should be made at the stud with the tag showing the Ground earth symbol This connection is required to maintain the overall electrical safety of the installation and ensure the EMC performance of the equipment failure to comply with the wiring requirements will affect the performance of the system and may cause a hazardous condition to occur Ensure that a good electrical connection is made between both the unit and the burner panel then between the burner panel and ground earth Where necessary scrape any paint away from connection points and use shake proof washers to ensure a reliable electrical connection The screen of the signal cable MUST not be used to provide the electrical safety ground earth a separate connection using the largest cross sectional area ground earth wire possible MUST be made If the display unit is mounted into a burner cabinet door ensure there is a good electrical connection betwe
194. meter is not required but highly recommended Option parameter 38 0 is only available when option 30 5 oxygen input select is not set to zero and the optional oxygen probe interface unit is connected Since the oxygen alarm values relate to the oxygen setpoint values oxygen setpoint values must first be entered in adjust ratio mode Option parameter Meaning 38 0 value 0 Alarms disabled Oxygen low and high alarms are disabled 1 Alarms enabled no non volatile lockout Oxygen low and high alarms are enabled and option parameters 38 1 to 41 4 will become available If an alarm value is exceeded a fault number will appear but no non volatile lockout will occur Alarms enabled with non volatile lockout Oxygen low and high alarms are enabled and option parameters 38 1 to 41 4 will become available If an alarm value is exceeded a fault number will appear and a non volatile lockout will occur 02 Options 38 1 to 38 4 Oxygen low alarm values at low fire 0 0 99 9 LV3 02 m Options 39 1 to 39 4 Oxygen low alarm values at high fire 0 0 99 996 LV3 02 Options 40 1 to 40 4 Oxygen high alarm values at low fire 0 0 99 9 LV3 2 Options 41 1 to 41 4 Oxygen high alarm values at high fire 0 0 99 9 LV3 Using option parameters 38 1 to 41 4 it is possible to set different oxygen alarm values at high fire and low fire for each profile At firing
195. municate to the YB110 via Modbus With the burner off enter full commissioning mode see section 5 3 1 1 by pressing Menu Burner Setting enter suppliers passcode LV3 then Menu Screen Configuration Display Press the Modbus Configuration button The default is Integrated NX6100 Next set the Modbus Node id to match the YB110 for example 1 See Fireye bulletin BL 1001 for details as to configuring the Modbus in the BurnerLogix At this point you will set the current Modbus configuration to PPC BurnerLogix When the dialog box appears press 39 C Change Next press the RS485 Comms button and select the baud rate that matches the BurnerLogix YB110 The default is 9600 N 1 The currently displayed message from the YB110 display should now appear in the lower right section of the TSD Any status or lockout messages for the YB110 will be displayed here also The fault numbers assigned to YB110 lockouts is the Modbus message number found in BL 1001 plus 200 For example if the YB110 locked out during PTFI the message on the TSD104 would be F207 LOCKOUT FLAME FAILURE PTFI That is Modbus message number 7 200 F207 See Section 6 8 for a list of TSD Fault messages Caution Do NOT mechanically connect the servomotor to the driven shaft until the servo motor direction has been established and set See section 3 2 for details 2 6 15 Oxygen Probe Interface Connection PPC6000 The Oxygen Probe Interface is not powered from the PPC60
196. n Interface Oxygen Cell mV 0 100mVac PM3 Oxygen Interface Oxygen Cell mV 0 100mVac PM4 Oxygen Interface Oxygen Cell Temperature 0 100mVdc PM5 Oxygen Interface Oxygen Cell Temperature 0 100mVdc PM6 Oxygen Interface Flue Temperature 0 100mVdc PM7 Oxygen Interface Flue Temperature 0 100mVdc PM8 Oxygen Interface Heater Output 0 40Vac PM9 Oxygen Interface Heater output 0 40Vac NX610 Display Relays General Purpose Shown For Alarm see Section 5 5 1 Option 17 x Table A PR1 Display Unit Relay output 1 normally open 0 250V PR2 Display Unit Relay output 1 normally closed 0 250V PR3 Display Unit Relay output 1 common 0 250V PR4 Display Unit NO CONNECTION N A PR5 Display Unit Relay output 2 normally open 0 250V PR6 Display Unit Relay output 2 normally closed 0 250V PR7 Display Unit Relay outputs 2 amp 3 common 0 250V PR8 Display Unit Relay output 3 normally closed 0 250V PR9 Display Unit Relay output 3 normally open 0 250V NXTSD104 Touchscreen Display Relays General Purpose Shown For Alarm see Section 5 5 1 Option 17 x Table C PR1 Display Unit Relay output 1 common 0 250V PR2 Display Unit Relay output 1 normally closed 0 250V PR3 Display Unit Relay output 1 normally open 0 250V PRA Display Unit Relay output 2 common 0 250V PR5 Display Unit Relay output 2 normally closed 0 250V PR6 Display Unit Relay output 2 normally open 0 250V 34
197. nce to status 7 The HIGH input PA9 to PA11 still must be made during this time If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 Not Applicable to PPC6000 Note Status 6 is reserved for air pressure detection and is not implemented in this control This function must be provided by the burner controller The selected motors are moved up towards the purge position When the drives have all stopped the control moves to status 8 If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 The controller confirms all required drives are at their purge positions and gives a purge proved signal by providing line voltage to terminal PE8 high fire switch The control will remain in this status until the burner controller signals the end of pre purge by breaking PA11 HIGH input If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 The selected motors are moved to their ignition positions The purge proved signal is switched off When the drives have all stopped moving the control advances to status 10 If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 185 Stage no 11 14 Stage name Ignition N A Moving to low fire Description The controller co
198. nfirms all required drives are at their ignition positions and gives an ignition proved signal by supplying line voltage to terminal PE7 low fire switch The controller will hold the drives at their respective ignition positions until the signal to modulate is received from the burner controller This is performed by closing the circuit on PA10 PA11 AUTO input If the fuel profile select input is removed PE9 10 11 or 12 the control will immediately move to status 1 NOTE Statuses 11 to 14 control the light up sequence of the burner and are provided by the burner controller device used for the application This control will jump from status 10 to status 15 when the light up is completed Not Applicable to PPC6000 Once the AUTO signal is received the fuel and air motors are moved from their ignition positions to their low fire positions These positions may or may not be the same as the ignition positions The ignition prove terminal PE7 low fire switch is switched off If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 Once the drives have reached their low fire positions and an AUTO signal is received PA10 PA11 the control will advance to status 16 IF Option 23 0 warming limit is enabled drive will remain at low fire until time set by Option 23 0 expires NOTE terminal PE7 will always be OFF during status 15 186 Stage Sta
199. ng the sensor during normal operation Maintenance procedures should ensure that the sensor is inspected for evidence of condensates from the process collecting at the sensing point If evidence of condensate is found then preventative action must be taken to eliminate the cause The ambient operating temperature range is 0 to 70 C The unit MUST be earthed to maintain electrical safety and ensure process Connection reliable operation 1 4 The conduit connection for steam pressure sensors is PG9 an adaptor for 72 NPSL is available Fireye 72 Conduit Adaptor P N35 37 1 25 WLR rr gt 2 5 Option link selection PPC6000 2 5 1 General Access to jumper s and fuse s is gained by removing the back cover of the PPC6000 UNDER SIDE VIEW OF JUMPERS AND FUSES Wickmann Littlefuse 1 PN 3701100043 1 AMP Fast Acting to protect 5V DC circuit Alternate Source Mouser Electronics PN 576 371100000 230VacLk2 amp 4 115Vac Lk1 amp 3 Bussmann S504 series P N GMD 630 Time Delay for 115V P N GMD 315 Time Delay for 230V to protect 24V circuit Alternate Source Mouser Electronics PN 504 GMD 630mA PN 504 GMD 315mA The PPC6000 has a number of option selection links located on the circuit board The function and settings are marked on the board alongside each link These links must be set to the correct position before power is applied to the control On some versions of the control addi
200. notonic Number of air non fuel motors Not Limited by profile e g 2 or 3 fuel motors All non monotonic NOTE Number of servomotors is limited in all profiles by VA rating See Section 3 1 11 Interface to PPC6000 Speed Microswitches Torque Voltage VA rating Protection Category Typical accuracy Accuracy as specified by EN12067 1 3 Digital outputs PPC6000 Controlled Shutdown Safety Shutdown Type Minimum current Maximum current per output Maximum voltage 1 4 Alarm output PPC6000 Alarm Type Minimum current Maximum current per output Maximum voltage CANbus 30 seconds for 90 degrees Open amp close positions Driving Holding NXC04 4Nm 3 ft lb 2Nm NXC12 12Nm 9 ft lb 18Nm NXC20 NXC40 20Nm 14 7 ft lb 18Nm 40Nm 29 ft lb 20Nm 24 30Vac supplied from control only 4 3VA NXC12 5VA NXC20 10VA NXC40 18VA NXC04 IP40 NEMA 1 NXC12 NXC20 IP54 NEMA 3S NXC40 IP65 NEMA 4 0 1 0 5 12 On off relay de energize for off 200mA rms 8A rms 250Vac rms On off relay de energize for off 200mA rms 4A rms 250Vac rms 1 5 Digital inputs PPC6000 Low Voltage digital inputs 1 to 4 HIGH Digital Switching OV to 5V pulsed Feed must be taken from input AUTO input the correct terminal as indicted in this manual Inputs 1 4 configurable for 4 20Ma Via function block programming
201. now open and show the two parameters to be entered If you are unsure about a parameter look in the documentation Bulletin NXAB 1001 for a complete description of the function Another useful feature is the tip text If you move the mouse pointer over the edit field but do not click it a tip will appear This will give the allowable range for the parameter if applicable The first parameter here is called Comment This is text used to describe a function purely for documentation purposes If you wish you may leave comment blank but for illustration enter some text such as Pump 1 Fault in this example The second parameter here is the actual digital input number to use This is how the system knows which terminals to read the input voltage from Enter a number 1 for the input number parameter Pressing will transfer these new parameters to the block and close the parameters window Pressing Cancel will discard the parameters you ve just entered Pressing Apply will transfer the new parameters to the block and leave the parameters window open This is useful when entering reviewing the parameters for several blocks Click Apply While leaving the parameters window open click on the other digital input block You may need to move the parameters window if it is covering this block In this example the block is partially covered 191 E gt The parameters window automatically updates itself with parameters
202. ns to their low fire positions These positions may or may not be the same as the ignition positions The ignition prove terminal PE7 low fire switch is switched off If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 Once the drives have reached their low fire positions and an AUTO signal is received PA10 PA11 the control will advance to status 16 IF Option 23 0 warming limit is enabled drive will remain at low fire until time set by Option 23 0 expires NOTE terminal PE7 will always be OFF during status 15 Once the fuel and air motors reach their low fire positions they are modulated according to the demand placed on the burner In this burner status the high fire switch and low fire switch outputs PE8 amp PE7 will come on at high and low fire respectively and may be used for indication purposes If a HIGH input is provided by closing PA9 PA11 this control will move to status 17 If the AUTO input is removed by opening PA10 PA11 this control will modulate down to low fire then jump to status 15 Note Terminal PE7 will not be energized in this case This may be used to provide a low fire post purge or a low fire hold function If the fuel profile select input is removed PE9 10 11 or 12 the control will immediately move to status 1 If this control wishes to turn the burner off there is no call for heat for examp
