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NEXUS INTEGRATED BURNER CONTROL SYSTEM

1. COMMISSIONING SHEET Site Engineer Commenis Serial No Boiler No Fuel Date Gas Pressure Sensor System Configuration Type 2 0 High Lim 2 5 Air Damper 2 select 1 3 Zero 2 1 Test vol 2 6 Auxiliary relay function 1 4 Span 2 2 Leak rate 2 7 Flame det device 3 0 Press 2 3 Vent valve 2 8 Safety time config 4 0 Lovv lim 2 4 gnition time 4 1 Lovv fire hold time 4 2 Post purge time 4 3 Extended pilot time 4 4 Permanent pilot select 4 5 Mod Input Setpoint 1 Setpoint 2 Miscellaneous Mod speed 5 4 5 4 Site Passcode 0 1 Mod input type 5 5 5 5 Serial Comms Passcode 1 0 5 6 Boiler safety limit 5 6 5 6 Povver Supply Frequency 1 1 0 Modulation units 5 7 5 7 Serial Comms Address 1 2 Aux mod input 5 8 5 8 Gas Lead Drive 5 1 Setpoint type 6 0 8 0 Oil Lead Drive 5 2 Zero 6 0 8 1 Bumpless Transfer 5 3 Span 6 2 8 2 Aux input 1 10 0 Control Value 6 3 8 3 Aux input 2 10 1 P 6 4 8 4 Aux input 3 10 2 1 6 5 8 5 Aux input 4 10 3 D 6 6 8 6 Aux input 5 10 4 Remote zero 6 7 n a Aux input 6 10 5 Remote span 6 8 n a Aux input 7 10 6 Limit Type 7 0 9 0 Aux input 8 10 7 Lovv Limit 7 1 9 1 Aux input 9 10 8 High Limit 7 2 9 2 Aux input 10 10 9 VVarming Limit 7 5 9 5 VVarming Time 7 6 9 6
2. 0000000 0000000 0000000 Gas Proof of Closure Oil Proof of Closure Calibration Commissioning data checksum RAM test Program memory check sum Microprocessor clock Single fuel only allowed Boiler safety limit exceeded Forced shutdown from digital input Forced limit alarm from digital input Auxiliary digital input Secondary flame sensor input Secondary safety shut down relay Secondary program memory checksum LED 33 The gas main 2 valve proof of closure signal is not responding correctly The oil valve proof of closure signal is not responding correctly The calibration data could not be read The unit will not perform a safety shut down but instead will use default calibration values This means that potentiom eter and sensor inputs may be inaccurate Subset 1 zero data 2 checksum incorrect The commissioning data memory on the CPU board has been corrupted Erase all option parameters and fuel air ratio setpoints e Contact supplier Subset page number The main memory on the CPU board has malfunctioned e Interrupt power to the unit The program memory on the CPU board has been corrupted elnterrupt power to the unit The timing reference on the CPU board is incorrect els option parameter 1 1 set for the correct frequency e s the on site frequency incorrect e Use a filtered uninterruptable power supply if the voltage supply is excessiv
3. 3 With the display showing POO use the UP DOWN keys to move each servo motor If the dis played position decreases as UP is pressed or increases as DOWN is pressed reverse the servo motor output UP DOWN connections Adjusting microswitch positions Each time a burner start up sequence is initiated the unit will move the fuel and air damper servo motors to their closed and purge positions to prove correct servo motor and potentiometer operation Each servo motor must have microswitches to limit the close and purge positions obtainable during this proving operation To set the microswitch positions follow the procedure below Enter commission ratio mode Move each servo motor to approximately 45 either by hand or using the UP DOWN keys Holding the DOWN key adjust the low limit microswitch until the servo motor will no longer move down 4 Holding the DOWN key gradually slacken off the low limit microswitch until the servo motor starts moving down Continue to slacken off the microswitch until the servo motor stops with a reading on the display of approximately 2 to 3 5 Move the servo motor up and down a few times to check that the servo motor stops each time at approximately 2 to 3 and readjust the microswitch if necessary This position will allow for some tolerance in microswitch operation 6 Hold the UP key and tighten up the high limit microswitch until the servo motor will no longer move up 7 Holding the UP ke
4. NEX 1001 JUNE 27 2013 NEXUS INTEGRATED BURNER CONTROL SYSTEM CE Cy LISTED DESCRIPTION The Fireye NEXUS Integrated Controller is a microprocessor based Flame Safeguard and parallel positioning combustion controller built into one compact user configurable package The system consists of the Controller Display Wiring sub panel Temperature Pressure Sensors Servo Motors and ComFire Software The Flame Safeguard portion of the control package provides burner sequencing including safe start check proof of main valve closure selectable main gas safety proving sequence supervised pre purge low fire starting position pilot and main trials for ignition main flame supervision and post purge Safety event timings are provided to meet North American and CE Standards Time proven Fireye Flame Scanners and amplification circuits using UV UV Self Check and Infrared sensors provide fast reliable scanning of most commonly burned fuels Ten user defined auxiliary inputs pro vide supervision of safety critical and non safety critical inputs Control of up to four Channels using an independent Servo Motors for each controlled element allows precise positioning accurate to 0 19 of the fuel and air metering devices over the burner s fir ing range One of two fuel profiles can be selected for each fuel channel with 24 positions per profile including Closed Purge Ignition Preferred StartTM Low Fire and an additional 20 inte
5. 37 ft Ibs 120V NX50 2 Servo Motor 20Nm 230V 65 VVIRING BASE 77 NX1466 1386 PF Servo Motor Supply L1 PA1 PF1 I P 1 2 3 common Fuel 1 up 2 PF2 UP 1 fault mute Fuel 1 down PA3 o Po SUPPLY PF3 2 gas LK3 lt FUSE Fuel 2 up PA4 Lko lt o PF4 3 oil Fuel 2 down PAS Ss PF5 I P 4 5 flow common Air pressure sw 2 Damper 1 up PA6 PF6 I P 4 flow Air pressure sw 2 Damper 1 down PA7 PF7 I P 5 no flow Air pressure sw 2 Damper 2 up PA8 PF8 Flow common Air pressure sw 1 Damper 2 down PAQ PF9 Flow Air pressure sw 1 PF10 No flow Air pressure sw 1 PF11 HP A UV scanner PB1 PF12 I P A UV scanner PB2 JP6 eee ISOL 485 PF13 P B Unused PB3 PF14 Neutral PB4 JP7 eee TEAM 15 IPC Hot L1 PB5 PF16 PC Ignition PB6 PF17 I P D Burner select on off PB7 PF18 I P D Pilot valve PB8 PF19 IPE Gas valve 1 PB9 PF20 I P E Gas valve 2 PB10 PF21 IR scanner Oil valve PBI PF22 IR scanner Burner fan PB12 Vent valve PB13 Auxiliary relay PB14 PE PE1 Fuel 1 pot supply PE2 Fuel 1 feedback in Alarm 1 N 0 PC1 PE3 Fuel 1 pot ground Ov Alarm 1 N C PC2 PE4 Fuel 2 pot supply 2 Alarm 1 common PC3 PES Fuel 2 feedback in Alarm 2 N 0 PC4 PE6 Fuel 2 pot ground Ov Alarm 2 N C PC5 PE7 Damper 1 pot supply Alarm 2 common PC6 PE8 Damper 1 feedback in PE9 Damper 1 pot ground Ov PEIO Damper 2 pot supply PE11 Damper 2 feedback in PE 12 Damper 2 pot ground Ov PE13 Aux modula
6. Air pressure switch still made No fuel selected Burner not selected High control limit exceeded Unit in commission ratio mode Burner off via serial comms Hold FAULT MUTE key when faults clear Wait for burner fan to stop Check EK 1 oil input and EK2 gas input Check EK11 burner select input Check EK18 and wait for press temp to drop Press NEXT to advance to next setpoint Turn burner on using ComFire software Drive positioning fault occurs before drives move to purge Stored close positions do not match actual close positions Check feedback potentiometers and servo motor micro switches Reset close positions using commission ratio Drive positioning fault occurs when drives reach purge Pilot main 1 and main 2 valves will not open Ignition transformer does not energies Drives stuck at ignition and burner has not fired Stored purge positions do not match actual purge positions No feed on BURNER SEL No feed on IGN COM Drives cannot reach ignition pos Valve proving in progress Check feedback potentiometers and servo motor micro switches Reset purge positions using commission ratio Check terminal PB7 Check terminal PB6 Check servo motor micro switches and linkages Wait for proving sequence to finish Drives stuck at ignition and burner has fired Ignition time has not elapsed Wait for ignition time to elapse Reduce ignition time option parameter
7. Description Commission ratio mode is used for entering a nevv 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 adiust ratio mode must be used after all the required set points have been entered Entering commission ratio mode RUN MODE BURNER OFF 4 SUPPLIER PASSCODE To enter commission ratio mode turn the burner off Once the burner has completely shut down press the key labelled COM and obtain the supplier passcode value using the UP DOWN keys Press the key labelled COM ENTER If the entered passcode was correct servo motorservo motor positions will be seen on display COM will be flashing in addition to P00 This represents the closed position setpoint Using commission ratio mode CAUTION Use extreme care while commissioning the system While operating in commis sioning mode the safety of the system is the sole responsibility of the commissioning engineer 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 that a hazardous condition cannot occur and to allow the data to be stored in the controller
8. FLOW or NO FLOW for either airflow sensor are not responding correctly Subset faulty input 1 512 A forced lockout has occurred due to the removal of the high level on auxiliary input configured to provide this function when the unit is firing on gas A forced lockout has occurred due to the removal of the high level on auxiliary input configured to provide this function when the unit is firing on oil A forced lockout has occurred due to the removal of the high level on auxiliary input configured to provide this function when the unit is modulating on gas The safety shutdown relay is not responding correctly Subset required state 0 off 1 on The main gas valve 1 relay is not responding correctly Subset required state 0 off 1 on The main gas valve 2 relay is not responding correctly Subset required state 0 off 1 on The pilot valve relay is not responding correctly Subset required state 0 off 1 on The vent valve relay is not responding correctly Subset required state 0 off 1 on The ignition transformer relay is not responding correctly Subset required state 0 off 1 on The oil valve relay is not responding correctly Subset required state 0 off 1 on The auxiliary relay is not responding correctly Subset required state 0 off 1 on 53 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000
9. Motor to the Air Damper or Fuel Valve being controlled The Servo Motor MUST provide permanent connection to the controlled element to provide safe reliable and repeatable operation FIGURE 4 NX04 Servo Motor 1 0 24mm p 4518 102mm 4 27 8 72mm Dimensions for clearance only refer to Servo Motor bulletin for exact dimensions FIGURE 5 NX20 Servo Motor 1 0 25mm 4 0 100mm 5 1 16 125mm Dimensions for clearance only refer to Servo Motor bulletin for exact dimensions 11 FIGURE 6 12 NX50 Servo Motor 1 0 25mm B 5 0 124mm gt 5 1 16 128mm gt Dimensions for clearance only refer to Servo Motor bulletin for exact dimensions Optional Servo Motor Requirements Should the Servo Motors not be supplied by Fireye the following guidelines should be followed when selecting suitable motors All servo motors must be of the same operating voltage not exceeding 250V rms high voltage ver sion 50V rms low voltage version All motors must be AC 50 or 60Hz The servo motor current must not exceed 150mA rms high voltage version 750mA rms low volt age version If the motor voltage is lower than the supply voltage then a suitable power supply such as a trans former must b
10. To adjust the position of a servo motor use the scroll keys to point to the servo motor to be adjusted and then use the UP DOWN keys to adjust its position Depending on the profile selected fuel 1 servo motor or fuel 2 servo motor may not be available Each setpoint in the profile is referred to with a letter and number refer to the table below COMMENTS Close This defines the positions the servo motors will move to when the burner is off and must be set to the lowest posi tion each servo motor can reach Purge This defines the positions the servo motor will move to when the burner is purging and must be set to the highest position each servo motor can reach Burner select input must be on for PO1 and above Ignition Position during ignition May be outside the normal firing range P03 Low Fire Low fire setpoint PXX High Fire High fire setpoint which is the last setpoint entered max P23 34 The procedure for entering or modifying a profile is as follows Enter commission ratio mode see page 34 PO 0 close is displayed 2 If the close setpoint has been entered before and no change is required press AUTO MAN NEXT Otherwise move each servo motor to its lowest position and press COM ENTER 1 purge is displayed if the burner select input is placed on 3 Select the burner and the required profile on The servo motors will automatically move to their highest positions and stop If the purge se
11. amp off oil amp gas select fault mute auxiliary 1 to 5 Type Maximum Current Burner Select Type Maximum Current Pressure temperature Input 0 5V Maximum Current Maximum Voltage Accuracy 4 20mA Maximum Current Burden Resistor Accuracy Communications Interface Pulsed digital OV for off 5V for on Output for these digital contacts must be taken from correct supply terminal as described in the manual 250 mA approximately supplied from unit Digital OV for off 90 264VAC for on Also provides feed for pilot main 1 and main 2 Supplying circuit must be able to provide sufficient current for the pilot main valve 1 and main valve 2 simultaneously Less than 2 mA 50V absolute maximum 1 of full scale 50 mA absolute maximum 220R nominal 1 2 of full scale 2 wire RS485 plus ground with termination resistor selected using a link See NX5701 serial communications protocol manual for details External Display Interface Interface Fireye specific NX1020 Gas Pressure Sensor Supply Voltage Supply Current Ambient Temperature Range Protection Category Dimensions Pipe Thread Mounting Dimensions Weight Working Pressure Burst Pressure Accuracy Signal 24Vdc 10 Approximately 10mA 32 160 F 0 to 70 C NEMA3 IP44 1 3 4 44mm dia x 3 3 8 85mm long incl connector 1 2 NPT or B S P 1 1b 450g NX1025 0 58 PSI 0 4 Bars NX
12. number will be displayed as a code by the 7 green lamps on the control unit Refer to Fault Listing to determine Fault Code If all faults which caused a safety shutdown have cleared hold down the FAULT MUTE reset key for approximately three seconds to remove the faults and restart the burner The function of the FAULT MUTE reset key may also be achieved using the FAULT MUTE reset input Non Volatile Lockout If power is removed from the unit while a fault is still present the fault will be stored in non volatile memory When power is restored to the unit the fault number will still be present and it will be nec essary to remove the fault before restarting the burner Fault Subsets As an aid to fault finding most faults also have a fault subset which gives additional information about the type of fault or what the burner was doing when the fault occurred these are only available using the commissioning display or via Comfire Where applicable the subsets are given in the fault listing To view a fault subset press the engineer s key 51 Fault Listing LEDON O LED OFF LED F 2 9 9000000 mM 00060000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 52 Fuel servo motor incor rect position Fuel 2 incorrect position Air damper 1 incorrect position Air damper 2 incorrect position Fuel 1 servo moto
13. 1 8 155 2mm W x 11 1 16 280mm H Control unit 3 0 78mm W x 9 0 225mm H x 5 7 8 148mm D 5 7 8 148 mm tall installed in vviring base 6 6 lbs 3 0kg including wiring base 2 line 20 character dot matrix vacuum fluorescent AC up down with feedback potentiometer 3 Channel 2 Fuel 1 Air 4 Channel 2 Fuel 2 Air 2 4 Max Number of Setpoints Per Profile 24 including close purge and ignition Positioning Accuracy Response Time to Positioning Error Maximum Motor Current Maximum Motor Voltage Motor Speed Range Potentiometer Feedback Voltage Potentiometer Resistance Range Relay Outputs Alarms Type Maximum Current Maximum Voltage 0 1 15s for 1 0 1s for 5 0 150mA rms 250VAC rms 10s 90 to 60s 90 5Vdc for potentiometer with full range travel 15Vdc for 340 potentiometer with 90 travel selected using a link 1 to 5K ohms 5V 3 to 15K ohms 15V On off relay de energize for off 2A rms pilot duty 4A rms power factor gt 0 6 250VAC rms Ignition Type Maximum Current Maximum voltage On off relay de energize for off 1 9A rms ignition load 4Arms power factor gt 0 6 250VAC rms Burner motor vent main and pilot valve outputs Type Maximum current Maximum voltage Digital Inputs On off relay de energize for off 2A rms pilot duty 4A rms power factor gt 0 6 250VAC rms Pri Air on amp off Sec air on
