Fireye PPC4000 SERIES Manual
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Fireye PPC4000 SERIES Manual

Fuel air ratio controller
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PPC-4001
JUNE 20, 2016
PPC4000
SERIES
FUEL AIR
RATIO
CONTROLLER

DESCRIPTION

Fireye PPC4000, the newest member of the Nexus family, is a state of the art parallel positioning
system for all types of liquid or gaseous fuel fired combustion systems. When combined with a Fir-
eye flame safeguard system such as the Fireye BurnerLogix control, the PPC4000 offers the most
compact and advanced parallel positioning system available. Four fuel profiles allow the PPC4000
to accommodate a variety of applications such as two fuels, with and without, the optional variable
frequency/speed drive (VFD/VSD). With each profile having up to 24 points entered to assure a
smooth "curve", the microprocessors within the PPC4000 interpolate points between entered values
and precisely position fuel and air servos to within ± 0.1 degree, and the VFD to within 0.1% of its
full scale range. The result is improved efficiency by eliminating hysteresis typically found in slide
wire or single point positioning systems. Additional gains in burner efficiency can be realized by
adding the optional (VFD/VSD) drive board and Fireye O2 probe. The PPC4000 is capable of con-
trolling a total of ten servo motors, four servos per profile. All servo motors and displays operate on
a secure communications protocol and can be "daisy chained"/ multi-dropped together for simplified
wiring. Available servos from Fireye have torque ranges of 4 Nm (3 ft./lb.), 20 Nm (15 ft./lb.), and
50 Nm (37 ft./lb.). Two independent PID control loops for temperature or pressure control provide
precise, accurate control of firing rate for unmatched response to load changes. Ten safety rated user
definable line voltage inputs are standard and can be configured for functions such as burner on, set-
point select, lead lag, setback, etc. The PPC4000 also contains programmable relays that can be used
for various functions throughout the burner sequence. Built in lead lag sequencing for up to four
boilers is included in every PPC4000. The PPC4000 contains an SD (Secure Digital) card interface
that provides data logging of a burner's operation at user defined intervals as well as upload/down-
load capability.
The User Interface, NXD410, contains a tactile feel keypad and a four line backlit LCD screen. The
NXD410 offers dedicated keys that facilitate various every day tasks done by the boiler operator.
Among these are C-MODE, BURNER ON/OFF, ADJUST SETPOINT, LOW FIRE, AUTO/MAN
(modulation) and LEAD LAG (sequencing). This eliminates the tedious task of entering various
modes and passcodes to search for the desired parameter. The NXD410 has a HOME screen that
shows four lines of instant and pertinent information about the current state of the burner. A HOME
key on the keypad will direct the user to this screen from anywhere within the menu system. An intu-
itive menu system and easy to use navigation keys optimally placed on the keypad provide an easy
flow to all parameters in the system. An INFO key is available that allows the installer/operator to
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Summary of Contents for Fireye PPC4000 SERIES

  • Page 1: Description

    “daisy chained”/ multi-dropped together for simplified wiring. Available servos from Fireye have torque ranges of 4 Nm (3 ft./lb.), 20 Nm (15 ft./lb.), and 50 Nm (37 ft./lb.). Two independent PID control loops for temperature or pressure control provide precise, accurate control of firing rate for unmatched response to load changes.

  • Page 2: Key Features Of The Ppc4000 System

    A minimal Nexus system includes the PPC4000 parallel positioning controller, NXD410 User Inter- face, 59-562-2 UI interface cable, appropriate Fireye pressure and/or temperature transducers, and a minimum of two servos for a single fuel application. Optionally an O2 probe and (VFD/VSD) card can be added.
  • Page 3  Warning: Electro-mechanical high steam pressure or high water temperature limits must remain in the running interlock circuit of the flame safeguard control. This manual describes the installation, commissioning, operation and maintenance of the PPC4000 series fuel air ratio controls. It may be used in conjunction with the following other manuals: •...

  • Page 4: Table Of Contents

     TABLE OF CONTENTS Description ........1 Flue Temperature Alarm Limits ....46 Key Features of the PPC4000 System.

  • Page 5: Ppc4000 System Specifications

     PPC4000 SYSTEM SPECIFICATIONS PPC4000 Control: Supply Voltage: PPC4000 120 VAC (+10%, -15%) 50/60 Hz PPC4000-230V 230 VAC (+10%, -15%) 50/60 Hz Power Consumption: 15 VA Temperature Rating: Operating: 32°F to 140°F (0°C to 60°C) Storage: -4°F to 158°F (-20°C to 70°C) Humidity Rating: 85% RH, non-condensing Protection Category: NEMA 1 (IP01) Unit Dimensions: 5.0"...
  • Page 6  Protection Category: NEMA 4X indoors only, IP66 (front) Unit Dimensions: Panel Cutout: 13.22 (336mm)L x 10.51 (267mm)H Shipping Weight: Approx. 6.2 lbs. (2.8 kg) NXCESO2 Oxygen Probe: Supply Voltage: 24 VDC ± 10% Power Consumption: 27 VA, 13 VA (steady state) Temperature Rating: Operating: 32°F to 140°F (0°C to 60°C) Storage: -4°F to 158°F (-20°C to 70°C)