203. o be made Scrolling the list in an upward direction will scroll through all oxygen probe interface options available until 0 nothing is displayed Enter this value to disconnect the specified device from any hardware Scrolling the list in a downward direction will stop when the currently selected item is displayed and the value will stop flashing The display will show type information for each device present such as O2 probe but the commissioning engineer should be aware of which serial number device is being used for which function 02 m Option 30 1 Oxygen probe calibration offset value 0 999 LV3 This option parameter is only available if option 30 0 is non zero This option parameter must be set to the calibration offset value that is specified with the Fireye probe supplied When using another manufacturer s O2 probe with a 4 20mA signal for O2 value enter the O2 value for 4 0mA in this option parameter Example 0 O2 000 109 02 m3 Option 30 2 Oxygen probe calibration gain value 0 999 LV3 This option parameter is only available if option 30 0 is non zero This option parameter must be set to the calibration gain value that is specified with the Fireye probe supplied When using another manufacturer s O2 probe with 4 20mA signal for the O2 value enter the O2 value for 20 0mA in this option parameter Example 2196 O2 210 NOTE If the value of 30 1 and 30 2
204. o maintain electrical safety and ensure reliable operation 5 51 140 mm 4 04 102 85 mm 8 mm 5 51 140 mm 4 91 124 Enclosure is 2 8 71mm deep Power CANbus and Probe cable entry 21 2 4 The oxygen trim option CAUTION Use extreme care when handling the oxygen probe and wear heatproof gloves Ensure the burner is off before removing the oxygen probe from the flue If the boiler is to be operated with the probe removed fit the blanking cover supplied since dangerous levels of carbon monoxide may be present in the flue 2 4 44 Oxygen Probe description The oxygen trim monitoring function is designed to be used with either an NXO2PK4 NXO2PK6 or NXO2PK8 oxygen probe The probe offers fast accurate response and good reliability when mounted in accordance with the guidelines in this section The probe is available in three different sizes 2 4 2 Installation of oxygen probe Model Dimension no A B c D 2 173 6 81 215 8 5 295 11 6 470 18 5 NXO2PKG6 362 14 25 406 15 99 486 19 13 659 25 95 NXO2PK8 716 28 19 757 29 8 873 32 95 1013 39 88 CLEARANCE REQUIRED TO INSTALL SEE DIM B LAU amp REMOVE FROM FLUE SEE DIM C DA P4 246 9 7 2 TYP 0 08 20 FLEXIBLE ca 96 3 8
205. o the flame safeguard control These outputs MUST NOT have a load greater than 30mA i e relays lamp etc damage to the PPC6000 will result 172 Typical Wiring Diagram E110 IMPORTANT Low Voltage vertical terminal strips All low voltage circuits and communication wire must be fully shielded braided type wire of the specified gauge and number of conductors Table 2 6 1 A provides the only approved wire for this application No or equal is provided Use of wire not approved by Fireye may VOID warranty All wiring to terminal block PA amp PB as well as to any optional daughter board e g VSD and the Power CANbus wiring to the display must be fully shielded braided wire per Table 2 6 1 A Under no circumstances should these input outputs be connected to mains PPC6000 TA 24 vac Sup vac Sup CANoUs Q CANbus Q D A Input 1 O D A Input C D A Input 3 D A Input 4 Q High Purge Auto Common Analog 1 O 0 vic O OOOO DOOO or destroy the unit CABLE CLAMP PROFILE SELECT PURGE POSITION PROVE Flame Monitor 606099 GO IGNITION POSITION L F S PROVE NON RECYCLE LIMITS SWITCH OO RECYCLE LIMITS BURNER 9 ALARM 8A FUSE Refer to bulletin E 1101 for remaining Flame Monitor 1 0 connections A complete schematic can be found at http
206. ode 141 Description No EK27 Commission setpoint The current setpoint being commissioned 0 Closed setpoint 1 Purge setpoint 2 Ignition setpoint 3 Low fire setpoint 4 24 profile setpoints EK28 Commission Setpoints entered The number of setpoints that have been successfully entered during this commission ratio session EK29 Modulation rate The current modulation rate of the burner 0 Low Fire 100 High fire EK30 Burner Status Status of the start up sequence See section 4 2 EK31 Fuel Profile Selected The currently selected fuel profile EK32 Number of commission setpoints The number of setpoints entered for the current selected profile 0 No setpoints entered 1 Close setpoint only 2 Close and purge setpoints 3 Close purge and ignition 4 24 profile setpoints EK33 Modulation mode 0 Auto mode 1 Manual from keyboard TSD 2 Low fire hold from keyboard TSD 4 Local 1 8 Local 2 12 OFF from Display Ex 10 would be local 2 LFH 4 would be local1 auto mode EK36 Nearest setpoint The number of the profile setpoint which is nearest to the current modulation position Voltage reference error V The error between the measured voltage reference and the calibrated value has been exceeded for 3 seconds Typically this value will be 0 05v and F19 will occur if it is 0 12v If the value is high ensure none of the low voltage inputs are above 5 volts EK38
207. ogram May be used by a custom program EK159 Banking water temperature water temperature measured in or EK160 to Not used by the standard EK199 manufacturers program May be used by a custom program EK200 Prog Currently running manufacturers custom user modulation program name and revision number if applicable EK101 200 are controlled by the loaded modulation program The values given below are for the latest version 40 production version but user programs may change add to these 149 6 7 Troubleshooting 6 7 1 Display General Problem RN Possible cause Display shows it s serial Display CAN bus wired number but not data incorrectly from control unit PPC6000 not running Display will not light at 24VAC supply to display all missing PPC6000 not running Measured value incorrect Wrong sensor voltage Incorrect sensor wiring Wrong zero or span Wrong sensor input type Suggested action Check wiring of CAN bus PT3 and PT4 Check PPC6000 low voltage electronics fuse FS2 If blown investigate all low voltage external wiring and replace fuse if necessary with a new one of the correct type and rating Check for 24VAC on PT1 and PT2 Check fuse FS1 If blown investigate all high and low voltage external wiring and replace fuse if necessary with a new one of the correct type and rating Check SENS SUPP link see 2 5 3 Check SENS IN link see 2 5 3 Check wiring to te
208. ol is in auto mode the PID control loop will modulate the boiler to maintain the measured value at the same level as set by this parameter LE option 21 2 Set point 1 proportional band 0 999 00 0 99 9 0 00 9 99 LV1 This is the width of the proportional modulation band that is used by the PID control loop for setpoint 1 For example if the setpoint was 100 psi and this term was set to 10 psi then the proportional band would be from 90 psi to 100 psi A measured value of 90 psi would give high fire and 100 psi would give low fire assuming no integral or derivative terms were entered A value of 0 means no proportional band the burner would stay at low fire until the high limit Cut Out is reached then turn off Proportional control is therefore needed to allow the burner to modulate Option 21 3 Set point 1 integral time 0 999 seconds LV1 This is the integral time used in the PID control loop for setpoint 1 It may be set to any value from 0 to 999 seconds If a value of 0 is entered the integral function is disabled otherwise the time entered is the number of seconds the control will take to give an additional modulation change equal to that currently given by the proportional term The lower the number apart from zero the more affect the integral function has A large number will cause the integral term to act very slowly Integral control is required for the burner to accurately reach its setpoint 97
209. om 0 00 to 9 99 84 LE option 15 2 Modulation input zero value 999 to 999 99 9 to 99 9 9 99 to 9 99 LV3 This value will normally be left at zero It is the measured value to be displayed when the sensor connected is at its minimum value If a 4 20mA sensor is used this parameter should be set to the 4mA value usually zero NOTE This option has been modified to allow for vacuum systems available after June 2011 l Eao ion 15 3 Modulation input span value 999 to 999 99 9 to 99 9 9 99 to 9 99 LV3 This value is the measured value to be displayed when the sensor connected is at its maximum value If a 4 20mA sensor is used this parameter should be set to the 20mA value NOTE This option has been modified to allow for vacuum systems available after June 2011 EET option 15 4 Setpoint display units 0 3 LV3 This option selects the displayed units for setpoint and measured value Option parameter Meaning 15 4 value 0 Show measured value as PSI Show measured value as bar option 15 5 Boiler high safety limit 0 999 0 0 99 9 0 00 9 99 LV3 If a 4 20mA sensor is used and this parameter is set to a value other than zero PPC6000 will lockout when the value is exceeded Note When a 4 20mA sensor is used external limits must be in place to protect the boiler in case of sensor failure Zero disables this parameter Option 15 6 Modulation Tim
210. on EK153 and 154 If the control limits are holding the burner off EK18 will be zero EK104 User modulation mode This will normally be zero A custom modulation program may change this value if it is modifying the modulation rate EK105 PID not required If this value is 1 the internal modulation PID is not running This may be because the burner is off in commission manual mode or for another reason valves open or it is in post purge EK107 Warming Limit Active If this value is 1 the warming limit function see option parameter 23 0 is holding the burner at low fire status 15 EK108 Tracking Active If this value is 1 the remote tracking function is active See option parameter 20 7 The AUTO modulation rate will come from analog input 5 EK109 Remote Setpoint 1 Active If this value is 1 the remote setpoint 1 function is active See option parameter 20 7 The value of Setpoint 1 will come from analog input 5 EK111 to Not used by the standard EK114 manufacturers program May be used by a custom program EK116 to Not used by the standard EK132 manufacturers program May be used by a custom program EK133 SP2 selected remotely If this value 1 the second PID modulation setpoint SP2 has been selected remotely via serial communications including sequencing and Modbus EK134 Boiler sequencing communications If this value 1 the control is receiving good setpoint selection requests via serial communicat
211. on 09 7 Reserved 82 Option 09 8 Reserved 82 Option 14 1 Limit Relay 0 8 LV3 83 Option 14 2 Oxygen and Flue Temperature Limit Relay 0 8 LV3 83 Option 15 0 Modulation sensor input type 0 3 LV3 84 Option 15 1 Modulation input decimal places 0 to 2 84 Option 15 2 Modulation input zero value 999 to 999 99 9 to 99 9 9 99 to 9 99 LV3 85 Option 15 3 Modulation input span value 999 to 999 99 9 to 99 9 9 99 to 9 99 LV3 85 Option 15 4 Setpoint display units 0 3 LV3 85 Option 15 5 Boiler high safety limit 0 999 0 0 99 9 0 00 9 99 LV3 85 Option 15 6 Modulation Time 0 120 seconds LV3 85 Option 15 7 Bumpless Transfer 0 or 1 LV3 86 Option 15 8 Low before Off 0 or 1 LV3 86 Option 15 9 reserved 86 Option 16 2 Allow profile swap 0 to 16 LV3 87 Option 18 1 to 18 4 Low Voltage Fail safe Alarm Lockout Inputs 0 460 LV3 91 6 Option 19 1 to 19 4 Fail safe Alarm Lockout Display Messages LV3 93 Option 20 0 Set point Select input 0 35 LV3 94 Option 20 1 Boiler Shutdown input 0 35 LV3 95 Option 20 2 Low Fire Hold input 0 35 LV3 95 Option 20 3 Oxygen Trim Disable input 0 35 LV3 95 Option 20 4 Ignition Wait input 0 35 LV3 96 Option 20 5 Purge Hold input 0 35 LV3 96 Option 20 6 Purge Time Start input 0 35 LV3 96 Option 20 7 Analog Input 5 function 0 2 LV3 96 Opt