14. 4 1 59 Commissioning Problem PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Cannot get past PO Unit in safety shutdown Air pressure switch still made No fuel selected Burner not selected High control limit exceeded Unit in commission ratio mode Burner off via serial comms Hold FAULT MUTE key when faults clear Wait for burner fan to stop Check EK1 oil input and EK2 gas input Check EK11 burner select input Check EK18 and wait for press temp to drop Press NEXT to advance to next setpoint Turn burner on using ComFire software Px or Ax display flashes constantly and servo motor positions cannot be altered Drives moving to position Valve proving test in progress Burner off in adjust ratio mode AO A1 A2 displayed Wait for drives to reach position Wait for valve proving test to finish Fire burner to alter points in adj ratio mode Use commission ratio mode to alter these Px or Ax display does not flash and servo motor positions cannot be altered Incorrect servo motor selected No feed on SERVO MOTORor COM servo motor microswitch open Use the top quadrant keys to select a servo motor Check for feed on terminal PA1 Adjust servo motor microswitch Servo motors appear to move too quickly 15V potentiometer supply incorrectly selected Change the link on the backplane board to select a 5V potentiometer supply Servo motor fee
15. Safety Valve Proving Sequence nneessesnesnnesnesnnnnnnnnennennnennensnennnrnnnnnnnnnennnnnnnnnen nennen sn 26 The DIS Play ainia 28 Adjustment srs ans sr dandi ss 30 Operation in Commissioning 32 Option Parameters cascada id ii 38 Derivation of Modulation 50 Faults and Fault Findin uen ea ae en a 51 Engineers Keita iria aran da 55 Tro bl amp Shooine u nennen nee 59 Commissionng ri lakk alas 62 Ordering Information zusam ui 65 Witing Base Layout sas 66 Technical Specifications General Supply Voltage Power Consumption Supply Frequency Ambient Temperature Range Maximum Connected Load Control Unit Protection Category Unit Dimensions Weight Type of Display Servo Motor Control Type Maximum Number of Servo Motors Maximum Number of Fuels Profiles 120 230 VAC Approx 20VA 50 60Hz 32 140 F 0 to 60 C 2000 VA NEMA 1 IP 00 The unit must be situated in a clean environment according to EN 6730 1 Indoor Unit must be mounted in a NEMA 12 IP52 rated enclosure Outdoor Unit must be mounted in a NEMA 4 IP54 rated enclosure Wiring Base UL listed 6 7 32 158mm W x 13 0 330mm H Wiring Base UL Recognized 6
16. a Fault Occurs Description 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 Each fault number is prefixed on the commissioning display by a letter This letter describes the sta tus of the fault F This means that a fault has occurred and is still present The fault may be internal or external to the unit C This means that a fault did occur but has now cleared For example F60 Means fault 60 has occurred and still exists C73 Means fault or alarm limit 73 has occurred but has subsequently been rec tified This is known as a cleared fault When A Fault Occurs To cancel the alarm relay briefly press the FAULT MUTE reset key on the user display or if the commissioning display is connected press the RUN key A separate FAULT MUTE reset switch will be REQUIRED if no display is connected Using the NX550 display Use the Engineer s select key to view the FAULT NUMBER and look up the fault number s shown to discover why the fault occurred If all faults which caused a safety shutdown have cleared hold down the RUN key for approxi mately three seconds to remove the faults and re start the burner The function of the RUN key may also be achieved using the FAULT MUTE reset input Using the LED Display If a fault is present the red fault lamp will be illuminated and the fault
17. are moved to the ignition position for the selected profile The unit will wait for the gas valve proving sequence to finish if it is still in progress Pre lgnition Pilot Ignition Pilot Ignition Interval Once the fuel and air motors are at their ignition positions the ignition transformer output is energized and pre ignition time 13 is initiated Once t3 has elapsed the ignition transformer pilot valve outputs are energized and the first safety time 14 is initiated If oil is selected use timing in the start up sequence table for main valve 2 When the first safety time t4 has expired a flame must be detected or the unit will lockout the burner The ignition transformer output is turned off and interval time t5 is initiated Main Ignition Once the pilot interval time t5 has elapsed both main valve outputs for gas main oil valve output for oil is energized and the second safety time t6 is initiated Wait for Flame Established Moving to Low Fire Modulation When the second safety time t6 has expired the pilot valve output is turned off If permanent pilot is selected and the burner is firing on gas the pilot will remain open with main valve 2 Main interval time t7 is initiated When interval time t7 has elapsed the flame is considered established and the fuel and air motors are moved from their ignition positions to their low fire positions Once the fuel and air motors reach their low fire positions they are mo
18. less than the safety time configuration set by Option 4 0 the table time will be used 41 Option 4 5 Permanent gas pilot select 0 1 intermittent pilot This option parameter allows the selection of permanent pilot operation when the burner is firing on gas When firing on oil this operating parameter is ignored Non permanent pilot Interrupted pilot Permanent pilot operation when firing on gas Intermittent pilot Option 4 6 Pilot valve with without main valve selection 0 1 This option parameter allows the selection of pilot operation with or without the main gas valve 1 when firing gas When firing oil this parameter is ignored and the pilot valve always operates with out the main gas valve The option parameter should be set to suit the configuration of the gas train Pilot operates without the main gas valve when firing on gas Pilot operates with the main gas valve 1 when firing on gas Option 4 7 Limit Modulation This option parameter allows the burner to modulate from P04 setpoint to one setpoint below the maximum firing position 0 No modulation limit 1 Limit modulation used Option 5 1 and 5 2 Lead drive for gas and oil respectively 0 1 These option parameters set the lead drive for the gas and oil profiles 0 Lead drive is air damper 1 Lead drive is currently selected fuel Note The other drives do not lag behind the lead drive all drives move in step an
19. minimum input signal low fire maximum input signal high fire Measured value input PID control values displayed with no decimal place Measured value input PID control values displayed with 1 decimal place Measured value input PID control values displayed with 2 decimal places Option 8 1 Setpoint 2 zero value 0 999 00 0 99 9 0 00 9 99 When setpoint 2 is selected this is the measured value which is displayed when the minimum signal level OV or 4mA appears at the modulation input This parameter is not used when a track modula tion input type is selected Option 8 2 Setpoint 2 span value 0 999 00 0 99 9 0 00 9 99 45 46 When setpoint 2 is selected this is the measured value which is displayed when the maximum signal level 5V or 20mA appears at the pressure input This parameter is not used when a track modula tion input type is selected Option 8 3 Setpoint 2 control value 0 999 00 0 99 9 0 00 9 99 This is the control value which is used in the PID control loop for setpoint 2 When the unit is in auto mode the PID control loop will modulate the boiler to maintain the measured value at the same level as this parameter Option 8 4 Setpoint 2 proportional term 0 999 00 0 99 9 0 00 9 99 This is the width of the proportional band that is used by the PID control loop for setpoint 2 If the setpoint was 5 00 bar and this term was set to 1 00 th
20. only one slave to turn on or off Option 12 8 Sequencing OFF delay 1 15 minutes When the control is under sequence control this parameter determines the minimum amount of time between one slave coming OFF and the next slave coming OFF This parameter is not used on a two boiler system because there is only one slave to turn on or off Option 13 1 Sustained modulation time before OFF ON transistion This parameter is an optional time delay vvhich is applied vvhen the normal modulation limit for a slave to be activated is reached Once the time limits specified in option parameters 12 7 amp 12 8 have passed or always in the case of a two boiler sytem the modulation from the PID control is moni tored Providing the modulation stays above the ON threshold for greater than the time set by option 13 1the slave will come on Option 13 2 Sustained modulation time before ON OFF transistion This parameter is an optional time delay which is applied when the normal modulation limit for a slave to be de activated is reached Once the time limits specified in option parameters 12 7 amp 12 8 have passed or always in the case of a two boiler sytem the modulation from the PID control is monitored Providing the modulation stays below the OFF threshold for greater than the time set by option 13 2 the slave will go OFF Option 50 0 Erase enable 0 1 CAUTION If this value is displayed as a 2 the opt
21. shows the number of the pro file setpoint nearest to the last modulation position ENGINEER S KEY PARAMETER LIST NAME DESCRIPTION Flame Sensor Signal Value Signal value received from the flame sensor input For the IR input 0 Fully dark 999 Fully light For the UV ionisation probe input 0 100 Flame signal Signal gt 50 Flame detected Measured Gas Pressure mBar Measured pressure from gas pressure sensor sensor must be enabled and gas must be selected Valve Close Time test S Time for vvhich each half of the valve prove test vvill be conducted refer to Gas safety valve proving sequence for details This time counts down to zero during stages 2 and 4 of the valve prove test Gas Pressure Change P ast Maximum pressure drop rise allowed during the valve prove test refer toGas safety valve proving sequence for details Modulation Rate Current percentage modulation rate based on lead drive position where 0 Low fire or burner off 100 High fire Nearest Profile Setpoint The number of the profile setpoint which is nearest to the current lead drive position Drives Still Moving Represents which drives are currently at their setpoints where 0 All drives are at their setpoints and not moving NON ZERO One or more drives are not at their setpoints Potentiometer Supply Voltage V The measured potentiometer supply voltage Voltage Reference Error V The erro
22. that these inputs expect dynamic low voltage 0 5V signals and must be taken from the MAIN COMMON terminal provided Do not connect these inputs to Line Voltage PF2 Fault Mute input is not required if NX550 display is used Aux A to Aux E inputs These inputs can be used for safety related functions refer to Option Parameters 10 1 to 10 5 These inputs should be connected using multi strand overall shielded two conductor PVC insulated 22AWG 7 30 300V 80 C 7 0 2mm wire Wiring must comply with all applicable codes ordinances and regulations and where required must comply to NEC Class 1 Line Voltage wiring Note that these inputs expect dynamic low voltage 0 5V signals and must be connected between the relevant terminals provided Do not connect these inputs to Line Voltage Flow com output and flow no flow inputs These terminals should be connected to the FLOW COM appropriate terminals on the burner s air HOW d r pressure svvitch using multi strand overall shielded 3 core PVC insulated REN 22AWG 7 30 300V 80 C 7 0 2mm wire Wiring must comply with all applicable UP 4 5FLOWCOM PF5 AIR PRESSURE codes ordinances and regulations and VP 4 FLOW PF6 SWITCH 2 where required must comply to NEC Class 1 Line Voltage wiring The flow input PF9 should be energized when air pres sure is present If required a second air pressure switch may be connected using the separate terminals as requi
23. the gas safety valve proving sequence on stage 3 of the start up sequence If any step of the gas valve proving sequence fails the unit will perform a safety shutdown and lockout the burner 1 Open main valve 2 Main valve 2 or the vent valve is opened for the first safety time t4 or 3 seconds whichever is the smaller If main valve 2 or the vent valve does not open the unit will indicate a fault A check is made to ensure that the test section pressure is below 15 of nominal gas pressure 2 Pressure rise interval All valves are closed and the gas pressure is monitored for T onds During this time the test section pressure may not rise by more than P the unit will indicate a fault test SEC test Lf this occurs 3 Open main valve 1 Main valve 1 is opened for the first safety time t4 or 3 seconds which ever is the smaller If main valve 1 does not open the unit will indicate a fault 4 Pressure drop interval All valves are closed and after a pre set delay of 10 seconds the gas pressure is monitored for t seconds During this time the test section pressure may not drop by more than Pest If this occurs the unit will indicate a fault A check is also made to ensure that the test section pressure is between the low gas pressure limit and high pressure range of sensor 5 Valve prove finished The gas safety valves have been proved satisfactorily and the unit may proceed with ignition The unit remains in state 5
24. units to the IN position Final Checks Before applying power make the following checks The unit is set for the correct line supply voltage All other link positions are correct The fuse within the unit is intact and of the correct value All wiring and connections have been made according to the specifications detailed in this chapter FLAME SCANNERS 45UV3 1050 45UV5 1009 48PT2 9000 CAUTION The UV1 UV2 UVSA UV90 and 45UV3 ultra violet flame scanners are non self checking UV systems and should be applied only to burners that cycle often e g a minimum of once per 12 hours in order for the safety checking circuit to be exercised If component checking is required during burner operation for constantly fired burners utilize the self checking ultra violet flame scanners 45UV5 or the infrared flame scanner 48PT2 which uses auto check amplification circuit SCANNER SELECTION FIREYE P N BULLETIN DESCRIPTION 48PT2 1003 48PT2 9003 48PT2 1007 48PT2 9007 SC 103 nfrared 1 2 straight mount 96 2 4m cable rated for Tray Cable Exposed Run TC ER Infrared 1 2 90 angle mount 96 2 4m cable rated for Tray Cable Exposed Run TC ER nfrared 1 2 straight mount 48 1 2m cable rated for Tray Cable Exposed Run TC ER nfrared 1 2 90 angle mount 48 1 2m cable rated for Tray Cable Exposed Run TC ER UV1A3 UV1A6 UV8A UV2 45UV3 1050 UV 1 2 straight 36 0 9m cab
25. until the burner is switched off The gas pressure high and low limits are checked for burner status between 11 and 16 VALVE PROVE TEST SEQUENCE A Check all B Open main C Pressure rise D Open main E Pressure F Valve prove valves closed valve 2 interval Valve 1 drop interval test finished Main valve 1 Main valve 2 Vent valve Gas pressure sensor EM Energized high Ignore MIA Energized if vent valve selected BE Energized if vent valve not selected For the proving sequence Test 15 given by the following formula Trest 3600 V Pg Prest P atm P test Q Where V Volume of test section l cu ft P Measured gas pressure above atm mBar psi Prest Max test pressure drop rise mBar psi P Q Maximum permitted leakage rate Veu ft hr atm Atmospheric pressure 1013mBar The unit automatically calculates Pest and ties based on the entered gas pressure test volume and leakage rate During the calculation the unit chooses Pest to keep ties low and avoid lengthy pre purges The calculated values of Piest and ties may be seen on the engineers key see the engineer s key EK37 38 39 26 Modulation During stage 16 modulation the unit vvill position the fuel and air motors as programmed for the profile selected In auto modulation mode the system will modulate as necessary to either track the input or maintain the p
26. used to control the oil pump off unless firing on oil and burner status between 10 and 16 Table 1 Set up sequence 2 Auxiliary relay output used to control a steam atomizing valve off unless firing on oil and burner status between 6 and 16 Table 1 Set up sequence 3 Auxiliary relay output used to control a steam purge valve on firing on oil and burner status 17 or 18 4 Auxiliary relay output used to control boiler sequencing valve relay off unless the boiler is selected as sequencing slave in standby and the measured value is below setpoint 5 Output energized when flame signal is above on threshold off when below threshold Option 1 5 Reset hours run 0 1 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 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 1 6 servo motor Display 0 3 Angular degrees to 1 decimal place Angular degrees no decimal place Percentage to 1 decimal place Percentage no decimal place Option 2 0 Gas pressure select 0 2 If an NX1020 gas pressure sensor is connected to the system it is possible to select gas pressure monitoring and or gas valve proving using this option parameter 0 Gas pressure input not used The gas valve leak test is not per
27. was set to 1 00 then the proportional band would be from 4 00 to 5 00 bar A value of 0 means no proportional band Option 6 5 Setpoint 1 integral term 0 100 This is the integral term which is used in the PID control loop for setpoint 1 It may be set to any value from 0 to 100 where 0 means no integral term Option 6 6 Setpoint 1 derivative term 0 100 This is the derivative term which is used in the PID control loop for setpoint 1 It may be set to any value from 0 to 100 where 0 means no derivative term Option 6 7 Setpoint 1 remote zero value 0 999 VVhen setpoint 1 is selected and the remote setpoint function is enabled see Option 5 8 this is the PID control value displayed vvhen a 4mA signal is present on the auxiliary modulation input See Derivation of Modulation Rate There is no such function for setpoint 2 This parameter is not used when a track modulation input type is selected Option 6 8 Setpoint 1 remote span value 0 999 VVhen setpoint 1 is selected and the remote setpoint function is enabled see option parameter 05 8 this is the PID control value displayed vvhen a 20mA signal is present on auxiliary modulation input See Derivation of Modulation Rate There is no such function for setpoint 2 This parameter is not used when a track modulation input type is selected Option 7 0 Setpoint 1 control limit type 0 2 This option parameter defines the control limit type for setpo
28. 1030 0 375 PSI 0 20 Bars 15psi lbar 1 29 of span 1 2 of value 0 5 VDC NX1025 and NX1030 Steam Pressure Sensor Supply Voltage Supply Current Ambient Temperature Range Protection Category Dimensions Pipe Thread Mounting Dimensions Weight Working Pressure Burst Pressure Accuracy NX1040 Boiler Temperature Sensor Supply Voltage Supply Current Ambient Temperature Range Protection Category Probe Dimensions Body Dimensions Weight Working Temperature Range Maximum Temperature Accuracy Working Temperature Signal Insertion Well 24Vdc 10 Approximately 10mA 32 160 F 0 to 70 C NEMA3 TP44 1 3 4 44mm dia x 3 3 8 85mm long incl connector 1 2 NPT or B S P 1 1b 450g NX1025 0 58psi 0 4 bar NX1030 0 375psi 0 20 bar 1200psi 80bar 1 2 of span 1 2 of value 24Vdc 10 Approximately 10mA 32 160 F 0 to 70 C NEMA3 IP44 1 4 6mm dia x 7 7 8 200mm long 2 5 8 66mm dia x 3 0 75mm long 1 2 1b 200g 0 to 350 C 32 662 F 842 F 450 C Sensor element 0 5 of span Sensor circuit 1 0 of span 0 8 of value 32 300 F 0 150 C 0 5 VDC Not included Approvals UL 372 Primary Safety Controls for Gas and Oil Fired Appliances Classification in accordance with EN298 F T L L J B Tested in accordance with the Gas Appliance Directive GAD 90 396 EEC encompassing the following standa
29. 62 COMMISSIONING SHEET Profile 1 Fuel 1 Air 1 Air 2 Profile 2 Fuel 1 Air 1 Air 2 Close PO Close PO Purge P1 Purge P1 Ignition P2 Ignition P2 Low Fire P3 Lovv Fire P3 P4 P4 P5 P5 P6 P6 P7 P7 P8 P8 P9 P9 P10 P10 P11 P11 P12 P12 P13 P13 P14 P14 P15 P15 P16 P16 P17 P17 P18 P18 P19 P19 P20 P20 P21 P21 P22 P22 P23 P23 63 COMMISSIONING SHEET Profile 1 Fuel 2 Air 1 Air 2 Profile 2 Fuel 2 Air 1 Air 2 Close PO Close PO Purge P1 Purge P1 Ignition P2 Ignition P2 Low Fire P3 Low Fire P3 P4 P4 P5 P5 P6 P6 P7 P7 P8 P8 P9 P9 P10 P10 P11 P11 P12 P12 P13 P13 P14 P14 P15 P15 P16 P16 P17 P17 P18 P18 P19 P19 P20 P20 P21 P21 P22 P22 P23 P23 64 ORDERING INFORMATION Main Components Part Number Description NX3100 UL ULC approved Controller 3 channel for up to 3 independent servo motors 2 fuel 1 air Selectable purge PTFI and MTFI timings NX4100 UL approved Controller 4 channel for up to 4 independent servo motors 2 fuel 2 air Selectable purge PTFI and MTFI timings NX1386 1 NX1466 1 Closed wiring base surface mounting UL listed links and fuse set for 120V Open wiring base cabinet mounting UL
30. N OF MODULATION RATE 6 4 6 5 6 6 7 X Switch by 6 0 10 1 10 2 COMMS LOWEST SETPOINT PRIORITY Measured LIMITS Modulation SELECT LOWEST PRIORITY lf3 3 1 amp PC19 is 4 20mA an HIGHEST PRIORITY Selection of Setpoint 1 Switch by 8 0 8 0 0 8 0 1 8 0 2 3 4 8 4 8 5 8 6 9 X f58 2 8 Boiler PC19 is 4 Sequencing 20mA amp Measured LIMITS Modulation Value LOWEST PRIORITY Serial Comm k Low Fire Hold amp e gt PRIORITY Setpoint 2 Warning Limits HIGHEST Selection of Setpoint 2 Manual HIGHEST Mode PRIORITY For a selection box e g MOD RATE SELECTION the input which is valid active with the highest priority shown nearest the bottom will be MOD RATE mapped to the output SELECTION For example a low fire hold signal will override a modulation com mand from serial communications however if the unit is in manual mode nothing will override the current modulation setting ACTUAL MODULATION RATE FIRED 50 FAULTS AND FAULT FINDING The Fault Display The unit carries out a number of internal and external checks during operation If a fault is found a fault number is used to identify the type of problem A list of fault numbers may be found later in this section Depending on the type of fault the unit may perform a safety shutdown of the burner and activate the alarm relay For details of how to restart the burner after a fault has occurred refer to When
31. NG 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 replace ment or repair as above provided In no event shall Fireye be liable for consequential or special dam ages of any nature that may arise in connection with such product or part FIREYE NEX 1001 3 Manchester Road JUNE 27 2013 Derry New Hampshire 03038 USA Supersedes April 3 2013 www Fireye com
32. Option 9 5 Setpoint 2 warming limit 0 999 00 0 99 9 0 00 9 99 If the boiler s measured value is below the value of this parameter and the unit is in auto or sequenc ing mode the burner will be held at low fire Option 9 6 Setpoint 2 warming time 0 999 If the boiler s measured value remains below the warming limit set in option 09 5 for longer than the warming time set here in minutes the boiler will be allowed to modulate normally Options 10 0 to 10 9 Auxiliary input functions Option parameters 10 1 to 10 9 determine the functions of the 10 auxiliary inputs Please note only auxiliary inputs A to E may be set and used for safety critical functions 14 to 20 Refer to Aux A to E inputs in wiring section for terminal designations If more than one input is selected to have the same function the lower number input is used Refer to following page for details Option Parameter nput Channel Default Function 10 0 PF1 PF2 Fault mute 10 1 PF11 PF12 None must be selected 10 2 PF13 PF14 None must be selected 10 3 PF15 PF16 None must be selected 10 4 PFT7 PF18 None must be selected 10 5 PF19 PF20 None must be selected 10 6 10 7 10 8 10 9 PF1 PF3 Gas select PF1 PF4 Oil select PF5 PF6 Air pressure switch 2 FLOW PF5 PF7 Air pressure switch 2 NO FLOW row D gt Auxiliary Input Switch Functions Auto manual selection A high lev
33. a hazardous situation to occur 38 Option Parameter List Note If an option parameter is marked with it is not possible to adjust its value using the site passcode The option parameters marked with can only be adjusted in the commissioning mode after entering the supplier passcode If using the supplier passcode and it is still not possible to adjust the value of an option parameter the burner must be turned off first Option 0 1 Site passcode 0 999 154 is the default site passcode This is a three digit passcode which will allow the site engineer or end user to enter option set mode and adjust a limited range of option parameters those not marked with in this section Options 0 5 and 0 6 Serial communications passcodes 0 999 These passcodes enable boiler sequence control serial data communications or both For more details on how to enable these features contact the equipment supplier and have the 6 digit CPU serial number ready this may be read using the engineer s key see Engineer s Key section for details Note that serial data communications is always available when the unit is in commission ratio mode regardless of the passcode entered Option 1 1 Power supply frequency 50 60 The unit must be configured for the correct power supply frequency The setting is either 50 or 60Hz Option 1 2 Serial communications unit address 0 15 If the unit is to be connected to other equipme
34. ct may be involved Wiring must comply with all applicable codes ordinances and regulations Wiring where required must comply with NEC Class 1 Line Voltage wiring Loads connected to the Controller must not exceed those listed in the specifications as shown in this manual All external controls connected to this unit must be listed or recognized by authorities who have jurisdiction for the specific purpose for which they are used Maximum connected load must not exceed 2000VA The controller wiring base MUST be mounted within a burner cabinet or similar enclosure and MUST be earthed to the overall enclosure to ensure safe and reliable operation The clamping bars on the control unit perform only an earth function and do not provide strain relief the signal cable shields only connect at the clamping bar Secure all cables carried in conduit at both ends using a suitable anchorage method in the cabinet CAUTION HAZARDOUS VOLTAGES MUST BE ISOLATED BEFORE SERVICE WORK IS CARRIED OUT Use multiple conductor braid shielded cable similar to Belden 8735 for 3 conductor application or Belden 9939 3 conductor 9940 4 conductor or 9942 6 conductor For UL approval all single conductor wiring should be TEW AWM or MTW within the cabinet Conductors to be pulled through conduit should be THHN or TFFN The maximum wire size that the wiring base will accept is a single 16 AWG Should multiple conductors be required on a single ter
35. d stay in ratio during modulation Instead the lead drive is used to calculate the current modulation rate and for drive position checking For this reason the lead drive position should not be the same for any two profile setpoints If this is the case the lead drive should be changed from fuel to air or vice versa Choose the servo motor that has the furthest travel Do not choose a servo motor with a flat curve Option 5 3 Bumpless transfer operation 0 2 This option parameter determines how the modulation rate is affected when power to the unit is interrupted or the modulation mode is changed The options are as follows 0 If the burner is fired up in MANUAL mode the drives remain at low fire until modulated manually If the modulation mode is changed from AUTO to MANUAL while the burner is firing the drives remain at their current positions 1 If the burner is fired up in MANUAL mode the drives are modulated to the last positions used in MANUAL mode If the modulation mode is changed from AUTO to MANUAL while the burner is firing the drives are modulated to the last positions used in MANUAL mode 2 The unit powers up in the last selected modulation mode If the burner is fired up in MANUAL mode or the modulation mode is changed from AUTO to MAN UAL while the burner is firing the drives are modulated to the positions used last time in MANUAL mode Option 5 4 Modulation speed 25 100 This op
36. dback will only go up to approx 35 5V potentiometer supply incorrectly selected Change the link on the backplane board to select a 15V potentiometer supply Option parameter not available Another option parameter must be set first Set option parameter usually XX 0 to a non zero value to enable other params in group Option parameter not adjustable Wrong passcode entered or burner firing Enter the supplier passcode and or turn the burner off before changing the value Not possible to enter commission ratio mode Not possible to enter adjust ratio mode Supplier passcode incorrect Burner firing Supplier passcode or adjust ratio passcode incorrect Enter correct passcode Turn burner off Enter supplier passcode with the burner on OR adjust ratio passcode with the burner off Gas Valve Proving Problem PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Proving sequence takes a long time Nominal gas pressure test volume or leakage rate incorrect Check option parameters 02 3 02 6 and 02 7 Expected time shown on EK38 Main valve 2 does not open Vent valve has been selected Check option parameter 02 8 Vent valve does not open Vent valve not selected Check option parameter 02 8 Main valve 1 and or main valve 2 do not open Valve proving not selected No feed on BURNER SEL Check option parameter 02 0 Check for feed on
37. dulated according to the demand placed on the burner Move to Post Purge If the fuel selection is changed or the burner on signal is removed the main valve outputs are turned off The fuel motor is moved to Its closed position the air motor is moved to its purge position and the post purge time is initiated 24 Post Purge When the post purge time has elapsed the burner motor is turned off and the unit returns to stage 1 to wait for another start up Ey HALAWVYVd NOlLdO Yad LAS AONANOAS LSAL JAOHd 3 448 3 0371 3 3 SNI IG 1531 3408d 3ATVA au nd a 25 J WJOJSULI uoylubi 10 0 UR Y INEA JU A SALA 1014 INEA UEN H INEA UEN 102190 ewel4 s youmg MO Aly Joajas Jaulng pe biq be ba bi ebind ail qeys enejul ens suon SNBA hing 4sod l Pr A awe vonu uo s d 4804 N BA de a nd 5 804 0 NPOA 10 10 ule lu i l n f n 10 H SNA usado saung 8 SMN 91 41 YEM er JOlld PIOH y e emo LE vl el 9 5 u nb dn 31838 1491 GAS SAFETY VALVE PROVING SEQUENCE If the gas valve proving is enabled refer to section option select 2 0 and a gas profile is selected the unit will begin
38. e low oil pressure alarm Forced Shutdown Oil only This function is only active when firing on oil A high level on the input switch closed prevents the unit from going into a controlled safety shutdown condition burner lockout If the high level is removed the display will show LIMIT 45 and the limit relay will operate This is the function required by the low oil temperature alarm Forced Lockout Gas only This function is only active when firing on gas A high level on the input switch closed prevents the unit from going into safety shutdown condition burner lockout If the high level is removed the display will show F22 and the fault relay will operate This is the func tion required by the low gas pressure alarm Forced Lockout Gas during modulation only This function is only active when firing on gas and after the unit moves away from the ignition A high level on the input switch closed prevents the unit from going into safety shutdown condition burner lockout If the high level is removed the display will show F24 and the fault relay will operate This is the function required by the high gas pressure alarm Fan Interlock This function is a normally open contact or switch that closes after the blower output PB12 is energized Fuel Pump Interlock This function is only active when firing on oil This function is a normally open contact or switch that closes after the auxil iary relay output PB14 is e