212. on 20 1 boiler shut down is wired to input 2 low voltage PA6 PA11 and programmed as 20 1 2 the boiler would stay off as long as the switch is closed In this case if the wire fell off the boiler would START gt reverse this function option 20 1 would be set as 20 1 22 This would require the switch be closed to start the boiler In this case if the wire fell off the boiler would SHUT DOWN The table below indicates the value for each of these inputs to affect the desired condition Please consider the broken wire condition when programming these options 94 Option Table 20 0 A Digital Input Numbers Digital input used Digital Input Numbers Input CLOSED Input OPEN Powered ON 0 None Input disabled Input 1 PAS to PA11 LOW VOLTAGE 21 supplied from PA11 ONLY ira d supplied from PA11 ONLY su pplied from PA11 ONLY supplied from PA11 ONLY Option 20 1 Boiler Shutdown input 0 35 LV3 1 4 A high level on the input specified here will cause the boiler to go off and stay off until it is removed No fault alarm is generated 16 or 20 Will cause the burner to SHUT OFF permanently Should NOT be used 21 24 low level on the input specified here will cause the boiler to go off and stay off until it is switched high ON No fault alarm is generated The input numbers are as specified in Option Table 20 0 A above This is useful when integra
213. on to a PC or non Fireye equipment the optional isolated RS485 daughter board should be installed The RS485 cabling MUST be overall braided shielded screened 3 core PVC insulated 24 AWG 7 0 2mm Since this cable may be run adjacent to and or in the same conduit as high voltage wiring its voltage rating must exceed the maximum voltage carried by any other cable connected to the control or run in the same conduit Terminate the screen at each control using the cable clamps provided Incorrect connection or application of excess voltage may damage or destroy the units being connected Sequencing RS485 COMMS BUS TO PC COMFIRE 41 Cay Building Automation RS485 COMMS BUS ISOLATE TO BAS VIA MODBUS See Bulletin MOD 6101 PB11 PB12 PB13 PB11 PB12 PB11 PB12 NOTE Due to differences in communications hardware it may be necessary to reverse the A and B wires Eg For details on connecting PPC6000 series controls to a PC on the communications bus refer to the manual NX 1502 Comfire2 combustion analysis tool RS485 B PB 6 RS 485 GND PB 7 RS 485 ISOL A PB 11 RS485 ISOL B PB 12 NOTE Isolated RS485 PB11 thru PB13 for use with Modbus BAS RS485 ISOL GND PB 13 integration Requires optional Daughter Board See MOD 6101 for details NOTE Interposing terminal blocks should be avoided when shielded cable is required Interposing terminals present a risk of electrical noise
214. onding modulation position Once the profile has been reset this option parameter will automatically be reset to 0 Option 30 9 Automatic trim commissioning 0 1 LV3 111 Sy The unit is able to automate the manual calculation procedures option parameter 34 5 automatically calculating and entering flow values oxygen trim setpoints and boiler transport delay The automatic commissioning procedure will only work if the following conditions are met Option parameter 30 9 automatic trim commissioning is set to 1 An oxygen probe is fitted and fully operational The unit is in adjust ratio with the burner firing a single fuel only A hydrocarbon ratio has been entered for the current fuel see option parameters 35 1 35 4 The auto commissioning procedure will usually take between 10 and 30 minutes depending on number of setpoints and is performed by the unit as follows Beginning with high fire the unit moves the drives to each point in the firing range The display will show O2 When the measured oxygen reading settles the unit stores the measured oxygen reading as the new oxygen setpoint The drives are moved to the next position directly below high fire Ph 1 and wait for the oxygen to stabilize The unit moves the air drives up to the point above the current setpoint leaving the fuel drive in the same position The display will show Flow calc An 1 When the new oxygen reading settles the unit calculate
215. onnect to another a terminal is provided to allow the screens to be connected by forming a tail with the braided screen of each cable the length of unscreened cable should be kept as short as possible but in any case MUST not exceed 1 6 30mm per cable tail Connect all signal cable braid screens to ground earth using the screen termination clamps provided on the control Connect all cable screens to ground earth at the control only with the exception of the cables that connect the temperature and pressure sensors where fitted Where the wiring is run through one unit to connect to another terminals are provided to ensure the screen connection is maintained 1 The cable should be prepared by cutting around the outer insulation taking care not to damage the screen 1 o 2 Pull the insulation apart to expose 3 8 in 10 mm of the screen 2 e 3 8in 10mm Slide the exposed braid screen down between the vertical cable clamps on the PPC6000 The conductive 3 cushion provides grounding earthing 2 6 3 GROUND EARTH connection The PPC6000 MUST be connected to ground earth the connection should be made at the stud with the tag showing the Ground earth symbol This connection is required to maintain the overall electrical safety of the installation and ensure the EMC performance of the equipment failure to comply with the wiring requirements will affect the perfor
216. ons on the display To do this follow the procedure below 1 Ensure that the correct servo motor direction is set before connecting the servo motor to the relevant valve If the servo motor direction is incorrect use the relevant option parameter to reverse Move the valve to its fully closed position and adjust the servo motor position by driving the motor so that approximately 1 is shown on the display Move the valve to its fully open position by driving the servo motor and check that the display reads approximately 90 or the maximum angular opening required from the servo motor if this is less than 90 3 5 Adjusting microswitch positions Each time a burner start up sequence is initiated the control will move the fuel and air damper motors to their respective closed positions to prove correct motor and potentiometer operation Each motor has microswitches fitted to set the close position obtainable during this proving operation and limit the maximum open position to prevent burner boiler damage in the event of a system failure To set the microswitch positions follow the procedure below 1 2 Enter commission ratio mode see section 5 Move each motor to approximately 45 using the UP DOWN keys this is to ensure the DOWN key will drive the motor 3 Holding the DOWN key tighten up the low limit microswitch until the motor will no longer move down 4 Holding the DOWN key gradually slacken off the low lim
217. ontrol will position the fuel and air motors within the programmed profile appropriate to the requirement for heat The control has 2 modes of operation using the standard Fireye PID modulation function Remote and Local The mode of operation is set via the keypad by pushing the Burner ON OFF key and selecting the mode Using the programmable block function option within the control it is possible for the modulation control to be generated with alternate options these are not covered in the standard manual as they may be generated by the user For an overview of Function Block Programming see Section 10 4 4 4 Normal Remote mode In Remote mode the modulation rate is determined by the internal PID control settings Manual modulation from the keypad or by one of the following remote influences e Auxiliary modulation input e Serial communications 4 4 2 Local mode LOC 1 LOC 2 In Local mode the modulation rate is determined by either the internal PID settings or Manual modulation via the UP DOWN keys External modulation inputs and setpoint selection inputs are ignored When Local1 is displayed the burner is running using the Setpoint 1 PID settings When Local2 is displayed the burner is running using the Setpoint 2 PID settings 59 Sy 5 Commissioning the control WARNING This manual may cover more than one model from the PPC6000 series Check for additional information at the end of this chapter W
218. oportional integral and derivative Proportional Typical older modulating systems employ only proportional control This would be similar to the slide wire type found on most steam boilers When using only a proportional control the system rarely achieves setpoint as the burner firing rate is lowered as the pressure comes up At some point the input meets the actual demand and the pressure no longer raises or lowers thus an offset between desired setpoint and actual operating pressure occurs The only time the pressure and setpoint are the same is if the actual load equals the lowest firing rate of the burner this is rare An example of proportional only set up might be Setpoint is 100 PSI proportional range is 10 PSI That is low fire is at 100 PSI high fire is at 90 PSI with a 1 1 relationship in between e g 95PSI equals 50 rate A good starting point for the P value in most cases is about 10 of setpoint Integral If the integral term is turned on the control compares the actual pressure against setpoint at an adjustable interval If there is an offset the firing rate is increased by a small percentage until the next interval This will continue until the pressure equals the setpoint The same routine occurs as the pressure rises above the setpoint Too much or too little integral will cause over and undershoot of the setpoint Integral is set in seconds per repeat in the PPC6000 For example if the P were set at 10 psi with a
219. option links for the correct voltage and input type SENSOR IN PB 9 SENSOR GND PB10 Incorrect connection may damage or destroy NOTE Do NOT use the Black wire of the PXMS the units being connected Sensor 40 WARNING Do not wire the Sensor live with power on With JPI in the IN position a 220 ohm resistor is put across terminals PB9 and PB10 Shorting or miss wiring these terminals may damage this resistor Should the resistor become open an external 220 ohm 1 72 watt resistor may be installed across terminals PB9 and PB10 2 6 17 Remote Setpoint Analog Input 5 PPC6000 The auxiliary modulation input cabling must be overall screened PVC insulated minimum 24 AWG 7 0 2mm number of cores as required by the relevant sensor Since this cable may be run in conduit with high voltage wiring it s voltage rating must exceed the maximum voltage carried by any other cable connected to the control or run in the same conduit Ensure link JP2 is set to the IN position if the input is being connected to a device with a 4 20mA output AUX MOD IN PA 12 AUX MOD GND PA 13 Incorrect connection may damage or destroy the units being connected CABLE CLAMP 2 6 18 RS485 interface PPC6000 The RS485 interface included in the basic control is intended to be used for interconnection of several Fireye units or connection of a lap top computer during commissioning if it is intended to make a permanent connecti
220. option parameter allows the engineer to overcome this limitation in one of two ways First the modulation range of the burner can be limited so that the burner may only modulate between points P one set point above low fire and P one set point below high fire Since oxygen trim is not affected by this limitation each drive may be trimmed between the points and Ph This means that it is not possible to over fire or under fire the burner but a degree of trim may still be achieved at high and low fire Note that this option may reduce the turn down of the boiler Option parameter Meaning 31 0 value Modulation not limited Burner modulates from to Pp Oxygen trim works over full range from to Ph but may not be able to apply trim at high fire or low fire depending on trim direction The burner always modulates to the desired modulation rate which may limit the system s ability to maintain the desired oxygen value Normal modulation range limited to to Ph 4 always Oxygen trim works over full range from to Ph and can apply extra trim at low and high fire limited by and Py This setting is useful when there is extra capacity usually air flow available for the burner but otherwise it will reduce the turn down ratio of the boiler 2 Options 31 1 to 31 4 Trim Type for profiles 1 to 4 0 to 2 LV3 113 These option parameters determine which drive will be trimmed Air or Fuel
221. ors 24 2 4 5 Boiler temperature sensors 24 2 4 6 Steam pressure sensors 25 2 5 Option link selection PPC6000 26 2 5 1 General Access to jumper s and fuse s is gained by removing the back cover of the PPC6000 26 2 5 2 Line supply voltage LK1 4 PPC6000 26 2 5 3 SENS IN and SENS SUPP boiler temp pressure sensor PPC6000 27 2 5 4 REMOTE SETPOINT PPC6000 27 2 5 5 5485 communications termination resistor PPC6000 27 2 5 6 R8485 serial communications termination resistor daughter board 27 IN 27 IN 27 IN 27 IN 27 2 6 Wiring 29 2 6 1 General 29 2 6 2 Grounding cable screens 32 2 6 8 GROUND EARTH connection 32 2 64 Ground earth Connection display unit 33 2 6 5 Terminal Designation 33 2 6 8 LINE and NEUTRAL supply PPC6000 amp PE2 35 2 6 7 Safety Shutdown output PPC6000 36 2 6 8 Controlled Shutdown Relay Output PPC6000 36 2 6 9 X Alarm Relay output RELAY 4 on the PPC6000 36 2 6 10 Auxiliary Relay Outputs display 37 2 6 11 Fuel Select Profile Select Input Purge and Ignition Prove Outputs PPC6000 37 2 6 12 Low Voltage Digital Inputs PPC6000 relevant Engineer s Keys EK1 EK4 Sec 6 6 2 38 2 6 13 Servo motor and Display Connection PPC6000 38 2 6 14 Display Connection with PPC6000 and BurnerLogix YB110 39 2 6 15 Oxygen Probe Interface Connection PPC6000 40 2 6 16 Pressure temperature sensor input PPC6000 40 2 6 17 Remote Setpoint Analog Input 5 PPC6000 41 2 6 18 RS485 int