39. e provided The motor supply to the Controller must be protected with a suitable fuse for the motors being used to ensure that damage to the control unit does not occur the absolute maximum fuse value is 4A The servo motor time for 90 movement must not be less than 10 seconds or more than 60 seconds All servo motors must have internal limit switches fitted which are adjusted to prevent excessive rotation All servo motors must be able to drive the load imposed on them All servo motors must have suitable protection for the burner environment for example NEMA4 1P65 for applications exposed to the weather If in any doubt about a particular servo motor s suitability seek confirmation from your equipment supplier who have a list of suitable units Potentiometer requirements All servo motor potentiometers should be good quality plastic film types with high resolution Depending on the supply voltage a minimum resistance is allowed for the feedback potentiometers to prevent excessive current consumption See page 21 Option Link Selection Pot Supp for details The potentiometer must be securely attached to the output shaft of the gearbox in such a way as to give accurate indication of the shaft position under all conditions and at all times Wiring CAUTION Disconnect the power supply before beginning installation to prevent electrical shock equipment and or control damage More than one power supply disconne
40. ed must comply to NEC Class 1 Line Voltage wiring 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 in the same conduit AUX MOD SUPPLY PE 13 CABLE CLAMP UV Flame Sensor In the case of a non self checking scanner UVIA UV2 UVSA 45UV3 connect the scanner leads to terminals PB1 and PB2 Refer to bulletin SC 102 for more information For a self checking scanner 45UV5 1007 1008 1009 connect the signal leads red to terminals PB1 and PB2 connect the shutter leads black to the Hot and Neutral of the main power supply ter minals PB5 and PB4 Refer to bulletin SC 101 for extended wire run recommendations and wire type UV SENSOR 45UV5 1007 1008 1009 SHUTTER BLACK L1 PB5 L2 PB4 UV TUBE H ON WIRING RED PB1 PB2 __ BASE NX1466 Mount the UV sensor in such and way that an ignition spark will not simulate the presence of a flame IR Flame Sensor Install and wire the 48PT2 IR scanner according to the instructions supplied with the scanner in Bulletin SC103 IR SENSOR RS485 interface The RS485 cabling must be overall shielded 3 conductor PVC insulated 22AVVG 7 30 300V 80 C 7 0 2mm wire Terminate the screen shield at one unit only using the cable clamp provided For details on connecting NX Series integrated burner controllers and a PC onto the comm
41. efully and ensure you fully understand the product requirements Failure to follow them could damage the product or cause a hazardous condi tion Check the ratings given in these instructions to ensure the product is suitable for your application After installation is complete check the product operation is as described in these instructions FIGURE 1 Mounting the Control Unit 6 7 32 157 6mm 5 7 8 148mm 6 1 8 155 2mm 5 7 8 148mm 31 16 77 5mm F k LISTED VERS RECOGNIZED COMPONENT NOTE INCHES FOR CLEARANCE PURPOSES USE MM FOR PANEL LAYOUT FIGURE 2 The control unit is designed to be mounted inside the burner control cabinet The cabinet should have a minimum protection level of NEMA 12 IP52 for indoor use or NEMA4 IP54 for outdoor use The control unit should be mounted so that
42. el on the input forces the unit into manual modulation mode Manual up A high level on this input will force the unit to modulate up if manual is selected via one of the other auxiliary inputs Manual down A high level on this input will force the unit to modulate down if manual is selected via one of the other auxiliary inputs Setpoint select The level of the input determines whether setpoint 1 or setpoint 2 is used A low level selects setpoint 1 Refer to option parame ters 6 0 and 8 0 Release to ignite Once the system has purged the drives will move to their ignition positions A high level on the input will start the ignition sequence Release to modulate Once the burner has ignited and the ignition time has elapsed the drives will move to their low fire positions After the low fire hold time has elapsed a high level on the input will permit the drives to modulate Lead boiler select If boiler sequencing is enabled a high level on the input selects the unit as the lead boiler Profile select The input will select between firing profile 1 or 2 for the selected fuel Purge Hold A closed contact will hold the purge Oil valve proof of closure A high level on this input confirms the closure of the main oil valve This function may only be used in circumstances where the relevant approvals for the specific application allows a proof of closure switch to be used Gas valve proof of closure A high level on this
43. ely noisy Subset expected frequency 50 60Hz An attempt has been made to select a gas profile when an oil profile has been already commissioned or vice versa Choose a different profile selection eErase the existing profile Subset selected fuel code The boiler s measured value has exceeded the pressure temperature safety limit or the Fireye pressure temperature sensor is not responding correctly Subset 1 sensor feedback lt 1V 2 sensor feedback gt 5V 3 sensor failed during test 4 safety limit exceeded The burner has been forced into a shutdown situation from the digital inputs operates alarm relay 2 The burner has been forced into a limit alarm situation from the digital inputs operates alarm relay 2 A digital input is faulty Look for a short between two inputs The flame sensor input is not responding correctly If the fault persists for 23 hours the burner will be shutdown A secondary fault has occurred with the main 1 main 2 pilot vent or safety shutdown relays If the fault persists for 23 hours the burner will shutdown Subset 1 safety shutdown 2 main 1 4 main 2 8 pilot 16 vent A fault has occurred with the program memory on the CPU board If the fault persists for 23 hours the burner will shutdown Contact supplier F49 000 0000 Secondary watchdog A fault has occurred with the CPU watchdog If the fault persists for 23 hours the burner will shutdown Co
44. en the proportional band would be from 4 00 to 5 00 bar A value of 0 means no proportional band Option 8 5 Setpoint 2 integral term 0 100 This is the integral term which is used in the PID control loop for setpoint 2 It may be set to any value from 0 to 100 where 0 means no integral term Option 8 6 Setpoint 2 derivative term 0 100 This is the derivative term which is used in the PID control loop for setpoint 2 It may be set to any value from 0 to 100 where 0 means no derivative term Option 9 0 Setpoint 2 control limit type 0 2 This option parameter defines the control limit type for setpoint 2 where 0 No limits 1 Absolute limit The values entered in option parameters 9 1 and 9 2 are the actual limit values 2 Deviation limit The values entered in option parameters 9 1 and 9 2 represent a deviation from the setpoint 1 control value This means that if the setpoint control value is changed the limits are auto matically changed correspondingly Option 9 1 Setpoint 2 low limit control value 0 999 00 0 99 9 0 00 9 99 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 9 2 Setpoint 2 high limit control value 0 999 00 0 99 9 0 00 9 99 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
45. ervo motor internal feedback potentiometer must be secured within the servo motor to ensure that there is no possibility that the potentiometer can become discon nected from the motor output shaft 30 For each servo motor it is necessary to adjust the potentiometer s position relative to its shaft in order to obtain the correct open and closed positions on the display To do this follow the procedure below 1 Move the valve to its fully closed position and adjust the potentiometer s position on the motor shaft so that approximately 2 to 3 is shown on the display 2 Move the valve to its fully open position and check that the display reads approximately 85 to 88 or the maximum angular opening required from the servo motor if this is less than 90 If the displayed position decreases as the valve is opened reverse the supply connections motor terminals 5 amp 7 to the feedback potentiometer If the displayed position range is incorrect check that the correct potentiometer supply voltage has been selected Control Direction It is necessary to ensure that each motor travels in the correct direction when moved using the UP DOWN keys on the keyboard To do this follow the procedure below Enter commission ratio mode refer to Commission Ratio Mode page 34 2 Check that when the DOWN key is pressed each motor moves its valve towards the closed posi tion If not reverse drive signals on motor terminals 2 amp 3
46. est volume 0 0 99 9 liters This must be set to the volume in liters of the test pipe section between the two safety valves including the volume in each valve on the test section side Refer to Valve Prove Test Sequence page 26 39 40 Option 2 7 Maximum permissible leakage rate 0 99 9 Ih 1 This is the maximum permissible leakage rate allowed during the valve leak test in liters per hour this value must be set according to the installation and local regulations Refer to Valve Prove Test Sequence page 26 Option 2 8 Vent valve select 0 2 This option parameter is used to select the operation of the vent valve No vent valve used Use main valve 2 to vent into the boiler when using V P S Vent valve used output energized to open valve used for V P S Vent valve used output energized to close valve powered at sequence 5 Option 2 9 Fuel Valve Proof of Closure select 0 3 This option parameter is used to select the proof of closure function Use option 10 to map digital outputs Deselected no proof of closure function selected Gas main valve 2 checked Oil valve checked Both main gas valve 2 and oil valve checked Option 3 0 Flame detection device 0 2 Depending on the application one of three different flame detection options must be chosen IR detector Ultraviolet UV detector non self checking Ultraviolet UV detector w
47. f the gas pressure sensor input is enabled see section on Option Paramenters for details 0 100 display of flame signal values above 5 are taken as flame present A signal of 10 should be maintained for normal burner operation CONTROL LED INDICATORS G TT UP The control unit display is comprised of one red fault indicator and seven green operational indi cators During normal operation the red indicator is off and the seven green indicators shovv status informa tion see belovv If a fault occurs the red indicator is illuminated and the green indicators shovv the fault number see Fault Listing AUTO Flashed when the unit is in sequencing mode Illuminated when unit is in auto modulation mode STATUS Illuminated when boiler pressure temperature is below the low control limit and the burner is ready to fire PURGE Flashed when the servo motors are moving to pre purge Illuminated during the pre purge time IGNITION Flashed when the servo motors are moving to ignition Illuminated when the burner is modulating RUN Flashed when the servo motors are moving from ignition to low fire Illuminated when the burner is modulating FLAME Illuminated when a flame signal is detected AIR Illuminated when air pressure is detected by the air pressure switch FAULT INDICATOR Illuminated when a fault causes safety shutdown 29 SERVO MOTOR ADJUSTMENT Feedback Potentiometer A WARNING The s
48. fety valve proving sequence for details Selected Profile 0 No profile selected 1 Gas profile 1 2 Oil profile 1 3 Gas profile 2 4 Oil profile 2 Setpoints Entered The number of fuel air setpoints entered for the current profile where 0 No setpoints entered 1 Close setpoint only 2 Close and purge setpoints 3 Close purge and ignition 4 Close purge ignition and lovv fire 5 thru 24 etc Commission Status Current commissioning mode vvhere 0 Normal run mode 1 Adiust ratio mode 2 Commission ratio mode Commission Profile Commission Setpoint The expected commission ratio profile where 1 Gas profile 1 2 Oil profile 1 3 Gas profile 2 4 Oil profile 2 The current commission ratio setpoints 0 Closed setpoint 1 Purge setpoint 2 Ignition setpoint 3 Low fire setpoint 4 thru 24 profile setpoints Number of Commission Setpoints Modulation Mode The number of setpoints entered in the current commission ratio session 0 No setpoints entered 1 Close setpoint only 2 Close and purge setpoints 3 Close purge and ignition 4 thru 24 profile setpoints The current modulation mode 0 Auto mode 1 Manual from external limit 2 Manual from keyboard 3 Boiler sequencing control 4 Low fire hold Undefined 56 Shutdown profile setpoint When the unit performs a safety shutdown this
49. for five seconds to allow any gas in the test sec tion to be vented easily during the proving sequence The fuel motor is held in position until step 1 of the safety valve proving sequence open main valve 2 or vent valve is completed Prove Closed Posi tion If gas is selected the gas valve proving sequence begins The fuel and air motors are moved down until they stop The final positions are compared with the closed positions stored in memory Prove Air Pressure Prove Purge Positions Pre Purge The fuel and air motors are moved up towards the purge position the burner motor is started and air pres sure prove time t1 is initiated When the air pressure prove time t1 has elapsed the air pressure switch must give a pressure signal or the unit will lockout the burner If firing on oil and primary air is selected both primary and secondary air signals must change from no pressure status If firing on gas and primary air is selected the primary air signal must remain at no pressure status The fuel and air motors are moved up until they stop The unit measures the time taken for each motor to travel from the close to the purge position and the final measured positions are compared with the purge positions stored in memory The timed pre purge t2 is initiated The fuel motor is moved towards the closed position during this time Move to Ignition Positions When t2 has elapsed the fuel and the air motors
50. formed and the gas pressure limit values are ignored 1 1 NX1020 gas pressure sensor used The unit monitors the gas pressure including the gas pressure limits if a gas profile is selected but does not perform gas valve proving 2 NX1020 gas pressure sensor used The unit monitors the gas pressure including the gas pressure limits and per forms gas valve proving if a gas profile is selected Option 2 1 Gas pressure sensor zero 0 999 mBar This is the minimum gas pressure rating of the installed gas pressure sensor in mBar Option 2 2 Gas pressure sensor span 0 999 mBar This is the gas pressure above atmospheric measured by the sensor in mBar at its maximum out put range of sensor Option 2 3 Gas pressure nominal 0 999 mBar This is the nominal line pressure of the gas supply delivered to the burner in mBar Option 2 4 Gas pressure low limit 0 999 mBar This is the minimum gas pressure above atmospheric permitted by the unit before a gas pressure limit fault is given For safety reasons this value should not be set to more than 200mBar below the nominal gas pressure Option 2 5 Gas pressure high limit 0 999 mBar This is the maximum gas pressure above atmospheric permitted by the unit before a gas pressure limit fault is given Ensure the value is set within the capability of the sensor if being used for an S class application 250 mBar for NX1020 sensor Option 2 6 T
51. incorrect Measured value incorrect Incorrect potentiometer wiring Wrong sensor voltage Wrong sensor input type Incorrect sensor wiring Wrong zero or span Setpoint 1 or 2 incorrectly selected Check POT SUPP link refer to POT supply page 21 Check wiring to terminals PD11 17 Check SENS SUPP link see option link section Check SENS IN link see option link section Check wiring to terminals PE 20 23 Check option parameters 6 1 6 2 8 1 8 2 Check EK17 and select other setpoint Setpoint incorrect Setpoint 1 or 2 incorrectly selected Option params 6 3 8 3 incorrect Value updated via serial comms Check EK17 and select other setpoint Enter option set mode and change values Change setpoint using ComFire software Hours run shows Hours run keeps toggling Modulation rate is 0 No profile selected Hours run gt 999 hours Burner not modulating Select oil or gas profile 1st digits show thousands 2nd show units Wait for burner to finish start up sequence Burner status is flashing Unit in safety shutdown mode Burner status before shutdown displayed Gas pressure not shown Gas pressure incorrect Start up Problem PROBLEM Gas sensor not selected Wrong zero or span POSSIBLE CAUSE Select sensor using option parameter 02 0 Check option parameters 2 1 and 2 2 SUGGESTED ACTION Burner will not start Unit in safety shutdown
52. ing care not to damage the shield 1 Pull the sleeving apart to expose 3 8 10mm of the screen 2 Slide the exposed length of shield between the clamping bars 3 Refer to figure 7 FIGURE 7 gt NE 10mm EARTH connection Make the earth connection to the unit using the earth stud provided Ensure that a good electrical connection is made both between the control unit and the burner panel and between the burner panel and earth Where necessary scrape any paint away from connection points and use locking star washers to obtain a reliable electrical connection Always use the largest cross sectional area earth wire possible LINE HOT and NEUTRAL supply MAX 6A The LINE HOT L1 and NEUTRAL N L2 must NEUTRAL PB 4 NEUTRAL N be connected using multi strand single conductor SUPPLY PB 5 LINE HOT PVC insulated 16 18 20 AVVG 600V 90 C 16 02mm wire Wiring must comply with all applicable codes ordinances and regulations and where required must comply to NEC Class 1 Line Voltage wiring If a fuse greater than 4A is used each relay pump fan and vent output supplied via this ter minal MUST be separately fused at 4A maximum to protect the relay contacts from welding Burner fan output NEUTRAL The burner fan output must be connected to the external L motor contactor using multi strand single conductor Ba EN B CONTACTOR PVC insulated 16 18 20 AWG 600V 90 C 16 0 2mm wire Wiring mu
53. input confirms the closure of the main gas valve This function may only be used in circumstances where the relevant approvals for the specific application allows a proof of closure switch to be used Trim Enable A high level on this input will enable oxygen trim Spare Input is ignored Forced lockout A high level on the input switch closed prevents the unit from going into safety shutdown condition burner lockout If the high level is removed the display will show F17 and the fault relay will operate This is the function required by the extra low water alarm Forced shutdown A high level on the input switch closed prevents the unit from going into a controlled shutdown condition burner off If the high level is removed the display will show LIMIT 42 and the limit relay will operate This is the function required by the low water alarm Forced alarm A high level on the input switch closed prevents the unit from going into a limit condition If the high level on the input is removed the display will show L 43 and the limit relay will operate This is the function required by the high water alarm Forced Lockout Oil only This function is only active when firing on oil A high level on the input switch closed prevents the unit from going into safety shutdown condition burner lockout If the high level is removed the display will show F23 and the fault relay will operate This is the func tion required by th
54. input current drops below 3 0 mA the display will flash Lo If the input current rises above 21 mA the dis play will flash Hi This display parameter is not available if tracking modulation input is selected SETPOINT Indicates the required pressure or temperature of the boiler according to the zero and span values entered as option param eters If a tracking modulation input is selected this display parameter shows percentage modulation rate FAULT NUMBER If no faults are present this display parameter will not be available If the unit detects an internal or external fault this display will indicate the number of that fault see section on Faults and Fault Finding for details HOURS RUN Displays the hours run for the current profile selection If no profile is selected the display will show 28 This display parameter is used in commission ratio This display is used in adiust ratio mode They indicate the profile setpoint currently under adjustment or being displayed If the display is flashing the unit is waiting for an event to occur before the point may be altered VVhen the display stops flashing the point may be altered PROFILE SET is not available in run mode MODULATION This is the percentage modulation rate based on the position of the lead drive where 0 is low fire and 100 is high fire GAS PRESSURE FLAME SIGNAL Measured gas pressure in mBar This parameter is only available i
55. int 1 vvhere No limits Absolute limit The values entered in the option parameters 7 1 and 7 2 are the actual limit values Deviation limit The values entered in option parameters 7 1 and 7 2 represent a deviation from the setpoint 1 control value This means that if the setpoint control value is changed the limits are auto matically changed correspondingly Option 7 1 Setpoint 1 low limit control value 0 999 00 0 99 9 0 00 9 99 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 7 2 Setpoint 1 high limit control value 0 999 00 0 99 9 0 00 9 99 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 7 5 Setpoint 1 warming limit 0 999 00 0 99 9 0 00 9 99 If the boiler s measured value is below the value of this parameter and the unit is in auto or sequenc ing mode the burner will be held at low fire Option 7 6 Setpoint 1 warming time 0 999 If the boiler s measured value remains below the warming limit set in option 07 5 for longer than the warming time set here in minutes the boiler will be allowed to modulate normally Option 8 0 Setpoint 2 input type 0 4 The setpoint 2 input type must be selected as follows Setpoint 2 not available Track modulation input Where
56. ion parameter data has been up loaded into the unit ensure all option parameters are set to match the requirements of the burner it is connected to 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 it is connected to 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 unit will perform a safety shutdown preventing the burner from firing In order to erase information in memory for a specific profile selection this option must be set to 1 Once the unit has left setup mode this parameter will automatically be reset to 0 If this option parameter is set to 2 see caution message above Option 50 1 Erase command 0 5 When erase enable option 15 0 is set to 1 this option parameter determines which information will be erased when the unit leaves option set mode No erase Erase profile 1 gas oil Erase profile 2 gas oil Erase profile 1 gas oil Erase profile 2 gas oil 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 unit will be initialized to the same state as when it was shipped 49 FIGURE 10 DERIVATIO
57. iring must comply with all applicable codes ordinances and regulations Wiring where required must comply with NEC Class 1 Line Voltage wiring This input should be connected to the burner select switch and or external limit circuit using multi strand Hal PB7 single conductor PVC insulated 16 18 20 AVVG 600V 90 C 16 0 2mm vvire VViring must comply vvith all applicable codes ordinances and regulations and vvhere required must comply to NEC Class 1 Line Voltage wiring The device connected to this input must be capable of supplying the current required by the main and pilot valves and fused up to a maximum of 6A If a fuse greater than 4A is used each fuel valve output MUST be separately fused at 4A maximum to protect the relay contacts from welding 15 Oil Gas Fault Mute Reset Inputs These inputs if not required for the functions shovvn can be vvired in the same vvay and used for non safety related functions Refer to Option Parameters 10 0 10 6 and 10 7 WARNING The fault mute reset silence switch must be within sight and sound of the burner 16 These inputs should be connected using multi strand UP 1 2 3COM PFT overall shielded multi conductor PVC insulated 22 AVVG 7 30 300V 80 C 16 0 2mm wire Wiring must comply VEGAS PPS with all applicable codes ordinances and regulations and where required must comply to NEC Class 1 Line Volt age wiring Note
58. ith shutter device controlled by product relay self checking Option 3 1 False flame detection time This option parameter is only applicable to the UL only product NX3100 4100 False flame detection time lt 3 seconds False flame detection time lt 30 seconds Option 3 2 Flame failure response time This option parameter is only applicable to the UL only product NX3100 4100 0 Flame failure response time lt 1 second 0 left to retain compatibility with CE product 1 Flame failure response time lt 1 second 2 Flame failure response time lt 2 seconds 3 Flame failure response time lt 3 seconds Configuration 7 EP170 8 EP160 g s 10 Option 4 0 Safety time configuration 0 10 Determines which set of safety times are used This value must be set according to the application and local regulations Pilot Wait for Ignition Main Trial Flame Interval for Ignition 6 Established t5 t7 Prove Air Supervised Pre Pilot Trial Pressure Purge gnition for gnition tl t2 t3 t4 4 4 5 4 5 4 4 0 0 0 0 Note Times are shown in seconds For a full explanation of each safety time see Operation in run mode For response times to flame failure during operation see Option 3 2 Safety time configura tions similar to Flame Monitor timings are indicated by the Flame Monitor programmer model num ber in parenthesis Tf an oil profile is selected t4 will always be 5
59. ler sequencing is enabled to determine the switching points for the boiler Option 12 4 Lead boiler select 0 1 When the unit is under sequence control setting this option parameter to will force the unit to assert itself as the lead boiler If this option parameter is set to 1 AND OR an auxiliary input is high assuming the auxiliary input has been configured for lead boiler select see option parameters 10 1 and 10 2 the unit will assert itself as the lead boiler If two or more units have been set as lead sequencing is disabled Option 12 5 Standby low limit control value 0 999 00 0 99 9 0 00 9 99 If the unit is placed in standby mode by boiler sequence control the boiler s pressure is maintained between two limit values This option parameter determines the pressure at which the boiler will be turned on when in standby mode Option 12 6 Standby high limit control value 0 999 00 0 99 9 0 00 9 99 If the unit is placed in standby mode by boiler sequence control the boiler s pressure is maintained between two limit values This option parameter determines the pressure at which the boiler will be turned off when in standby mode Option 12 7 Sequencing ON delay 5 15 minutes When the unit is under sequence control this parameter determines the minimum amount of time between one slave coming ON and the next slave coming ON This parameter is not used on a two boiler system because there is
60. les rated for Tray Cable Exposed Run TC ER UV 1 2 straight 72 1 8m cables rated for Tray Cable Exposed Run TC ER UV 1 2 90 head 72 1 8m unshielded leads UV 3 8 straight 36 0 9m cables rated for Tray Cable Exposed Run TC ER UV 3 4 cast aluminum housing 8 2 4m cable 45UV5 1007 45UV5 1008 45UV5 1009 Self check UV 1 British thread mounts 230V 6 1 8m unshielded leads Self check UV 1 British thread mounts 120V 6 1 8m unshielded leads Self check UV 1 N P T threads 120V 6 1 8m unshielded leads 23 OPERATION IN RUN MODE STAGE NO Start up sequence VVhen a fuel selection is made and the burner select signal is given to start up the burner the control unit runs through the sequence described below If gas is the selected fuel and gas valve proving has been selected the unit also performs safety valve pressure proving in parallel with the start up sequence see option parameter 2 0 Gas Pressure Select STAGE NAME Safety Shutdown DESCRIPTION The burner is held in this state until all faults are removed Burner Off The burner is checked to make sure that it has switched off completely This includes main fuel safety valves closed no flame signal and a no air pressure signal Wait for Purge Open Fuel Valve Hold Fuel Valve The unit waits for a both burner select and a gas or oil select signal If gas valve proving is selected the fuel motor is moved up
61. lt Code Listing F41 for details Option 5 7 System modulation units 0 3 The system modulation units may be selected as shown below PSI pounds per square inch 43 Option 5 8 Auxiliary modulation input function 0 2 The auxiliary modulation input terminals PE 13 14 15 may be configured to perform a remote set point function See Derivation of Modulation rate for information on how this function is performed No function The input is ignored Remote setpoint The input determines the control value for the PID loop when setpoint 1 is selected providing the loop current is within the range of 3 5 21mA If the loop current is outside this range the unit reverts to using the setpoint 1 control value option parameter 6 3 Option parame ters 6 7 amp 6 8 give the zero and span for this input Remote tracking input The input determines the modulation rate providing the loop current is within the range of 3 5 21mA If the loop current is outside this range the unit reverts to using the normal modulation rate depending on current modulation mode This is different from using track modulation input option 6 0 0 or 8 0 1 because an out of range signal will cause those options to hold low fire This function will override both setpoints 1 and 2 4mA low fire 20mA high fire Option 6 0 Setpoint 1 input type 0 3 The setpoint 1 input type must be selected as f
62. metal housing This should be achieved as follows 1 Cut back approximately 4 100mm of overall insulation 19 20 Open the braided shield adjacent to the remaining insulation and pull all 6 cores through the opening Fold the shield back down the insulated cable Fit sleeving to the braid to insulate the earth cable formed by the braid Fit adhesive lined heatsink to cover the folded back screen and hold the earth sleeving Adjust the earth connection as required length must not exceed 4 100mm to reach either 4mm securing earthing studs and fit a suitable crimp ring terminal The shields of all cables must be connected at the main unit by cutting back the insulation where the cable passes them throughout the cable clamp to ensure a good earth connection is made OPTION LINK SECTION The NX1486 1366 Wiring Bases have 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 unit Line Supply Voltage LK1 4 The possible supply voltages are listed below together with the necessary fuse rating The correct fuse must be installed SUPPLY VOLTAGE LINKS REQUIRED FUSE RATING mA 110 LK1 and LK3 250 ANTI SURGE 230 LK2 and LK4 125 ANTI SURGE SENS IN and SENS SUPP boiler temp pressure sensor JP3 and JP5 If a boiler pressure temperature se
63. minal an interposing terminal strip will be required For multi conductor shielded requirements use multiple conductor braid shielded cable similar to Belden 8735 for 3 conductor application or Belden 9939 3 conductor 9940 4 conductor 9942 6 conductor For CE approval all cabling operating above 50V must be multi strand single core PVC insulated 16 0 2mm and should meet the requirements of LE C 227 or LE C 225 Do not use a green yellow conductor for any purpose other than earth To comply with EMC requirements wire the control unit using the specified cable sizes and shield connections Clamp all signal cable shields to earth using the clamping bars provided on the control unit Connect all cable shields to earth at the control unit end only with the exception of the cables that connect the display and pressure sensors The equipment described in this manual has been tested for compliance to the UL Standards and CE 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 local authority s requirements of the UL Stan dard and or CE Directives relevant to the particular installation 13 Using the cable clamp Clamping bars are provided on the control unit for termination of cable screens where necessary The cable should be prepared by cutting around the outer sleeve tak