222. other equipment it is important to ensure the same parameters are being used by both units 1 Ensure the efficiency is selected to be either net or gross in both units hand held equipment usually uses net since it is rare for hand held equipment to have knowledge of the boiler firing rate to include the radiated heat loss Ensure the same calorific value is being used by both units Ensure the same value for hydro carbon ratio is being used by both units Ensure the ambient inlet temperature being measured by the hand held is physically at the air intake to the burner as it should be for the PPC6000 If the hand held equipment does not measure the inlet temperature ensure the value it is using for ambient air temperature is representative of the application 5 Ensure the flue temperature and oxygen value are being measured at the same location in the flue to reduce the possibility of errors being introduced due to stratification of the flue gas 6 Fireye O2 probes measure oxygen in the flue without extracting and drying flue gases If attempting to compare the oxygen values being measured by the PPC6000 and a hand held equipment ensure the value being given by the hand held is corrected from a dry to a wet value as it will almost certainly be measured as a dry value The water being removed to prevent damage to the sensor cells in the hand held equipment SOR 170 my When comparing the values of efficiency displayed by the
223. ouchscreen being seen as a button press The function can be accessed by selecting the Menu button at the base of the touchscreen and then selecting Clean Screen from the list of functions available 17 05 50 2008 05 21 R X MAN Unito gt R Burner Settings Trends Items Timebase Fault Event Log Screen Configuration 0 Trends About Cleanscreendisables screencontrolfor 20 seconds Are you sure youwant to continue Cleanscreen Modulating eJ E aJ amp Reset Stop Fuel Control Menu Overview 71 D r When cleaning the touchscreen ensure the correct LCD screen cleaner is used Use of any other cleaning fluid or water may damage the screen There are designated commercial cleaning solutions on the market for touchscreens only Also these products are recommended to be used only with a very soft cloth Please note the directions and the warnings on the product CAUTION e Do NOT use any ammonia based window cleaner These chemical cleaners can ruin the touchscreen surface e Do NOT use any abrasive rags towels or paper towels An abrasive towel can scratch the touchscreen 5 4 14 Touchscreen Commission mode To allow Option Parameters or Drives to be adjusted it is necessary to enter the relevant access passcode To enter the passcode press MENU then BURNER SETTING then the COM button This will prompt the keypad pane to
224. p to be stable this parameter must be set accurately to the transport delay of the boiler when at low fire This option may be set between 5 and 60 seconds inclusive e To measure the transport delay ignite the burner and enter adjust ratio mode Select the low fire setpoint and allow time for the flue oxygen reading to settle Once the oxygen reading is steady make a step change to the fuel air ratio and start a timer As soon as the measured oxygen reading begins to change stop the timer Set the option parameter to the recorded timer value in seconds e Automatic trim commissioning option 30 9 will attempt to set this automatically However the value must be checked by the engineer Option 30 8 Reset oxygen trim profile 0 1 LV3 During full automatic operation the O2 trim system will learn and store the percentage of trim applied to various firing rates This provides a feed forward aspect to O2 trim If any changes to target O2 values are made after the system has been in operation the trim profile must be reset so as to not apply previous trim feed forward A new trim profile will be learned as the burner modulates Only the trim profile is affected The Oxygen setpoints and flow values are not changed This option parameter allows the learned trim profile to be reset If the option is set to 1 any learned profile currently held in memory will be reset and the trim drives will return to their commissioned positions for the corresp
225. positions other than high and low fire the alarm limit is interpolated between the two points For example if the oxygen limit has been entered as 5 of setpoint at low fire and 10 of setpoint at high fire the limit at mid fire will be 7 5 120 Gary The alarm limits may set to any value between 0 0 and 99 9 where the value entered relates to a percentage deviation from each oxygen setpoint in the firing range If the burner is firing it is only possible to make an adjustment to the option parameters that relate to the selected profile If the burner is not firing the alarm values for any profile selection may be adjusted An oxygen low alarm will be caused by one or more of the following events e level drops below 0 5 O2 for 30 seconds e level drops below the low alarm limit for 2 minutes e level drops below twice the low alarm limit for 30 seconds An oxygen high alarm will be caused by one or more of the following events e level rises above the high alarm limit for 2 minutes e level rises above twice the high alarm limit for 30 seconds When 2 probes the low alarm will also be caused by the following event e difference between the oxygen values exceeds the value set in option parameter 42 4 for 2 minutes Option 42 0 Second Oxygen probe interface serial number LV3 Each CANbus device connected to the system has a unique serial number allocated to it during production testing This n
226. r Option 44 7 Option 44 6 Set Minutes 0 59 LV1 See SET CLOCK Example after Option 44 7 Option 44 7 Set Seconds 0 59 LV1 See SET CLOCK Example after Option 44 7 SET CLOCK EXAMPLE To Set 6 30 45 PM Tuesday December 25 2007 The Values should be entered as follows 44 17 7 44 2 12 Day of Month Day of Week Hours 1246 Minutes Seconds Option 44 9 Reset Fault Log 0 1 LV3 This option clears the current the fault history Set the option parameter to 1 then press RUN than ENTER The control will erase the fault history and return to run mode Option 45 0 Erase Restore enable 0 1 LV3 124 CAUTION e If this value is displayed as a 2 the option parameter data has been up loaded into the control ensure all option parameters are set to match the requirements of the burner to which it is connected Failure to do so could cause a hazardous condition to occur After all option parameters have been checked to match the requirements of the burner to which it is connected reset this option parameter to zero to allow the system to operate If an attempt is made to operate the system with this option parameter set to 2 a fault will be generated and the control will perform a non volatile lockout preventing the burner from firing In order to erase information in memory for a specific profile selection see option parameter 45 1 this option must be set
227. r closed loop oxygen trim If oxygen trim proportional gain is not required for any profile selection set option parameter 34 0 to 0 If oxygen trim proportional gain is required set option parameter 34 0 to 1 Option parameters 34 1 to 34 4 will then become available Options 34 1 to 34 4 allow the loop gain to be set individually for each profile selection to any value between 0 0 and 99 9 Oxygen trim proportional gain is not normally required Option 34 5 Calculating and entering the flow values manually LV3 If the flow values are to be calculated manually the procedure below must be followed Enter Adjust Ratio Mode with oxygen trim disabled as outlined above 1 Select the high fire position This will cause the display to show A n where n is the number of the high fire profile point 2 Wait until the oxygen reading has stabilized the value can be viewed using the engineer s key 3 Record the excess air value at location x in the table For single fuel profiles this value may be found using the Engineer s Key parameter EKA8 provided the hydrocarbon ratio has been entered into the appropriate option parameter 35 1 35 4 for this fuel For multiple fuel profiles Refer to NOTE under section Options 35 1 to 35 4 4 Select the profile position immediately below high fire This will cause the display to show A n 1 5 Wait until the oxygen reading has stabilized and record the excess air value at location a in the tabl
228. r profile 3 only Option parameter 4 2 1 drive 2 used for profile 1 only Option parameter 4 0 15 drive 0 used for all profiles Option parameter 4 4 5 drive 4 used for profile 1 and profile only l option 05 Drive Options LV3 This parameter is used to specify direction for each servo drive This parameter has no effect for variable speed drives VSD If this parameter is changed affected profiles must be re commissioned by a qualified engineer A profile invalid fault see FAULT 64 will lock the burner out until this is done Number entered in parameter 5 X Drive Options Drive moves anti clockwise Drive moves clockwise 79 ay options 06 1 06 4 Profile Naming LV3 This selects the fuel associated with each profile 1 thru 4 to be displayed after the burner on hours e g 861 hours Profile 1 Gas visible on the main display during operation Normally available options Number entered in parameter 6 X Fuel solenoid valves opened NONE GAS1 GAS2 OIL1 Lo Ol GAS1 GAS2 OIL1 selection 3 allows combined gas and oil firing This selection may not be available on certain versions of this product In addition for special applications further options may be allowed again the availability depends of product version Options 07 x 08 x RESERVED VSD Option 09 0 Inverter control accuracy 0 1 LV3 This parameter affects the invert
229. rately DISPLAY MODULES FOR PPC6000 NX610 CANbus display for PPC6000 with upload download of PPC6000 data and three programmable relays NXTSD104 10 4 Touchscreen Display with upload download full commissioning data log internet connection four programmable relays 10 line voltage Digital Inputs ERVO MOTORS FOR PPC6000 NXC04 4 wire CANbus Servo motor 3 ft Ibs torque 4 Nm 50 60 Hz 24 VAC 16 PART NO DESCRIPTION NXC12 4 wire CANbus Servo motor 9 ft Ibs torque 12 Nm 50 60 Hz 24 VAC NXC20 4 wire CANbus Servo motor 14 75 ft lbs torque 20 Nm 50 60 Hz 24 VAC NXC40 4 wire CANbus Servo motor 29 5 ft Ibs torque 40 Nm 50 60 Hz 24 VAC XPANSION INTERFACE MODULES FOR PPC6000 NXDBMB Modbus RTU communications card SD interface daughter board with two VSD channels one analog output two NXDBVSD ounter inputs two programmable relays isolated RS485 Modbus RTU ommunications NXO2INT CANbus O2 interface module with Fireye and generic 4 20mA probe inputs 2 PROBES FOR PPC6000 NXO2PK4 O2 probe assembly for flues 300mm to 1000mm Includes NXIATS CANbus ambient temperature sensor flange kit NXO2PK6 O2 probe assembly for flues 600mm to 2000mm Includes NXIATS CANbus ambient temperature sensor flange kit NXO2PK8 O2 probe assembly for flues 1200mm to 4000mm Includes NXIATS CANbus ambient temperature sensor flange kit PPC6000 CANbus Inlet ambient Air Temperature Sensor Sensor 29 C to
230. rature of the second oxygen probe if fitted EK79 Second flue temp C The flue temperature as measured by the second oxygen probe if fitted EK80 Drive Error values for drives 0 to 9 The current error value for drives 0 to 9 These values will freeze when the control performs a safety shutdown so it may be possible to look at these values after a lockout to help determine the cause EK90 Burner cycles The number of times the burner has attempted to start EK91 Burner Lockouts The number of times the burner has locked out EK92 Commission data backup verification Description This counts up as the backup is progress verified when the burner is running If a difference between the actual commissioning data and the backup is found it will go to zero A value of 999 indicates that the entire backup has been verified so all commissioning data are backed up in the display 146 No Name Description EK93 Flow value The instantaneous calculated air or fuel flow value as used by the oxygen trim function If flow values have been entered during commissioning for the current profile this value will show the flow rate that corresponds to the current modulation rate At high fire the value will be 99 9 At low fire it will be this divided by the turn down of the boiler If fuel trim is active this will track air flow If air trim is active this will track fuel flow EK95 Spare EK97 Combustion air pressure error added