64. nergized refer to option parameter 1 4 for timing Option 12 0 Boiler sequencing enable 0 1 47 48 This option parameter enables boiler sequencing control via serial communications inter face Sequence control disabled The unit operates in a stand alone mode Sequence control enabled The unit will modulate and sequence its boiler according to instructions received from the lead boiler If communication with the lead boiler is lost the unit operates in stand alone mode Option 12 1 Boiler priority 0 9 This option parameter determines the order in which the boiler will be fired when operating under sequence control After the lead boiler the next boiler to be fired is the boiler with the next highest priority The examples below show how the priorities are chosen for a ten boiler sequencing system e g 1 If the lead boiler priority is the sequence is LEAD 1 2 3 4 5 6 7 8 9 e g 2 If the lead boiler priority is 5 the sequence is LEAD 6 7 8 9 0 1 2 3 4 Option 12 2 Low fire burner power output 0 0 99 9MVV This option parameter must be set to the power output from the burner when operating at low fire It is used when boiler sequencing is enabled to determine the switching points for the boiler Option 12 3 High fire burner power output 0 0 99 9MW This option parameter must be set to the power output from the burner when operating at high fire It is used when boi
65. ng the option links for the correct voltage and input type Connect the cable shield to the controller with the use of the clamping bar In the case of the NX1020 NX1025 and NX1030 steam pressure sensor and NX 1040 temperature sensor connect the cable shield at both ends Make all connections at the sensor transmitter first Gas pressure sensor input The pressure temperature cabling must NX 1020 be overall shielded 4 conductor PVC SASFHESSIN PENZ PRESSURE insulated 22AVVG 7 30 300V 80 C GAS PRESS GND PE 18 SENSOR 7 0 2mm wire Wiring must comply GAS PRESS TEST PE 19 V ila vvith all applicable codes ordinances and regulations and where required CABLE CLAMP must comply to NEC Class 1 Line 17 18 Voltage wiring Since this cable may be run in conduit with high voltage wiring its voltage rat ing must exceed the maximum voltage carried by any other cable in the same conduit Connect the cable shield at both ends using the clamping bar at the controller end Make all connec tions at the sensor first Auxiliary modulation input The auxiliary modulation input LOOP POWERED cabling must be overall shielded 4 20mA SENSOR mulit conductor number of con ductors as required by the relevant AUX MOD IN PE 14 sensor PVC insulated 22AVVG 7 AUX MOD GND PE 15 D Fn seson 30 300V 80 C 7 0 2mm wire Wiring must comply with all appli cable codes ordinances and regula tions and where requir
66. nsor or modulation potentiometer is used these links must be set to suit the type of sensor For example JP3 5 20 SENSORS V V V 4 20 mA LOOP POVVER SENSOR 24V POT SUPP potentiometer supply voltage JP1 The Controller can either supply 5V or 15V DC to the IPI potentiometers and is selected with link JP1 15v 5v If the potentiometer moves over its entire 270 range for 90 of servo motor travel select a 5V supply If the potentiometer is a 340 type but only moves over 90 of its range for 90 of servo motor travel select a 15V supply MINIMUM MAXIMUM POTENTIOMETER TYPE SUPPLY VOLTAGE POTENTIOMETER POTENTIOMETER JP1 JUMPER Ohms Ohms NEXUS 340 with 90 TRAVEL 15V 3K 15K 15V 270 WITH FULL TRAVEL 5V 1K 5K 5V 21 22 RS485 TERM RS485 serial communications termination resistor Please note there are two RS485 connections to the unit one non iso JP6 IN OUT lated and one optional which is isolated The position of the termination link is important only if theRS485 7 IN OUT serial communications are to be used JP7 if the optional isolated RS485 output and JP6 is for the non isolated RS485 output The two units at the end of the communications bus should have this link set to the IN position All other units should have the link set to the OUT position If only two control modules are on the communications bus set the links on both
67. nt via the serial communications interface it must be given a unique address using this option parameter Option 1 3 Air damper 2 select 0 3 This option parameter is used to select an additional air damper 0 Deselected no second air damper 1 Second air damper selected as primary air for oil firing 2 Second air damper selected as flue gas recirculation for gas firing 3 Second air damper available for both fuels 4 Second damper stays open during purge for both fuel options If a second air damper is selected option 1 3 3 the air servo motor is available for both fuels air switch 2 is not required The second air servo motor is driver open and closed during purge to check the operation of the end switches and speed of the servo motors selected option 1 3 2 or option 1 3 3 Note Once the second air damper is selected the only way to deselect it is to erase all profiles and option parameters using parameter 15 0 and 15 1 If a second air damper is selected option 1 3 1 as the primary air Flow and No Flow will be checked on oil to equal the secondary air Flow and No Flow On gas the primary air Flow and No Flow will be checked to on if no primary air is present Option 1 4 Auxiliary Relay Function Select 0 4 The auxiliary relay output can be used to perform several different functions as set by this option parameter 0 Deselected auxiliary relay output not used 1 Auxiliary relay output
68. ntact supplier O LEDON Q LED OFF 54 THE ENGINEER S KEY The engineer s key is a hidden key under the Fireye logo on the display With the use of the engi neer s key it is possible to read the values of internal system variables and external input and output states It is also possible to see the values of fault subsets refer to Fault Listing for details in order to obtain more detailed information about a fault vvhich has occurred VVhen using the engineer s key it is not possible to change any parameters Therefore it is not possi ble to affect the operation of the burner ENGINEER S KEY PARAMETER LIST NAME DESCRIPTION Digital Input 3 oil select Digital Input 2 gas select Safety Input C Safety Input D Safety Input E Fault Mute Safety Input A Safety Input B Air Flow Input Air NO Flow Input Burner Select Input Shows the state of each input Where 0 OFF 1 ON Primary Air Flow Primary Air NO Flow Undefined Track Input 2 0 Not tracking PE21 input 1 Tracking PE21 input VVarming Limit Active 0 Measured value above vvarming limit burner free to modulate 1 Measured value below warming limit burner held at low fire if the unit is in auto or sequencing mode PID SP Selected Indicates which setpoint the unit is currently operating from Boiler Status 0 Burner will not fire because the temperature pressure meas
69. ntil the fault is cleared and will perform any selected post purge and pre purge before moving to the ignition position General If any settings in the unit are to be changed it is necessary to enter a commission mode Three pass codes are available for this purpose 1 Site passcode allows adjustment of some option parameters 2 Adjust ratio passcode allows adjustment of some option parameters and entry to adjust ratio mode 3 Supplier passcode allows entry to all commissioning modes SUPPLIER SITE PASSCODE 1777 PASSCODE BURNER OFF COMMISSION RATIO MODE COMM KEY 0 COMM KEY BURNER ON Commissioning Data Option parameters Option parameters contain information about the configuration of the burner and the boiler Option parameters may be adjusted in option set mode but it may not be possible to adjust all of them if the burner is on 32 s Setpoints contain information about required servo motor positions There are four tables of set points or four profiles which may be visualized using the diagram below Profile Setpoints PROFILE 1 3 PROFILE 2 4 POSITION POSITION POSITION POSITION CLOSE Poo PURGE P01 INGNITION P02 LOW FIRE P03 HIGH FIRE PXX Up to 24 setpoints may be entered for each profile including close purge and ignition New set points may be entered in commission ratio mode Existing setpoints may be modified in adj
70. ofile This is only available on single fuel profiles which have all flow values entered Inverter Setpoint Inverter speed setpoint 0 999 Auxiliary Damper MotorSetpoint Setpoint in angular degrees Inverter Error Inverter speed error 0 999 Auxiliary Damper Motor Error How far motor is from its setpoint in angular degrees Inverter Drive Response Speed The measured time taken in seconds for the inverter to move from zero speed to 50 60Hz Auxiliary Damper Motor Response Speed s 90 The measured time taken in secs for drive to move over 90 Auxiliary Analogue Input 1 Auxiliary analogue input range as selected by option parameter 40 x Auxiliary Analogue Input 2 Auxiliary analogue input range as selected by option parameter 41 x Auxiliary Analogue Input 3 Auxiliary analogue input range as selected by option parameter 42 x 58 Auxiliary Analogue Input 4 Auxiliary analogue input range as selected by option parameter 43 x TROUBLESHOOTING Display Problem PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Display will not light Display shows garbage Keys do not work Display wired incorrectly Check wiring to connector PE Display will not light Fuse blown on backplane board Check fuse If blown investigate all external wiring and replace fuse with a new one of the correct type and rat ing Drive positions
71. ollows Track modulation input Where minimum input signal low fire maximum input signal high fire Measured value input PID control values displayed with no decimal place Measured value input PID control values displayed with 1 decimal place Measured value input PID control values displayed with 2 decimal places Option 6 1 Setpoint 1 zero value 0 999 00 0 99 9 0 00 9 99 When setpoint 1 is selected this is the measured value which is displayed when the minimum signal level OV or 4mA appears at the modulation input This parameter is not used when a track modula tion is selected Option 6 2 Setpoint 1 span value 0 999 00 0 99 9 0 00 9 99 When setpoint 1 is selected this is the measured value which is displayed when the maximum signal level 5V or 20mA appears at the pressure input This parameter is not used when a track modula tion input type is selected Option 6 3 Setpoint 1 control value 0 999 00 0 99 9 0 00 9 99 This is the control value which is used in the PID control loop for setpoint 1 When the unit is in auto mode the PID control loop will modulate the boiler to maintain the measured value at the same level as this parameter Option 6 4 Setpoint 1 proportional band 0 999 00 0 99 9 0 00 9 99 This is the width of the proportional band that is used by the PID control loop for setpoint 1 If the setpoint was 5 00 bar and this term
72. ounted as far away from the con trol unit as possible Ensure all connections to the ignition transformer are as short as possible and where possible do not run adjacent to any other wiring and that the ignition transformer earth connection is made to the panel earth and not the wiring base earth Alarm Relays Alarm relays are shown with NO power to Terminal PB5 When power ALARM 1N O PC 1 is applied to Terminal PBS the alarm relays will change state In the ALARM 1 PC2 event of a limit fault or forced alarm alarm ALARM 1 COM PC3 relay 1 will go OFF connecting alarm 1 COM PC3 to alarm 1 N C ALARM2N O PC4 PC1 In the event of a safety shutdown alarm relay 2 will go OFF ALARM2 N C POS connecting alarm 2 COM PC6 to alarm 2 N C PC5 ALARM 2 COM PC 6 These outputs must be connected using multi strand single conductor PVC insulated 16 18 20AVVG 600V 90 C 16 0 2mm wire Burner select ON OFF LIMITS input WARNING Any external limit device must be connected into the burner select ON OFF LIMITS line unless connected into the auxiliary inputs and the correct function selected e If a limit device is utilized in the burner select ON OFF LIMITS line it must be capable of supplying the total current required by the main and pilot valves e Any limit device connected to this unit must be listed or component recognized by authorities who have jurisdiction for the specific purpose for which they are used W
73. positions are not required press the AUTO MAN NEXT key to return the motors to their original positions or use the scroll keys to select a different setpoint Press the COM ENTER key to store the new motor positions for the current setpoint 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 motors This may be for one of the following reasons e The burner is not firing Switch the burner on and wait for the unit to begin modulating e The current setpoint is AO Al or A2 Use commission ratio mode to adjust these setpoints The servo motors are moving to the required positions Wait for the servo motors to stop moving Leaving adjust ratio mode ADJUST RATIO MODE gt RUN MODE To leave adjust ratio mode and return to run mode press the key labelled COM ENTER for gt 3 seconds then press the same key again to return to run mode Finding the Software Engineering Code There are two methods for finding the software Engineering Code 1 From run mode press the COM key The software engineering code is shown on the display 2 Use the engineer s key Refer to Engineer s Key section for details 37 OPTION PARAMETERS A CAUTION Use extreme care when entering option parameters Incorrect data entry could cause
74. r between the measured voltage reference and the calibrated value Gas Servo Motor Setpoint Setpoint for each servo motor in angular degrees Oil Servo Motor Setpoint Air Damper 1 Servo Motor Setpoint Air Damper 2 Servo Motor Setpoint Gas Servo Motor Error How far each servo motor is from its setpoint in angular degrees Oil Servo Motor Error Air Damper 1 Servo Motor Error Air Damper 2 Servo Motor Error Gas Servo Motor Response Speed s 90 The measured time taken in secs for each servo motor to move over 90 Oil Servo Motor Response Speed s 90 Air Damper Response Speed s 90 Air Damper 2 Response Speed s 90 Message GAP Undefined Undefined Manufacture Day Date of manufacture test of CPU board Manufacture Month Manufacture Year Software Issue Currently installed software issue EK64 CPU Board Hardware Issue EK65 CPU Board Serial No low 3 digits The 6 digit CPU board serial number EK66 CPU Board Serial No high 3 digits This serial number is required to obtain the boiler sequencing and or serial data communications passcodes EK68 Adjust Ratio Times 57 ENGINEER S KEY PARAMETER LIST NAME DESCRIPTION Commission Rate Time Number of Tries Oxygen Level optional NX280HW expansion unit must be fitted O2 Probe Status optional NX280HW expansion
75. r each drive These faults will occur if a drive is outside the allowable speed range of 10s 90 to 60s 90 Is the POT SUPPLY link set for the correct voltage Subset measured speed s 90 The flame detector did not register the presence of a flame when it should be present The flame detector registered the presence of a flame when it should not be present or when the shutter if selected was closed Subset burner status The air pressure switch SW 1 failed to register air pressure when it should be present or both the flow and no flow inputs are at the same state Subset burner status The air pressure switch SVV 1 registered air pressure when it should not be present subset 1 or the air pressure switch registered air pressure for more than 3 minutes after the burner was turned off subset 2 The air pressure switch SW 2 failed to register air pressure when it should be present or both the flow and no flow inputs are at the same state Subset burner status The air pressure switch sw 2 registered air pressure when it should not be present subset 1 or the air pressure switch registered air pressure for more than 3 minutes after the burner was turned off subset 2 EDON 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 0000000 Valve proving faul
76. r illegal speed Fuel 2 illegal speed Air damper 1 illegal speed Air damper 2 illegal speed Flame not detected Flame detected Air pressure not detected Air pressure detected Air pressure not detected Air pressure detected A drive positioning fault has occurred which will cause a safety shutdown of the burner This fault has occurred for one of the following reasons 1 During close position prove when a drive stops at a position which is outside the close set position by more than five degrees 2 During purge position prove when a drive stops at a position which 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 set point 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 fuel servo motor and the air damper servo motor are checked The other fuel servo motor is ignored Subset burner status 1 Before the pre purge starts all required drives are moved from their lowest positions closed setpoints to their highest positions purge setpoints 2 During this time a speed measurement is made fo
77. rds e ENV 1954 Internal and external behavior of safety related electronic parts e EN298 Automatic gas burner control systems for gas burners and gas burning appliances with or without fans e EN60730 1 Automatic electrical controls for household and similar use e prEN1643 Valve proving systems e prEN1854 Pressure sensing devices for gas burners and gas burning appliances e EN230 Monobloc oil burners safety control and regulation devices and safety times SAFETY INFORMATION WARNING The equipment 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 mounted on a burner boiler due regard must be given to the requirements of that appliance Before attempting to install commission or operate this equipment all relevant sections of this document must be read and fully understood If in doubt about any requirements consult the supplier Installation commissioning or adjusting of this product MUST be carried out by suit ably trained engineers or personnel qualified by training and experience The manufacturer of this equipment accepts no liability for any consequences resulting from the inappropriate negligent or incorrect installation commissioning or adj
78. recognized links and fuse set for 120V NX1386 2 Closed wiring base surface mounting UL listed links and fuse set for 230V NX1466 2 Display Part Number Open wiring base cabinet mounting UL recognized links and fuse set for 230V Description NX550 Panel mount 2 line by 20 character vacuum fluorescent display with eight multi function key pad NX551 Sensors Part Number Hand held 2 line by 20 character vacuum fluorescent display with eight multi function key pad Commissioning tool Description NX1020 1 Gas Pressure Sensor 0 4 5 PSI 0 122 w c 0 300 millibar 1 2 NPT NX1020 2 Gas Pressure Sensor 0 4 5 PSI 0 122 w c 0 300 millibar 1 2 BSP NX1025 1 Steam Pressure Sensor 0 28 PSI 0 2 bar 1 2 NPT NX1025 2 Steam Pressure Sensor 0 28 PSI 0 2 bar 1 2 BSP NX1030 1 Steam Pressure Sensor 0 375 PSI 0 20 bar 1 2 NPT NX1030 2 Steam Pressure Sensor 0 375 PSI 0 20 bar 1 2 BSP NX1040 1 Boiler Temperature Sensor 32 662 F 0 350 C 1 2 NPT NX1040 2 Boiler Temperature Sensor 32 662 F 0 350 C 1 2 BSP Servo Motors Part Number Description NX04 1 Servo Motor 3 ft Ibs 120V NX04 2 Servo Motor 4Nm 230V NX20 1 Servo Motor 3 ft Ibs 120V NX20 2 Servo Motor 20Nm 230V NX50 1 Servo Motor
79. red If the second airflow switch is not required two digital inputs may be wired using the flow COM PF5 as common for each external switch These two switches may be used for non safety related functions as listed for option parameter 10 8 and 10 9 UP 5 NO FLOW PF7 A SPDT switch is required for the air proving circuit Flow and no flow conditions are verified and lockout will occur in the event of no flow during run sequence or flow during an off condition Under no circumstances should these inputs be connected to Line Voltage Motor up down outputs and feedback potentiometer inputs LINE MOTOR The motor up down outputs should be connected MAX 4A SUPPLY using multi strand single conductor PVC insu MOTOR COM PA 1 lated 20AWG 600V 90 C 16 0 2MM wire MOTOR UP PA 2 4 6 8 Wiring must comply with all applicable codes MOTOR DN PA 3 5 7 9 ordinances and regulations and where required must comply to NEC Class Line Voltage wir ing The connections to the motor should be made via its switched inputs so that the internal POT GND PE 36342 is y microswitches prevent the motor being damaged 1f it is driven to either end of its travel Motor supply must be fused to protect the unit and the CABLE CLAMP motors Ensure the fuse rating is selected to suit a Aar ai the current rating of the triac output option fitted COMMON POT SUPPLY PE 1 4 7 10 FEEDBACK PE 2 5 8 11 Motor feedback potentiometer cabling must be o
80. ressure temperature of the boiler at the entered setpoint see Option Parameter 5 3 5 8 If boiler sequencing is enabled and active the unit will start stop and modulate according to instruc tions issued from the unit controlling the lead boiler In manual modulation mode the system will either modulate in response to the keyboard up down keys if the NX550 Display is mounted or the external up down signals Safety Shutdown A safety shutdown will occur under the following conditions e If any step of the gas proving sequence fails e In stages 1 9 inclusive if a flame is detected e In stages 11 16 inclusive if a flame is not detected e In stage 4 if the air pressure switch goes high air pressure present e In stages 7 18 inclusive if the air pressure switch goes low air pressure not present 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 refer to Fault and Fault Finding NX PRESSURE SENSOR TO BURNER 27 THE DISPLAY Description The display is a 2 line 20 character per line dot matrix vacuum fluorescent unit allovving the use of plain text messages for most display parameters The display must be mounted to allow commission ing of the system but once commissioning has been completed the display may be removed provid ing exte
81. return to step 2 The setpoints entered in the current commissioning session are not lost and the AUTO MAN NEXT key may be used to step through the start up sequence and fire the burner If a safety shutdown 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 Leaving commission ratio mode COMMISSION RATIO MODE DATA gt _ RUN MODE To leave commission ratio mode and return to run mode press the key labelled COM ENTER for gt 3 seconds then press the same key again to return to run mode e If P02 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 unit without returning to run mode 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 altered then only the setpoints up to P10 will be stored Therefore it is vital that FAULT MUTE 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 or purge setpoints POO or P01 are altered 35 Adiust ratio mode Description Adjust ratio mode is used only for changing an existing profile e Using adjust ratio mode it is possible to modify the se
82. rmediate points from low to high fire The individual servo motor s position and speed are verified and lock out will occur should either of these parameters be exceeded Modulation control is provided via the pressure temperature sensor s input The Fireye NX1025 NX1030 or NX1040 sensors provide checking circuits for fail safe operation PID setpoints are available for the chosen modulation input selectable up to two decimal points Track modulation is available for those applications requiring less precise control The NX550 Display allows commissioning and current status of the system through the use of its tactile membrane keypad The multi function keys allow the commissioning engineer the ability to access the various Ratio Modes and Option Select menus The two line 20 character Vacuum Fluo rescent Display clearly illuminates the Control Variable Firing Mode Fuel Selected and Hours Run It further allows the Boiler Operator access to the Auto Manual selector Motor Data servo posi tions and other operational parameters such as System Sequence Position Valve Proving Sequence Status Gas Pressure Flame Signal Modulation Rate and Setpoint as necessary Multiple Boiler Sequencing is accomplished through an RS485 Communications bus using ComFire software Lead Lag and Standby set points for up to tens 10 boilers can be configured Site Adjust Ratio and Supplier passcodes are issued with each Control for maxim
83. rnal svvitches and or lamps are mounted for fault indication and reset Ensure that the povver is off when connecting or disconnecting the display Description of Keys The FAULT indica tor will illuminate ilvi The UP DOWN keys steadily if a fault has are used to adjust 5 au INTEGRATED BURNER CONTROL the fire rate in the relay to close Press i the FAULT MUTE SEK manual mogulatior key to mute open PROVE MAIN FLAME micci n the alarm relays and MPLETE re set the control OR mods they are used Hold the FAULT or data entry MUTE key down for approximately two seconds to remove any cleared faults The SCROLL keys are used to select the current parame ter for the display In the commission mode these keys select which param eter is to be adjusted with the use of the UP DOWN keys Selects manual or auto burner modulation In manual the UP DOWN keys may be used to alter the firing rate Description of Display Parameters The dot matrix display will indicate all display information as plain text messages with the excep tion of the engineer s key values MOTOR 1 Indicates the position of each motor connected to the system in angular degrees When the burner is on only the motors used MOTOR 2 for the fuel being fired will be available MOTOR 3 Indicates the measured pressure or temperature of the boiler according to the zero and span values entered as option ACTUAL VALUE parameters If the
84. rvo motor positions for any setpoint in the firing range from low to high fire P03 and higher e It is also possible to view all setpoints P00 and higher even with the burner off e The setpoints may be chosen in any order e It is not possible to modify a servo motor position so that it is higher than the next setpoint or lower than the last setpoint e It is not possible to modify any servo motor position so that it is higher than the high fire setpoint e t is not possible to modify the close purge or ignition positions P00 1 or P02 respectively For this commission ratio mode must be used Entering adjust ratio mode To enter adjust ratio mode turn the burner on Once the burner begun its start up sequence press the key labelled COM ENTER and obtain the supplier passcode value using the UP DOWN keys Once the correct passcode value has been obtained press the key labelled COM ENTER Alterna tively the adjust ratio passcode may be used if the burner is on or off If the entered passcode was correct A n will be seen on the display in addition to the servo motor positions for the servos being used for the selected profile where n is the number of the setpoint cur rently under adjustment Using adjust ratio mode CAUTION 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 po
85. seconds regardless of the times chosen See Option 4 4 for extended MTFI s b Using configuration 7 or 9 the ignition transformer is off during t5 ok Options 9 and 10 allow an additional 30 second purge allowing the FGR damper to fully close A 30 second purge with the FGR damper closed is then achieved Option 4 1 Ignition time 0 999 sec The time at which the drives remain in their ignition positions before the unit moves the drives to low fire During status 14 of the start up sequence this time or time t7 is used depending on which one is the larger Option 4 2 Low fire hold time 0 999 sec During status 15 of the start up sequence this is the time at which the drives remain in their low fire positions before modulation Option 4 3 Post purge time 0 999 sec The time at which the drives remain in their purge positions after the burner has turned off If this option is set to 0 the drives will move straight to their closed positions after the burner has turned off and there is no post purge No post purge will be performed if the burner did not reach pre purge when turned off Note This optional postpurge must not be used to replace the pre purge time as dictated by the set ting of option 4 0 The correct pre purge time must still be chosen Option 4 4 Extended pilot time 0 20 sec The time for which the pilot valve remains open after the main fuel valve opens oil only If the time entered is
86. sitioning of either fuel or air could cause a hazardous situation to occur Close To adjust the position of a servo motor use the LEFT RIGHT scroll keys to point to the servo motor to be adjusted and then use the UP DOWN keys to move the servo motor Depending on the profile selected some servo motors may not be available To change the setpoint being modified use the LEFT RIGHT scroll keys to point to the profile point number A n and use the UP DOWN keys to adjust the value Each setpoint in the profile is referred to with a letter and number COMMENTS The close setpoint cannot be altered in adjust ratio mode Purge The purge setpoint cannot be altered in adjust ratio mode Ignition The ignition setpoint cannot be altered in adjust ratio mode Low Fire Low fire setpoint High Fire High fire setpoint which was the last setpoint entered max P23 36 The procedure for modifying a setpoint is as follovvs 1 Enter adjust ratio mode A n is displayed in addition to the servo motor positions where n is the number of the setpoint which is closest to the current firing position 2 Use the LEFT RIGHT scroll keys to point to the profile point number A n to be adjusted and use the UP DOVVN keys to move to the setpoint in the firing range to be altered Wait for the A n display to stop flashing and modify the fuel and air servo motors as required 4 If the modified
87. st comply with all applicable codes ordinances and regulations and where required must comply to NEC Class 1 Line Voltage wiring If a fuse greater than 4A is used in the supply to the unit the burner fan output terminal MUST be separately fused at 4A maximum to protect the relay contacts from welding 14 Ignition pilot valve main valves vent and auxiliary relay outputs If using proof of closure switches for either fuel valve ensure they are wired to the relevant auxiliary inputs and the corresponding option parameter is set accordingly refer to option parameter 10 1 10 9 IGNITION PB6 PILOT VALVE PB 8 GAS VALVE 1 PB9 GAS VALVE2 PB 10 Fuses not exceeding 4A must protect all relay outputs Using a fuse in the OILVALVE PB 11 unit supply of 4A or where the total current exceeds 4A use a separate fuse on each relay output to achieve this See cautionary note in Burner ventvatve PB13 Z select input AUX RELAY PB 14 These outputs must be connected using multi strand single conductor PVC insulated 16 18 20AWG 600V 90 C 16 0 2mm wire Wiring must comply with all applicable codes ordinances and regulations and where required must comply to NEC Class 1 Line Voltage wiring In most cases the outputs can be connected directly to the ignition transformer alarm device and valves without the use of external relays It is recommended that the ignition transformer should be m
88. t Gas pressure limit Forced lockout Not enough setpoints entered CPU board voltage reference Potentiometer supply incorrect Burner input Forced lockout gas firing Forced lockout oil firing Forced lockout gas during modulation Shutdown relay Gas valve 1 relay Gas valve 2 relay Pilot valve relay Vent valve relay Ignition transformer relay Oil valve relay Auxiliary relay O LED OFF LED eL lk 5 The measured gas pressure was not correct during the gas valve proving test Subset value prove status The measured gas pressure is outside the operating limits subset valve prove status or the gas pressure sensor is not responding correctly Subset 10 See option parameter 2 0 for details on changing the operating limits A high level on an auxiliary input has forced a lockout A fuel air ratio profile has been selected which does not have at least four set points commissioned Use commission ratio mode to enter more setpoints Subset fuel code The CPU board has an incorrect on board reference level Subset measured reference where 512 2 5V The unit has detected that the supply voltage to the potentiometers is too high or too low s the potentiometer supply voltage selection link installed Are the potentiometers wired correctly Subset expected potentiometer voltage 5 15 The burner inputs FUEL 1 SEL FUEL 2 SEL FAULT MUTE AUX 1 to AUX 5