231. re 16 Calculated flue gas CO2 level 36 Spare 17 Spare 37 Flame signal 18 Spare 38 Spare 19 Spare 39 Spare Option 29 1 Output1 zero value 4mA output LV3 Set this option to the value which a 4mA output represents Often this will be zero but non zero values may be used For example a value of 100 may be better suited for a minimum Flue Gas Temperature to ensure best resolution If this output has been assigned for VSD control in option 3 x then this setting will be ignored Option 29 2 Output span value 20mA output LV3 Set this option to the value which a 20mA output will represent For example value of 200 may be better suited for a maximum Flue Gas Temperature to ensure best resolution If this output has been assigned for VSD control in option 3 x then this setting will be ignored 106 E Option 29 3 4 20mA Output 2 function if not VSD LV3 Set this option to a value from the table in 29 0 to enable an analog output to re transmit system variables as a 4 20mA signal If this output has been assigned for VSD control in option 3 x then this setting will be ignored Option 29 4 Output2 zero value 4mA output LV3 Set this option to the value which a 4mA output will represent Often this will be zero but non zero values may be used If this output has been assigned for VSD control in option 3 x then this setting will be ignored Option 29 5 Output2 span value 20mA output LV3 Set thi
232. requires the burner to SHUTDOWN Line Voltage come on LINE VOLTAGE will be present on this terminal EK18 EK30 54 Signal Name Alternate Names Pin Description HFS HIGH FIRE Purge proved PE8 When the purge P1 position is reached pre purge or SWITCH post purge LINE VOLTAGE will be present on this Line Voltage terminal Line voltage will also be present here when the control is modulating and high fire is reached but only if the AUTO input is ON See OPT 16 2 for profile swap on the fly LFS LOW FIRE Ignition proved PE7 When the ignition P2 position is reached and the fuel air SWITCH ratio controller is ready for ignition LINE VOLTAGE will be Line Voltage present on this terminal Line voltage will also be present here when the control is modulating and low fire is reached but only if the AUTO input is ON See OPT 16 2 for profile swap on the fly The startup shutdown stages are as follows Stage name Description Non volatile The burner is held in this state until all faults are removed lockout safety shutdown The safety shutdown output PE5 PE6 will be open The controlled shutdown output on PE3 will also be OFF during this time however if the burner was running when the fault occurred the safety shutdown output will have opened first Burner off The burner is checked to make sure that it has switched off completely The fuel profile select inputs must all go OF
233. ring modulation A closed loop method is employed where adjustments to the speed reference signal are made based on the value of the feedback signal If the feedback signal from the drive is lost during a run condition e g the loop current drops below 3 5mA or encoder feedback fails the control will perform a non volatile lockout 7 3 Setting up the inverter for use with the PPC6000 series The PPC6000 will work with most inverters that meet the following criteria 4 20mA speed reference input 4 20mA speed feedback output or use separate encoder Remote run stop command The inverter must be powerful enough to accelerate decelerate the motor as required A good industrial inverter will have a significant overload capability meaning that it can supply well above the rated motor load for some time This might be something like 15096 or more for 1 minute An HVAC inverter typically will have no or very limited overload capability and may not be able to accelerate decelerate the motor quickly without current limiting This can cause drive position faults when driving to purge Analog inputs and outputs The analog inputs and outputs i e the 4 20mA reference and feedback signals on the inverter should be configured in the following way e 4 20mA signal this may be an option parameter and or a board jumper e Speed reference input e Speed reference output unless using encoder e Minimum frequency OHz for 4mA signal e Max
234. rminals PB8 10 Check option parameters 15 0 15 1 15 2 No profile selected Select a profile Modulation rate is 1 Burner not modulating Wait for burner to finish start up sequence Check PID proportional band must be greater than zero to modulate Burner status is flashing Control in non volatile lockout Burner status before shutdown displayed mode SEE ALSO Operation in Local Mode Operation in Local Mode NOTE This function is not available on displays manufactured after September 2007 Since a common PPC6000 display can be connected up to as many as sixteen PPC6000 s at once a common display must have the desired PPC6000 s address set in order to communicate This is done by entering local mode at the display and scrolling up or down to the desired address and exiting local mode If communications to a display is lost for approximately two seconds the display enters local mode If communications is reestablished the display will revert to normal operation To enter local mode press both the left and right arrow keys simultaneously The display will show the following TOP LINE The address unit number it is connected to N C indicates the PPC addressed is not present Set to match PPC6000 default is zero BOTTOM LINE Alternates between serial number and software version and the fault logging and commissioning backup status FL and CDBKP indicates a fault log and backup of the selected
235. rocess This control is not designed to work with inverters that take more than 60 seconds to drive from zero to maximum speed VSD E Option 09 5 VSD1 Speed Encoder Scaler 255 999 When using encoder feedback for VSD1 this option should be programmed to ensure that the feedback signal gives between 950 and 995 when the motor is at maximum speed drive signal at 20mA The value for the parameter may be calculated using the following formula Motor Max RPM x No of teeth on encoder Scaler 60 The value may need adjustment once the unit has been tested Specifically it must be ensured that the feedback received never exceeds this value In practice this may mean adding 2 to 5 to this value See section 9 2for more details 81 Option 09 6 VSD2 Speed Encoder Scaler 255 999 VSD When using encoder feedback for VSD2 this option should be programmed to ensure that the feedback signal gives between 950 and 995 when the motor is at maximum speed drive signal at 20mA The value for the parameter may be calculated using the following formula Motor Max RPM x No of teeth on encoder Scaler 60 The value may need adjustment once the unit has been tested Specifically it must be ensured that the feedback received never exceeds this value In practice this may mean adding 2 to 5 to this value See section 9 2 for more details Option 09 7 Reserved Option 09 8 Reserved
236. rsonnel A convenient check box has been added to the beginning of the symbols so that the Commissioning Personnel can mark each appropriate option as it is completed SYMBOL MEANS Ee Commissioning Personnel MUST execute this option 02 For Customers with O2 TRIM option Commissioning Personnel MUST ALSO execute this option VSD For Customers with VSD options Commissioning Personnel MUST ALSO execute this option By N After each appropriate option parameter is complete CHECK THE BOX 61 There are two 2 types of Displays available for the PPC6000 The first is the standard 12 key keypad shown below and the second is the optional 10 4 touchscreen NXTSD104 described in section 5 4 Both displays rely on the information in section 4 and the manual reads as though the standard display is being used so please read the entire section 4 regardless of the type of display in the configuration being used 5 3 1 1 Entering commission ratio mode To enter commission ratio mode turn the burner off Once the burner has completely shut down press the key labeled COM and select the supplier passcode value using the UP DOWN keys The supplier passcode is normally two sets of three numbers and is entered as shown below Run mode burner off Supplier passcode 1 gt ENTER set of numbers Supplier passcode 2 gt ENTER set of numbers If the entered passcode was correc
237. s and stores the new flow value If the oxygen reading exceeds 15 0 during this stage the unit shuts the burner down with F77 When the unit has completed the low fire point the measured boiler transport delay at low fire is stored in option parameter 30 7 Option parameter 30 5 oxygen trim enable is set to zero IM PO RTANT You must use adjust ratio mode to confirm each position from P3 low fire to Ph high fire If the flow values appear reasonable about 4 to 6 change at each position once you have finished setting option 30 5 to 1 will enable O2 trim There is a one minute delay after exiting commissioning mode before trim will enable If the flow values are unreasonable they may be adjusted manually by placing the cursor to the FLO position and using the up down arrows set the desired flow value Using EK44 verify the O2 levels at each position and adjust to match if required EK46 will help troubleshoot O2 trim issues BEFORE ENABLING TRIM USE ADJUST RATIO MODE TO MANUALLY CHECK THE CALCULATED FLOW VALUES OXYGEN SETPOINTS AND TRANSPORT DELAY THE LOW FIRE PERCENTAGE FLOW VALUE SHOULD CONFORM APPROXIMATELY TO THE TURN DOWN RATIO OF THE BURNER SUMMARY To perform automatic trim commissioning follow the procedure below 1 oa fF WN If the probe is new enter the offset and gain values in option parameters 30 1 and 30 2 which are supplied with the probe To re calibrate the probe refer to section 8 Enter a
238. s are available 16 45 46 2008 05 20 Burner Settings Opt Value Description M om _ PID1 PID1Setpoit 24 PIDIPBand 213 24 eripe 216 56 PID 1Low Limit cut in 217 7 2 PID 1HiLimit cut out 0 0 Remote SP1 ANS Zero 219 0 0 Remote SP1 ANS Span v Change view parameters R GAS MAN Unito Boiler actual 6 2 Boiler setpoint 6 6 Jbar Modulation rate COS Flame intensity Burner Start Sequence Wait for purge Openfuel valve Gas valve proving stage 1 Gas valve proving stage2 Prove air pressure Purge positionreached A Reset In the following example the Engineers Key values are displayed The scroll bar at the side of the data tab allows the user to move up and down the table 16 48 35 2008 05 20 Burner Settings DigIN10Profile 2 LV Digtalmputz HV input12 HV Digital input13 HV Air flow input FER Flame detected i eese co jowweame Change view parameters GAS Unito Boiler actual 6 2 bar Boiler setpoint 6 6 jbar Modulation rate Flame intensity Burner Start Sequence Wait for purge Openfuel valve Gas valve proving stage1 Gas valve proving stage 2 Prove air pressure Purge position reached CITI CS 69 5 4 11 Touchscreen Fault E
239. s option to the value which a 20mA output will represent If this output has been assigned for VSD control in option 3 x then this setting will be ignored Option 29 6 4 20mA Output 3 function if not VSD LV3 Set this option to a value from the table in 29 0 to enable an analog output to re transmit system variables as a 4 20mA signal Option 29 7 Output3 zero value 4mA output LV3 Set this option to the value which a 4mA output will represent Often this will be zero but non zero values may be used Option 29 8 Output3 span value 20mA output LV3 Set this option to the value which a 20mA output will represent Commissioning Oxygen Trim CAUTION Use extreme care when entering flow values and oxygen setpoints Incorrect setting of either could cause a hazardous situation to occur If the flow values and oxygen setpoints have been up loaded it is essential that the combustion is verified at each firing position to ensure a hazardous condition cannot occur If using automatic oxygen trim commissioning it is the sole responsibility of the commissioning engineer to ensure the values calculated by the system are correct and will not cause a hazardous condition to occur Once the oxygen trim is commissioned the trim flow limit must be set to ensure a fault in the oxygen trim will not cause a hazardous condition to occur In order for the oxygen trim system to function correctly the following information must be entered 1