89. terminal PB7 60 Modulation Problem PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Sensor or modulation rate inaccurate V I input setting incorrect 5 24V supply setting incorrect Check option parameter 05 5 Check SENSOR IN and SUPPLY links Intermittent positioning faults Modulation rate sticks at a profile setpoint Unit stuck at low fire Unit stuck at mod rate Lead drive setting incorrect Profile not suitable Profile too close to micro switch Poor Earth or screening Feedback potentiometer faulty Lead drive position similar or same as adjacent setpoint Meas value exceeds setpoint Lovv fire hold time not expired Warming limit active EK16 1 Unit in manual External low fire hold Sequencing low fire hold Serial communications Unit in commission mode Change lead drive option param 05 1 05 2 Increase servo motor range by adjusting linkages Move end points further away from high low Check wiring Move servo motor across range and check f back Enter commission ratio mode and change the lead drive setpoints or change lead drive No fault Wait for low fire hold time to expire Wait for boiler to warm up Press the AUTO key to change to auto mode Check auxiliary input functions Option Parameter 10 0 10 9 Increase the mod rate in manual mode Disable or change mod slider in ComFire Press RUN then ENTER to enter run mode 61
90. the circuit boards within it are vertical to maximize cool ing efficiency A clearance is required of a least 3 15 80mm above and 0 8 20mm below and at the sides of the controller enclosure The ambient operating temperature range of the equipment is 32 140 F 0 60 C Refer to pages 4 6 Technical Specification for more details The unit must be installed in a clean environment in accordance with EN6730 1 Mounting the Display ES q Pb v co ji ENTE 4 27 32 123mm so 4 HOLES M4 CLEAR Keypad Dimensions The display should be mounted on the front ofthe burner cabinet or similar accessible location It extends for 1 2 40mm behind the panel and 0 2 3mm in the front of the panel The maximum allowable panel thickness is 0 3 7mm PANEL CUT OUT 108mm PANEL FRONT FIGURE 3 Control Unit Exploded View listed wiring base CONTROL UNIT ENCLOSURE PSU BOARD BASEPLATE COVER UL listed base only BACKPLANE BOARD BASEPLATE 10 Servo Motor Installation Fireye NX04 NX20 and NX50 Servo Motors are available in 3 ft 165 4 Nm 15 ft 165 20Nm and 37 ft Ibs 50 Nm versions The accuracy of the final setup is contingent on the proper application of the motor to the controlled element Extreme care should be given to the secure mounting of the
91. tion allows adjustment of the modulation speed between 25 and 100 of the fastest modu lation possible while still obtaining the correct fuel air ratio When not modulating all drives move at their maximum speeds 42 Option 5 5 Modulation sensor input type 0 3 The modulation sensor input is configured to receive a standard 0 5V or 4 20mA signal or a Fireye fail safe pressure temperature sensor VVhen using a Fireye sensor the unit may be used to monitor the boiler high safety limit and perform a safety shutdown if it is exceeded Ensure that the links on the backplane board are set to correspond with the setting of this option parameter see Options Link section for details 0 5v operation Set the SENSOR IN link to V Set the SENSOR SUPPLY link as required 4 20mA operation Set the SENSOR IN link to I Set the SENSOR SUPPLY link as required NX1040 fail safe boiler temperature sensor Set the SENSOR IN link to V and the SENSOR SUP PLY link to 24V NX1025 and NX1030 fail safe boiler pressure sensors Set the SENSOR IN link to V and the SEN SOR SUPPLY link to 24V Option 5 6 Boiler high safety limit 0 999 NX1040 0 0 99 9 NX1030 If a Fireye fail safe boiler sensor is used such as the NX1025 NX1030 or NX1040 and track mod ulation input is not selected the unit may be used to monitor the boiler high safety limit and perform a shutdown if the limit is exceeded see Fau
92. tion input supply 24V Display 5v 14 Aux modulation input in IP Display key return POR PE15 Aux modulation input ground Ov Display data PD3 AUX PE16 Gas pressure sensor supply Display clock b JP4 PE17 Gas pressure sensor in Display serial PD5 1 POT PEO Gas pressure sensor ground Ov Display Ov PD6 PE19 Gas pressure sensor test R5485 Ov Poy JP3 a PE20 Stm press water temp sensor supply int TV SENSOR PE21 Stmpress water temp sensor in m JPS je eojn PE22 Stm press water temp sensor ground OV Hal k PE23 Sim press water temp test R5486 iso B PD11 Unused PD12 CARI 67 68 NOTES 69 70 71 72 NOTES 73 74 NOTES 75 NOTICE V ARRANTIES When Fireye products are combined with equipment manufactured by others and or integrated into systems designed or manufactured by others the Fireye warranty as stated in its General Terms and Conditions of Sale pertains 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 elec tronic tubes 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 FOREGOI
93. tpoint has been entered before and no change is required press AUTO MAN NEXT Otherwise press COM ENTER P02 ignition is dis played 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 If a change is required or the ignition setpoint has not been entered before move all the servo motors being used to their required ignition positions and press COM ENTER 5 To attempt ignition of the burner hold down the AUTO MAN NEXT key for approxi mately three seconds If a change is required to the ignition position move all of the servo motors to their required positions and press COM ENTER if no change is required press AUTO MAN NEXT 6 Wait for the display to show P03 low fire after the relevant safety times have elapsed If igni tion is unsuccessful and a safety shutdown occurs investigate the problem and repeat steps 2 5 to attempt ignition again 7 If the low fire setpoint has been entered before and no change is required press AUTO MAN NEXT Otherwise move each servo motor to the required low fire position and press COM ENTER P04 next profile setpoint above low fire is displayed 8 Repeat step 6 for each required profile setpoint up to a minimum of P04 and a maximum of P23 9 Leave commission ratio mode The last profile setpoint entered will become the high fire set point If a controlled shutdown occurs the unit will
94. um protec tion of the commissioned values AlI Setpoints and Options are passvvord protected through the three levels of protection The various passvvord levels provide Operators vvith Site protection Ovvners with Adjust Ratio protection and Commissioning Engineers with Supplier protection Table of Contents This manual NEX 1001 describes the installation commissioning operation and maintenance of the NX3100 4100 integrated burner controllers with software revision up to and including Version 3 03 It may be used in conjuction with the following other manuals NEX 1501 ComFire combustion analysis tool user manual NEX SO Boiler sequencing manual NEX 1002 NEXUS Expansion Interface and Expanded Burner Control System NEX 2004 Nexus NX04 1 2 Servo Motor Installation NEX 2020 Nexus NX20 1 2 Servo Motor Installation NEX 2050 Nexus NX50 1 2 Servo Motor Installation asan sa arama a 1 Mable of Contents is v lc essen anni 3 Technical Specifications l sa ska i nunna Hla 4 A DPrOVA O 7 Safety Information socero pepeo orir T Installation e 0 0000 8 WI o eaae E E addict 13 Option Link Selection nen ee TEE 21 Flame Seanners v s il ie ii 23 Operation in Run Mode inicias iii 24 Start Up Sequence sicuris nsore ap T EEEN OEE RE E EEEE ai aka nk na Map R 25 Gas
95. unications bus refer to bulletins NEX 1501 ComView combustion analysis tool or NEX SO boiler sequenc ing Refer to the following table for terminal identification FIGURE 8 PD8 PD7 PD9 PD8 7 PD9 PD8 PD7 PD9 GND GND GND COMMUNICATION BOILER SEQUENCING a GROUND PD7 9 SHIELD ON ONE UNIT ONLY ON ONE UNIT ONLY FIGURE 9 Display Connection r INTEGRATED BURNER CONTROLLER DISPLAY BOARD 5 SERIAL PD 1 45v CLOCK PD 2 KEY RETURN PD 3 DATA RETURN PD 4 CLOCK PD 5 SERIAL PD 6 Ov SHIELD SHOULD BE SECURED TO THE ENCLOSURE USING CABLE CLAMP BAR Pay particular attention to the corresponding termi MAXIMUM SHIELD TAIL LENGTH nal location on the display PDI to 1 PD2 to 2 SHOULD BE 4 100mm to 3 PDA to 4 PDS to 5 PD6 to 6 7 on SCREENING BRAID AND COVER WITH the display is unused SLEEVING FIT CRIMP RING TO END OF TAIL The display cabling must be overall shielded 6 conductor PVC insulated 22AWG 7 30 300V 80 C 7 0 2mm wire Wiring must comply with all applicable codes ordinances and regulations and where required must comply to the NEC Class 1 Line Voltage wiring Since this cable may be run in conduit with other wiring its voltage rating must exceed the maximum voltage carried by any other cable in the same conduit It is imperative the shield of this cable is connected to the display unit s
96. unit must be fitted The number of times the burner was reset Power output to the probe heater 0 100 1 Offset fault 2 Gain fault 4 Heater fault 8 Cell mv too high 16 Oxygen level lt 18 during pre purge O2 Trim Status optional NX280HW expansion unit must be fitted O2 trim Enable optional NX280HW expansion unit must be fitted Oxygen Probe Cell Temperature C optional NX280HW expansion unit must be fitted 0 O2 trim working or 1 no expansion unit fitted 2 Option 20 0 not 1 or 2 or option 20 5 not 1 or option 20 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 EK72 128 Passcode for trim incorrect 0 O2 trim disabled or inoperative 1 O2 trim enabled and operative Temperature of oxygen cell nominal 650 C F50 will be generated if outside the window 600 C after 15 minutes of power on to 700 C Oxygen Error Error between O2 measured value and O2 setpoint Trim Deviation flow Deviation in air flow imposed by trim 25 to 25 Excess Air Excess combustion air at the current firing position Oxygen Setpoint Current oxygen setpoint This is only available if trim is enabled and working Fuel Flow Calculated fuel flow for currently selected pr
97. ured value has exceeded the high control value 1 Burner will fire because the temperature pressure measured value has fallen below the low control value Confirm to Adjust Drive Moved 0 Unit not in commission mode or unit is in commission mode and drives moving to setpoints 1 Unit in commission mode and drives may be adjusted using the UP DOWN keys 0 Unit not in commission mode or unit is in commission mode and drives have not been moved using the UP DOWN keys 1 Unit in commission mode and drives have been moved using the UP DOWN keys Positions Proved 0 Drives have stopped moving ready for position prove test 1 Ready for position prove test but drives still moving Fault Alarm Relay 0 Fault alarm relay off 1 Fault alarm relay on Serial Communications Status 1 Toggles on message received 2 Serial communications passcode correct or in commission ratio mode 4 Boiler sequencing passcode correct 55 ENGINEER S KEY PARAMETER LIST NAME DESCRIPTION Lead Lag Status Burner status 0 Boiler sequencing inactive 1 Boiler held off via sequence control 2 Boiler in standby via sequence control 3 Boiler modulating via sequence control 4 Boiler is lead via sequence control Status of the start up sequence Refer to Gas safety valve proving sequence for details Valve Prove Status Status of the valve proving sequence Refer to Gas sa
98. ust ratio mode or commission ratio mode Option Set Mode Description Option set mode is used for changing the values of option parameters If the burner is on it may not be possible to adjust all of the option parameters Entering option set mode FAULT COMMISION RATIO MODE ADJUST RATE MODE gt OPTION SET MODE To enter option set mode enter commission ratio mode or adjust ratio mode see page 34 and press the key labelled FAULT MUTE MODE In commission mode the display will flash COM Using option set mode e Use the LEFT RIGHT scroll keys to point the select arrow at the option number on the top line of the display and use the UP DOWN scroll keys to display the option parameter to be changed Then use the LEFT RIGHT scroll keys to point the select arrow at the option value and use the UP DOWN keys to change the value of the option parameter e If the value has been changed the value vvill flash Press the key labelled COM ENTER to store the nevv value Leaving option set mode OPTION SET MODE a COMMISION RATIO MODE ADJUST RATE MODE To exit option set mode and return to commission ratio or adjust ratio mode press the key labelled FAULT MODE again OPTION SET MODE gt DATA gt RUN MODE To exit option set mode and return to run mode press the key labelled DATA RUN and then COM ENTER 33 Commission Ratio Mode
99. ustment of operating parame ters of the equipment This equipment MUST only be mounted on to burners as detailed in the contracted specification The supplier must approve any change in the specification in writing Control panels MUST NOT be left uncovered while power is on If it is essential to do so while rec tifying 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 the electrical supplies MUST be isolated Safety interlocks MUST NOT be removed or over ridden Any faults detected MUST be corrected before the unit is operated A CAUTION Some versions of this equipment contain a lithium battery Note The manufacturer of this equipment has a policy of continual product improvement and reserves the right to change the specifications of the equipment and the contents of this manual with out notice prevent possible hazardous burner operation verification of safety requirements and interlocks WARNING Explosion of fire hazard can cause property damage severe injury or death To must be performed each time a control is installed on a burner INSTALLATION This section contains basic installation information concerning choice of enclosure and servo motor environment vviring specification and connection details CAUTION Read these instructions car
100. verall shielded 3 conductor PVC insulated 22AVVG 7 30AVVG 300V 80 C 7 0 2mm wire Wiring must comply with all applicable codes ordinances and regulations and where required must comply to NEC Class 1 Line Voltage wiring Since this cable may be run in conduit with other wiring its voltage rating must exceed the maximum voltage carried by any other cable in the same conduit Connect the shield with the use of the clamping bar Make all connections at the servo motor first Incorrect connection may damage or destroy the motor potentiometer Pressure temperature sensor input The pressure temperature cabling LOOP POWERED must be overall shielded multi core number of conductors as required SENSOR SUPPLY PE 20 A by the relevant sensor PVC insu lated 22AWG 7 30 300V 80 C 7 2X werno 0 2mm wire Wiring must compl Y vvith all applicable and regulations and vvhere required must comply to NEC Class 1 Line Voltage vviring Since this cable may be run in conduit vvith high voltage vviring its voltage rating SENSOR IN PE 21 SENSOR SUPP PE 20 SENSOR IN PE 21 SENSORGND 22 2 y H must exceed the maximum voltage carried by any other cable in the CABLE CLAMP same conduit The input is suitable for use with 0 5V or 4 20mA signals externally or internally powered the NX1025 NX1030 steam pressure sensor or the NX1040 boiler temperature sensor Refer to option link section page 21 for details on setti
101. y gradually slacken off the high limit microswitch until the servo motor starts moving up Continue to slacken off the microswitch until the servo 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 88 8 Move the servo motor up and down a few times to check that the servo motor stops each time at the desired purge position Repeat steps 3 to 7 if necessary Locking the Servo Motor to the Valve Shaft WARNING Once the control and feedback connections to the servo motors are correct each servo motor must be locked to its shaft for all dampers and fuel valves In order to prevent the joint between servo motor and shaft moving it is recommended that the device used to link the two items is pinned together It is imperative these units remain connected correctly to ensure safe operation of the equip ment 31 OPERATION IN THE COMMISSIONING MODE Using the Commissioning Display WARNING While the unit is in commissioning mode or adjust ratio mode certain safety checks cannot be performed by the NX Series Controller and therefore the safety of the system operation is the sole responsibility of the commissioning engineer Do not allow the fuel to accumulate in the combustion chamber for longer than a few seconds without igniting an explosive mixture could result If a flame failure occurs at any point the unit will not attempt a re start u

NEXUS INTEGRATED BURNER CONTROL SYSTEM

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