240. s or import actual photographs of the combustion equipment for animation Summary of PPC6000 Features e State of the art surface mount technology e Smallest footprint available 7 0 x 4 5 x 2 5 e Capable up to ten servomotors powered from the control e Two PID loops for precise process control e Simple four wire CANbus wiring reduces time and mistakes e Optional VSD card provides two VSD s and one Analog output e Re transmittal of most data as 420mA output requires NXDBVSD option e VSD encoder feedback available e Standby lag boiler on water temp e Built in lead lag sequencing for up to four boilers e Fully programmable function block programming allows for custom applications such as draft control or feedwater control e Two levels of displays 12 Key Keypad with Backup 10 4 Color Touchscreen e Unparalleled worldwide support Safety information N WARNING The equipment described in this manual is capable of causing property damage severe injury or death It is the responsibility of the owner or user to ensure that the equipment described herein is installed operated and commissioned in compliance with the requirements of all national and local legislation which may prevail When this equipment is fitted to an appliance due regard must also be given to the requirements of that appliance Before attempting to install commission or operate this equipment all relevant sections of this document must
241. screen Disconnect Options Send Crow Retarh 01343 If the burner is firing then the modulation percentage will be displayed in a window between the Burner off and Auto boxes Using the buttons available from this window will change the way the burner is operating To exit this control mode window and return to the overview screen use the Overview button 5 5 4 9 Touchscreen Menu button Once the Menu button is pressed a pop up window appears on the right giving the user a choice of options If an option is unavailable it will be grayed out 13 11 03 eo OFF WGAS AUTO Unito Burner Settings Using the buttons available after Fault Event Log pressing the Menu button will generate a new pop up window in SEIN I EID the left hand area of the screen Trends About To exit this operation window return to the overview screen press the Overview button Operating hours 109 Profile GAS SELECTED S0 Profie2 0IL CleanScreen ZN a xh Burner Off i v x 5 4 10 Touchscreen Burner Reset Start Fuel Control Menu Overview 68 Settings button Once the Burner Settings button is pressed a window appears giving the user a choice of data types by Tab Selecting by touching a tab it as possible to view a variety of data in the example here the Option Parameter
242. sequencing Loc1 use PID 1 only Loc2 use PID 2 only LEAD Boiler is Lead upper case lead Boiler is not lead lower case OFF Turns burner off COM Changes operation to commission mode via a passcode In COMmissioning mode this key is the enter key 53 SS This fuel air ratio control performs burner start up and shut down in conjunction with an external burner controller The external burner controller provides burner management functions such as flame air pressure monitoring and it also controls the fuel shut off valves and combustion air fan 4 2 Start up sequence The start up and shutdown sequence is handled by a progression of stages each requiring a certain set of conditions to move on to the next one The progression through the stages requires handshaking between the two devices This is accomplished with a variety of signals Relevant Engineers Key if available will be shown as EK From burner controller to fuel air ratio controller Signal Name Alternate Names Pin Description H HIGH Purge request PAY Commands fuel air ratio controller to move the servos UP for either a pre purge or a post purge LOW VOLTAGE 5 Low Voltage This input is made by connection to PA11 If this input comes on during burner normal run modulation the burner will be turned off and a post purge initiated A AUTO Release to Modulate Releases the fuel air ratio controller to modulate as PA10
243. solated comms Modbus A 0 5V PB12 PPC6000 Isolated comms Modbus B 0 5V PB13 PPC6000 Isolated 0 Volt Modbus 0 5V PE1 PPC6000 PPC6000 neutral L2 115 230Vac PE2 PPC6000 PPC6000 live L1 115 230Vac PE3 PPC6000 Controlled Shutdown relay output 0 230Vac PE4 PPC6000 Alarm Relay 0 230Vac PES PPC6000 S S Relay 0 230Vac 33 Terminal Number Location Function Voltage Range PE6 PPC6000 S S Relay 0 230Vac PPC6000 Ign Prove Low Fire output 0 230Vac PE8 PPC6000 Purge Prove High Purge output 0 230Vac PE9 PPC6000 Profile 1 Select 0 230Vac PE10 PPC6000 Profile 2 Select 0 230Vac PE11 PPC6000 Profile 3 Select 0 230Vac PE12 PPC6000 Profile 4 Select 0 230Vac PK1 On Servomotor 24Vac Supply 24 40Vac PK2 On Servomotor 24Vac Supply 24 40Vac PK3 On Servomotor CAN 0 5V PK4 On Servomotor CAN 0 5V PK5 On Servomotor Screen connection Not applicable PL1 Oxygen Interface Unit Supply live L1 115 230Vac PL2 Oxygen Interface Unit Supply neutral L2 115 230Vac PL3 Oxygen Interface CAN 0 5V PL4 Oxygen Interface CAN 0 5V PL5 Oxygen Interface Analog input 2 NA future 0 5V PL6 Oxygen Interface Analog input 1 4 20mA O third 0 5V party probe PL7 Oxygen Interface Analog input Ov 0 5V PM2 Oxyge
244. stant gloves to hold the probe e Remove the six retaining screws The probe can be extracted from the flue taking care not to damage the sealing gasket e The only customer replaceable items are the flue thermocouple and oxygen filter e If it is necessary to operate the boiler while the probe is removed the blanking plate supplied with the equipment must be fitted to the probe flange e Refitting is the reverse of the removal procedure Ensure that the screws are tightened sequentially 9 1 4 Filter replacement e Remove the oxygen probe from the flue as detailed in section 9 1 3 and unscrew the insulating flue thermocouple mounting blocks from the snout e Before removing the three 6mm stainless steel nuts and spring washers which retain the snout it is important to hold the body horizontal or snout down to prevent soot or other deposits from falling into the probe body e When the 3 nuts and washers have been removed the snout can be drawn off the mounting studs to allow the captive filter assembly to be removed e new filter assembly part number 19 117 can then be inserted into the snout beveled side inwards e The snout can be refitted ensuring that the filter locates into the probe body The retaining washers and nuts should be tightened sequentially to seal the filter assembly to the flange 9 1 5 Probe mounted flue thermocouple replacement e Remove the oxygen probe from the flue as detailed in section 9 1 3
245. structions AN CAUTION Disconnect the power supply before beginning installation to prevent electrical shock equipment and or control damage More than one power supply disconnect may be involved Wiring must comply with all applicable codes ordinances and regulations Loads connected to the PPC6000 series must not exceed those listed in the specifications as given in this manual All external components connected to the control must be approved for the specific purpose for which they are used 18 SS 2 1 Mounting details for the PPC6000 control 6 26 159mm 0 75 19mm 3 15 4 65 80mm 118mm 6 93 176mm A Template for mounting is provided at the end of this manual for convenience See Section 8 There are two versions of the control one that is intended to be mounted inside of a burner control cabinet the other which has provision for conduit storage of field wiring etc that can be mounted without the need for a burner control cabinet If the version which is designed to be fitted inside of a burner control cabinet is being used the cabinet should have a minimum protection level of 1 IP40 for indoor use or IP54 for outdoor use The control can be mounted in any attitude clearances of a least 2 36 inch 60mm should be left around the unit to allow sufficient space for wiring and to ensure reliable operation The ambient operating temperature range of the equipment is 0
246. t P 0 will be seen on the display This represents the closed position setpoint 5 3 1 2 Changing from Commission Adjust Ratio mode to Option Set mode Commission Adjust ratio mode Option set mode To enter option set mode enter commission ratio mode or adjust ratio mode see sections 5 3 1 or 5 4 14 respectively and press the key labeled MODE 5 3 1 3 Changing from option set to Commission Adjust ratio modes Option set mode MEN Commission ratio Adjust ratio mode 5 3 1 4 Exiting from commission mode To exit from any commission mode to run condition press the key labeled RUN and then ENTER e g Option set mode ENTER __ Run mode NOTE Exiting from full commissioning mode at or higher will erase any point above the displayed Px If this is undesirable exit full commissioning mode at HIGH FIRE 62 Cay 5 4 Description of Touchscreen operation 5 4 1 The Touchscreen The touchscreen provides all of the functions required to control and monitor the burner it is also used to commission the control Once commissioning mode is selected the display background changes to red to alert the user that the control is in commissioning mode and therefore unable to monitor certain safety functions such as fuel air ratio positions For a detailed overview of the NXTSD104 see bulletin NXOGTSD 6101 Operator s Guide 5 4 2 Touchscreen Power on Initialization of the control and display will
247. t Cut In or 21 7 22 7 for High Limit Cut Out This is the control value the Nexus will start stop the burner after reaching the cut in out value This value is a differential value when option parameter 21 5 22 5 is set at 2 That is it is subtracted added from to the operating setpoint Once set this value will follow any change in the setpoint programmed in option 21 1 22 1 These values are actual values if 21 5 22 5 are set to 1 see table below Option parameter Meaning 21 5 22 5 value No limits The burner will run until another method is used to switch it off Absolute limit The values entered in option parameters 21 6 22 6 and 21 7 22 7 are the actual limit values Deviation limit The values entered in option parameters 21 6 22 6 and 21 7 22 7 represent a deviation i e offset from the setpoint 1 control value This means that if the setpoint control value is changed the limits are automatically changed correspondingly Use the left or right arrow key to move the cursor to the lower portion of the display then using the up down arrow key change the setting Press the ENTER key to accept the new setpoint To exit and return to the normal run mode press the RUN key followed by the ENTER key Deviation Example setting Opt 21 5 to 2 To maintain 100 psi on the boiler cut out at 115 psi cut in at 95 psi NOTE Opt 15 5 Boiler High Safety Limit If this option is set to a non zero exceedin
248. t applicable Currently unassigned Applicable if combustion air pressure monitoring is used using a 4 20mA pressure sensor This fault will lock out the burner if the measured combustion air pressure does not match that expected for the current firing rate for six 6 seconds Subset is not used will be zero Currently unassigned The option parameters have been uploaded via serial communications Check all values are correct and match the application then set option parameter 45 0 to 0 Subset Not applicable 137 Fault Description Number Profile Invalid This fault means that the control can t fire the currently selected F64 nolis es profile because it isn t sure it still matches the burner site configuration It could lead to a hazardous situation There are three possible causes to this fault 1 A drive has been commissioned in this profile but has now been deselected If a profile is commissioned with two air dampers but then the second air damper is de selected with option parameter 4 0 to 4 9 the profile is no longer valid Subset Drive number 0 to 9 2 Servo Drive changed If the system is commissioned then later one of the servos is changed for a new one i e different serial number any profiles that use that servo are now considered invalid This is to force the engineer to ensure the new servo is mechanically connected the same way as the original one Subset Invalid profile 1
249. tal input Selecting a non zero value will enable the operation of the Mute Reset function from the corresponding digital input It should be ensured that the digital input selected is not used for any other function option parameters 1 x 16 x and 18 x 20 x MUST be connected as shown in section 3 6 11 Please note any key button providing a fault mute function must be mounted local to the burner 76 Number entered in Mute Reset Function Digital inputs used parameter 01 2 O Comview amp Keyboard only NONE po IHpuf Input 1 PAS to PA11 Low Voltage 2 tpt 2 Input 2 PAG to PA11 Low Voltage L3 opat Input 3 PAZ to PA11 Low Voltage tpt Input4 PAB to PA11 Low Voltage I3 02 x Drive Name LV3 CAUTION e total electrical load for all connected servo motors must not exceed 40VA Each Drive connected to the system can be given a name which will than be shown on the text display there are a maximum of 10 drives 0 9 which can be connected the names are set by option parameter 02 0 to 02 9 The drives are displayed with the drive number first then a three character label such as 1GAS 2AIR SAIR etc The permitted drive names are Number Drive Considered Trim if Meaning entered in Name as selected parameter This drive will not be used Generic fuel drive Cup speed for rotary cup bumers FGR Fueldive NO Flue Gas Recirculation damper
250. ted Analogue Digital Input 1 The raw ADC counts from analogue digital input PPC6000 Terminal PAS 1 0 to 1023 for O to 5 00 volts 4mA 180 counts 20mA 900 counts 144 Analogue Digital Input 2 PPC6000 Terminal PAG Analogue Digital Input 3 PPC6000 Terminal PA7 Analogue Digital Input 4 PPC6000 Terminal PA8 Analogue Input 5 PPC6000 Terminal PA12 also remote setpoint Analogue Input 6 PPC6000 Terminal PB9 also boiler measured value Analogue input 7 Daughterboard terminal PZ12 PZ13 Also VSD1 Analogue input 8 Daughterboard terminal PZ13 PZ14 Also VSD2 Note for EK67 and EK 68 these two inputs Daughter board Frequency input 1 PZ7 0 to 12 volts Daughter board Frequency input 2 PZ9 to 12 volts Description The raw ADC counts from analogue digital input 2 0 to 1023 for 0 to 5 00 volts 4mA 180 counts 20mA 900 counts The raw ADC counts from analogue digital input 3 0 to 1023 for 0 to 5 00 volts 4mA 180 counts 20mA 900 counts The raw ADC counts from analogue digital input 4 0 to 1023 for 0 to 5 00 volts 4mA 180 counts 20mA 900 counts The raw ADC counts from analogue input 5 to 1023 for to 5 00 volts 4mA 180 counts 20mA 900 counts The raw ADC counts from analogue input 6 0 to 1023 for 0 to 5 00 volts 4mA 180 counts 20mA 900 counts The ADC counts from analogue input 7 0 to 999 for 4 to 20
251. termine which direction you need to go Bear in mind the burner should not continuously hunt or swing to maintain the desired setpoint It is normal for a slight over and undershoots of setpoint during serious load changes The values for the PID s are found at option parameters 21 2 21 3 and 21 4 for setpoint 1 PID1 and 22 2 22 3 and 22 4 for setpoint 2 PID2 These values are adjustable using the Site Passcode 154 168 eS It is safe to say that most burners do not have fuel and air control devices that have linear flow characteristics When commissioning the Fireye Nexus PPC parallel positioning system the following procedure will help assure the maximum benefit will be realized Before starting the installation the commissioning engineer should try to verify the maximum combustion air damper flow position so as to know the target high fire position This can be done by rotating the original jack shaft before it is removed and measuring the air damper opening If possible it should be marked for reference 9 4 Combustion Profile Setup Guideline There are 24 points available for creating a profile PO closed off to P23 high fire The first three positions PO P1 amp P2 are required to reach ignition which may or may not be the same as low fire P3 After establishing a good low fire and entering the values at P3 the display will now indicate P4 with the drives at the P3 position At this time the main air drive or drives
252. th LV2 or LV3 in this section This passcode can be zero in which case the user only needs to press the COM ENTER key twice to enter option set mode with limited access Option 00 2 Serial communications control address 0 15 LV3 If the control is to be connected to other equipment via the serial communications interface it must be given a unique address using this option parameter Additionally if more than one control unit is connected on the CAN bus for example to share a display the units must all have unique addresses BEFORE THEY ARE CONNECTED TO THE SAME CANbus 74 eS This option parameter allows the HOURS RUN display for all fuels to be reset to zero To perform a reset set this option parameter to 1 and leave option set mode When the burner begins to modulate the HOURS RUN display will be reset and the option parameter automatically returns back to 0 Option 00 3 Reset hours run 0 1 LV3 Option 00 4 User program select 0 1 LV1 This parameter may not be available Where it is available it allows the user to de select the Fireye s standard modulation program and select a user program The user program may be modified using PC software to change the controls behavior for non standard applications The programmable system only allows access to non safety related functions such as modulation enabling disabling burner start up and other similar functions Only the user program can be modified
253. tings Options 24 x Sequencing If the lead master boiler is turned off or fails to come on within three minutes while operating as the lead sequencing will be disabled and all lag slave boilers will revert to their own PID settings Should a lag boiler fail to come on within three minutes or the PPC6000 is faulted sequencing will immediately call for the next lag in the priority list If the lead master boiler is switched to manual modulation it will remain as lead bringing on lag slave boilers as required This will allow the operator to base load a lead boiler if required The PPC6000 can be the master lead boiler in a system that has PPC5000 or NX3100 4100 series as the communications message are the same The PPC6000 cannot be controlled by the PPC5000 or NX3100 4100 series controls as a boiler Stand by or Banking values The lag stand by or banking temperature or pressure is entered as PID 2 or Setpoint 2 values however options 22 2 22 3 22 4 the P and D values are unnecessary as the burner will start and remain at low fire until the lag stand by or banking cut out is reached These values will be entered by Setting option parameter 22 0 to 1 Enable Setpoint 2 Setting option parameter 22 1 to the desired setpoint value when in stand by Setting option parameter 22 5 to 1 Absolute Value Setting option parameter 22 6 to the desired cut in value when in stand by Setting option parameter 22
254. tion to a building management system is required Option 20 2 Low Fire Hold input 0 35 1 4 A high level on the input specified here will cause the boiler to go to low fire and stay there until it is removed 160r20 Should NOT be used 21 24 low level on the input specified here will cause the boiler to go to low fire and stay there until it is switched high ON The input numbers are as specified in Option Table 20 0 A above Option 20 3 Oxygen Trim Disable input 0 35 LV3 1 4 A high level on the input specified here will cause the oxygen trim function to switch off if it is selected until it is removed 16 or 20 Should NOT be used 21 24 low level on the input specified here will cause the oxygen trim function to switch off if it is selected until it is switched high ON The input numbers are as specified in Option Table 20 0 A above See option parameter 30 5 95 SS 1 4 A high level on the input specified here will prevent the burner from igniting The drives stay at their ignition positions but the light up sequence will not start until this input is removed 16 or 20 Should NOT be used 21 24 low level on the input specified here will prevent the burner from igniting The drives stay at their ignition positions but the light up sequence will not start until this input is switched high ON Option 20 4 Ignition Wait input 0 35 The input num
255. tional details reference the option links and fuses are provided on a label attached to the mounting base from which the product must be removed to gain access 2 5 2 Line supply voltage LK1 4 PPC6000 WARNING Incorrect setting of the Links WILL damage or destroy the unit The possible supply voltages are shown below together with the necessary fuse rating The correct fuse type and rating must be fitted failure to do so may result in damage to the control Supply voltage V Links required Fuse rating mA 120 LK1 and LK3 630 anti surge TIME DELAY 230 LK2 and LK4 315 anti surge TIME DELAY 26 C 2 5 3 SENS IN and SENS SUPP boiler temp pressure sensor PPC6000 If a boiler pressure temperature sensor or modulation potentiometer is used links JP3 and JP1 must be set to suit the type of sensor and voltage requirement For example 430v 5y e For a 4 20mA loop power sensor choose a 30V supply JP1 IN e For a 4 20mA loop power sensor choose current IN input 30v 5v e For a 0 5V modulation signal choose a 5V supply outisme IN e Fora0 5V modulation signal choose voltage OUT input 2 5 4 REMOTE SETPOINT PPC6000 If the remote setpoint or track signal is being used link JP2 must be set to suit the type of signal For example ouUT epa IN For a current input set JP2 to IN position to ensure burden resistor is connected JP2 j j i IN e Fora voltage input signal set JP2 to OU
256. to 1 Once the control has left set up mode this parameter will automatically be reset to 0 In order to restore information to the control from the back up held in the display see option parameter 45 2 this option must be set to a 1 Once the control has left set up mode this parameter will automatically be reset to 0 If this option parameter is set to 2 see caution message above Option 45 1 Erase command 0 5 LV3 When erase enable option 45 0 is set to 1 this option parameter determines which information will be erased when the control leaves option set mode 0 No erase 1 Erase profile 1 2 Erase profile 2 3 Erase profile 3 4 Erase profile 4 5 Erase all setpoints and initialize all option parameters If 5 is selected all profile setpoints will be erased and all option parameters will be set to default values The control will be initialized to the same state as when it was shipped NOTE You must exit commissioning mode to begin the erase Option 45 2 Restore command 0 999 LV3 MEMORY TEST To determine if the NX610 keypad display contains a valid memory press both left and right cursor arrow keys simultaneously The display will change to LOCAL MODE and toggle between two information screens One of these will contain the capitol letters FL CDBKP Ifall appear there is no valid memory in the display If no valid option parameter and profile is available from pr
257. to 60 C 32 to 140 F Refer to section 7 for more details Terminal Block PB Terminal Block PA Terminal Block PE Screen _ Termination Clamps 19 D PANEL FRONT HOLES M4 CLEAR 3 26 32 97mm 4 1 8 105mm PANEL CUT OUT 8mm E amp 3 7 16 87mm REMOVE AND REUSE For Mounting 1 5 8 40mm 4 1 4 108mm The display is held in using the four brass standoffs The panel is cut out inside the four mounting holes only Remove the four brass standoffs insert the screw studs through the mounting holes then re install the brass standoffs Do not over tighten the standoffs A Template for mounting is provided at the end of this manual for convenience See Section 8 20 Gary 2 3 Mounting details for optional Oxygen Probe Interface unit NXO2INT A Template for mounting is provided at the end of this manual for convenience See Section 8 The optional oxygen probe interface unit is designed to be fitted either within a control cabinet or without a control cabinet the unit has a protection level of NEMA4 IP65 providing suitable conduit glands are used The interface unit can be mounted in any attitude clearances should be maintained around the conduit entries to the unit to allow sufficient space for wiring etc the ambient operating temperature range is 0 to 60 C 32 to 140 F The unit MUST be grounded earthed t
258. umber cannot be changed and is used to uniquely identify each device When the system is in commissioning mode the serial number of all the connected devices is read by the PPC6000 and displayed as a list to allow the selection of the relevant serial number unit to be made Scrolling the list in an upward direction will scroll through all oxygen probe interface options available until 0 nothing is displayed Enter this value to disconnect the specified device from any hardware The FIREYE oxygen probe and associated electronics are not fail safe It is for this reason that the maximum amount of oxygen trim allowed must be limited by the commissioning engineer using option parameters 32 1 to 32 4 The trim must be limited to ensure that in the event of a probe fault incorrect O2 level the combustion does not become unsafe For applications demanding large amounts of oxygen trim to be applied or where oxygen monitoring is especially critical a second oxygen probe and controller can be selected here The two oxygen readings from the probes can be compared when the burner is running to provide fail safe oxygen monitoring Option 42 1 Second Oxygen probe calibration offset value 0 999 This option parameter is only available if option 31 0 is non zero This option parameter must be set to the calibration offset value that is specified with the probe supplied Option 42 2 Second Oxygen probe calibration gain value
259. unstable reducing this value has the effect of damping the inverter s response as its speed approaches its setpoint VSD Option 09 3 Inverter stop time 0 100 seconds LV3 Determines the minimum time between a burner shutdown and subsequent startup Set this parameter to give the inverter sufficient time to stop before the burner restarts This parameter will increase the time the burner is held in status 5 VSD Option 09 4 Inverter acceleration time 0 100 seconds 60 seconds recommended LV3 DEFAULT 30 The value entered for this parameter should be the time in seconds for the inverter s to move from minimum to maximum speed The inverter s should also be able to move from maximum to minimum speed in the same time if this is not the case adjust the time in the inverter s to ensure the time to accelerate and de accelerate are the same If this option parameter does not match the true VSD acceleration deceleration times drive positioning will be compromised and position faults will be likely Note This parameter can be set to values between 60 and 100 but this should only be used as a last resort if required and is not recommended If a very slow inverter is used care must be taken during commissioning that UP DOWN keys are not held for more than a few seconds It is possible that the control could get out of step with the inverter and cause a position fault during the commission p
260. urs If faults or limits are present and either the alarm or limit relay is closed press the MUTE RESET key to mute the alarm open the relay Take note of the fault message and use the Fault Listing to identify why the fault occurred If the faults which cause a non volatile lockout are still present when the alarm is muted the alarm will operate again when the alarm clears to indicate to the operator that the control may be restarted Once all faults have been diagnosed rectified and cleared press the MUTE RESET key for approximately three seconds to remove the fault messages and re start the burner 131 Gay The function of the MUTE RESET key may also be achieved via ComFire or using the MUTE RESET input See option parameter 1 2 6 3 Non volatile lockout If power is removed from the control while a fault is still present the fault will be stored in non volatile memory When power is restored to the control the fault number will still be present and it will be necessary to remove the fault before restarting the burner 6 4 Fault subsets As an aid to fault finding most faults also have a fault subset that gives additional information about the type of fault or what the burner was doing when the fault occurred Where applicable the subsets are given in the fault listing in section 6 5 6 5 Fault listing Fault Cause Description Number F01 External Alarm One of the low voltage alarm lockout inputs is causing an Fault
261. using the specified cable sizes and screen connections observing any maximum cable length limitations The manufacturer of this equipment recommends the use of bootlace ferules on all wire ends as a best practice Bootlace Ferules The equipment described in this manual has been tested for compliance to the CE and UL directives listed in the section headed approvals However once connected to a burner and other associated controls it is the responsibility of the installer to ensure the complete installation meets the requirements of the UL or CE directives relevant to the particular installation IMPORTANT Wiring Guidelines NOTE Interposing terminal blocks should be avoided when shielded cable is required Interposing terminals present a risk of electrical noise interference resulting in unreliable operation All wiring to this control must comply with National State and Local electrical codes In general all insulation must meet or exceed the highest voltage present on any conductor in a conduit raceway or panel e g 480 volt motor wiring would require at least 600 volt insulation Consult the National Electric code for guidance IMPORTANT Low Voltage vertical terminal strips All low voltage circuits and communication wire must be fully shielded braided type wire of the specified gauge and number of conductors Table 2 6 1 A provides the only approved wire for this application No or equal is provided Use of wire not approve
262. ven may cause damage to the device or motor Note The motor shaft when directly coupled will rotate in the opposite direction from the driven shaft For example if the gas valve rotates counter clockwise to open then the servomotor MUST be set to clockwise rotation in Option 5 x Shaft Positions as viewed from Shaft End For NXC04 NXC12 NXC20 NXC40 ONLY PO PO Option Parameter 5 x Option Parameter 5 x Set to 0 Set to 1 49 Sy Servomotor Shaft Position Warning It is not possible to reposition the shaft of the servomotor other than to the factory settings of either clockwise or counter clockwise That is the shaft flat as viewed from the shaft end will either be in the 9 12 o clock or 6 9 o clock position at PO burner off Using the out of the box settings will make future replacement of servomotors easier See previous page Some motors have a clutch release to allow for the driven device to be rotated for inspection after commissioning It must be noted that releasing the clutch while the motor is powered will cause the servomotor to drive back to the commissioned position Power should be removed if the clutch is used for this purpose 3 3 Locking the servo motor to the valve shaft WARNING Once the position of the servo motor shaft relative to the valve shaft is correct each motor must be locked to its valve shaft for all air damper s and fuel valve s In order to prevent the joint between motor
263. vent Log button Once the Fault Event Log button is pressed a window appears showing the Fault Event history Users may select to see Fault data only Events data only or a combined history as shown in this example For more information on fault codes and fault finding refer to the Fault Finding section of the PPC6000 manual bulletin NEX 6101 15 44 11 2008 05 21 2008 05 20 165 Fault Event Lo Description 1 19 Enter COMMISSIO l od Burner shutdown EAM ShowFauitHistory E ShowEventLog Clear All Item Date Time Switched OFF Burner startup Re start Mute 2008 05 20 15 10 49 Air pres not ON Air pres not ON 2008 05 20 14 23 40 Burner startup 2008 05 20 4 23 36 Switched ON REMOTE 2008 05 20 14 23 30 Burner shutdown 2008 05 20 14 23 29 Switched OFF 2008 05 20 14 23 27 Switched ON REMOTE 21 8 2 2 eo Main ignition Wait for flame established v Movingtolow fire X Boiler actual 2 Jbar Boiler setpoint 6 6 Jbar Modulation rate 1 Flame intensity 33 Burner Start Sequence ignition active Pilot ignition interval Modulation 5 4 12 Touchscreen Screen Configuration button Fireye Once the Screen Configuration button is pressed a window appears giving the user a choice of options From the General Tab a name may be entered for each profile
264. way to check this value using a calculation For the rest of the commissioning procedure treat the inverter drive in the same way as a motor The inverter drive has a closed position 4mA a maximum position 20mA a pre purge position an ignition position and up to 20 profile positions 159 8 The oxygen trim option CAUTION Use extreme care when handling the oxygen probe and wear heatproof gloves Ensure the burner is off before removing the oxygen probe from the flue If the boiler is to be operated with the probe removed fit the blanking cover supplied since dangerous levels of carbon monoxide may be present in the flue 8 1 Oxygen Pro probe description The oxygen trim monitoring function is designed to be used with an NX2012 oxygen probe This probe offers fast accurate response and good reliability when mounted in accordance with the guidelines in this section The probe is available in three different sizes 8 1 1 Installation of oxygen probe 8 1 2 Mounting the oxygen probe CLEARANCE REQUIRED TO INSTALL Model Dimension A B c D SEE DIM B p amp REMOVE FROM FLUE SEE DIM C 22 Z L 246 9 7 NXO2PK6 362 14 25 406 15 99 486 19 13 659 25 95 NXO2PK8 716 28 19 757 29 8 873 32 95 1013 39 88 no 2 173 6 81 215 8 5 295 116 a7o 18 5 20 FLEXIBLE CONDUIT ENTRY
265. wn until they are positions stopped by the closed position micro switches in the servos The final positions are compared with the closed positions stored in memory and must be within 5 of the stored values otherwise the control will lockout EK80 89 Variable speed drives must read zero 4 mA This includes any VSD VFD assigned to the chosen profile When all drives have stopped moving the control will advance to status 7 The HIGH input PA9 to PA11 still must be made during this time If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 Note Status 6 is reserved for air pressure detection and is not implemented in this control This function must be provided by the burner controller I N A Not Applicable to PPC6000 Moving to Purge The selected motors are moved up towards the purge position When the drives have all stopped the control moves to status 8 If the fuel profile select input is removed PES 10 11 or 12 the control will immediately move to status 1 56 Stage no 10 11 14 Stage Move to ignition positions Ignition N A my The controller confirms all required drives are at their purge positions and gives a purge proved signal by providing line voltage to terminal PE8 high fire switch Description The control will remain in this status until the burner controller si
266. ygen setpoint value is wanted press the ENTER key The value will be stored in memory 8 If the new oxygen setpoint value is not wanted or an adjustment is not required press the NEXT key to return to the value stored in memory 9 Once the flow value is shown on the display use the scroll keys to position the gt pointing to the FLO value use the UP DOWN keys to adjust the flow value as necessary The display will show the air flow value represented as a percentage of the air flow when the drives are at the HIGH FIRE position The display will start flashing to indicate that a change has been made 10 If the new flow value is not wanted or an adjustment is not required press the NEXT key to return to the value stored in memory 11 If it is necessary to adjust another setpoint in the firing range repeat the above procedure from step 3 12 After modifying an existing O2 trim profile use Option 30 8 to reset the feed forward function See option 30 8 for details 02 Option 30 0 Oxygen probe interface serial number LV3 Each CANbus device connected to the system has a unique serial number allocated to it during production testing This number cannot be changed and is used to uniquely identify each device When the system is in commissioning mode the serial number of all the connected devices is read by the PPC6000 and displayed as a list to allow the selection of the relevant serial number unit t
267. you desire Once the required values have been entered or changed the mode can be exited by pressing RUN followed by ENTER the X at the top right corner of the Burner Adjust window will be grayed out and inoperative 5 5 Using option set mode e Use the UP DOWN keys to select the Option parameter to be adjusted e Use the Scroll gt keys to navigate between Option numbers and the Option values e Use the UP DOWN keys to change the value of the option parameter When the correct value is selected then press the ENTER key to store the new value e Setor adjust all of the parameters as required by moving between the parameters and adjusting as described above 5 5 1 Option parameter list CAUTION e Use extreme care when entering option parameters Incorrect data entry could cause a hazardous situation to occur e Itis possible that additional parameters may be present in the unit depending on the application and or supplier Note Option parameters are marked with LV1 LV2 and LV3 which indicate what level passcode is required If when using the supplier passcode LV3 it is not possible to adjust the value of an option parameter then the burner must be turned off to make the adjustment Option 00 1 Site passcode 0 999 DEFAULT VALUE is 154 LV3 This is a three digit passcode that will allow the site engineer or end user to enter option set mode and adjust a limited range of option parameters those not marked wi

PPC-6001 - Fireye Inc.

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