  • Page 7: Approvals

     Temperature Sensors: Temperature Measurement Range: FXIATS-140: -40°F to 140°F (-40°C to 60°C) - see FXIATS-1 bulletin for technical info TS350-X: 32°F to 350°F (0°C to 176°C) TS752-X: 32°F to 752°F (0°C to 400°C) RTD Type: Platinum, 100 ohms ± 0.1% @32°F (0°C) Temperature Coefficient:.00385 ohms/°C Output: 4-20 mA, linear with temperature Operating Temperature Range: -13°F to 185°F (-25°C to 85°C)

  • Page 8: Part Numbers And Approvals

     PART NUMBERS AND APPROVALS Table 1: Agency Approvals     Fireye Part Number Control PPC4000 PPC4000-230V User Interface NXD410 NXTSD407 NXTSD413 Servos FX04, FX04-1 FX20, FX20-1 FX50, FX50-1 Oxygen Probe NXCESO2-8 NXCESO2-16 NXCESO2-30 Transducers BLPS-15 BLPS-25 BLPS-30 BLPS-200 BLPS-300...

  • Page 9: Ordering Information

     ORDERING INFORMATION Control PPC4000 Parallel positioning system, 120 VAC input. Used with flame safeguard control. PPC4000-230V Parallel positioning system, 230 VAC input. Used with flame safeguard control. NXCESVFD Plug-in assembly provides variable frequency (VFD/VSD) capability 60-2926 Enclosure, 12.5” x 10.5” x 6.5”, UL listed, fitted for PPC4000 129-190 Kit, fan replacement Display...

  • Page 10: Installation Procedure

     INSTALLATION PROCEDURE 1) A UL listed fuel/air ratio system is comprised of the following items. a.) PPC4000, fuel/air ratio controller b.) 60-2926, enclosure c.) NXD410, user interface d.) FX series servos 2) Wiring must comply with all applicable codes, ordinances and regulations. 3) Wiring must comply with NEC Class 1 (Line Voltage) wiring.
  • Page 11 5.35” (136mm) Use Fireye cable, part number 59-562-2 to connect from the NXD410 to the PPC4000 control. The DA15-FM connector plugs into the PLC port located on the backside of the NXD410. The cable dis- tance from the PPC4000 to the NXD410 is limited to 10 feet (3 meters) wire run.
  • Page 12  1. TBD 2. HIGH SD ACTIVITY STATUS/ALARM 3. LOW 4. AUTO 5. P4 6. P3 7. P2 8. P1 1. DI 10 2. DI 9 3. DI 8 4. DI 7 5. DI 6 6. DI 5 7. DI 4 8.
  • Page 13  P14 top 1. mbus A 2. mbus B 3. seq A 4. seq B 5. servo A 1. DI 10 6. servo B 2. DI 9 7. dis TX,ye 3. DI 8 8. dis TY,bl 4. DI 7 9. dis Rb,br 5.

  • Page 14: Ppc4000 Installation

     PPC4000 INSTALLATION Install the PPC4000 control where the relative humidity never reaches the saturation point. The Nexus PPC4000 system is designed to operate in a maximum 85% relative humidity continuous, non-condensing environment. Do not install the PPC4000 system where it can be subjected to vibra- tion in excess of 0.5G continuous maximum vibration.

  • Page 15: Wiring Connections

     The PPC4000 is mounted to the cabinet back plate using 4 X #8-32 screws. Following the mounting dimensions shown in Figure 4, drill and tap 4 mounting holes. Firmly screw the control to the cabinet back plate. WIRING CONNECTIONS Terminal Type Description...
  • Page 16  Terminal Type Description Rating/wiring P13.1 D1 10 Digital Input #10 120/230 VAC @ 1mA P13.2 D1 9 Digital Input #9 120/230 VAC @ 1mA P13.3 D1 8 Digital Input #8 120/230 VAC @ 1mA P13.4 D1 7 Digital Input #7 120/230 VAC @ 1mA P13.5 D1 6...

  • Page 17: Ppc4000 Mounting And Wiring

    The suggested order of wiring is as follows: 1. Power inputs, L1, L2, Earth (AWG 18, 300 vac) P3.1, P3.2 2. NXD410 user interface using Fireye cable 59-562-2 P12.7-P12.10; P2.1, P2.4 3. Servo motors P2.2, P2.3, P2.5, P2.6, P12.5, P12.6, P12.11, P12.12 4.
  • Page 18  Table 2: SENSOR RANGE and SETTINGS Part Increment Sensor Type Set Point Range Cut In Cut Out Mod Range Number Decrement 0 - 15 PSI 1.0 - 14.0p 0 - 6.0p 0.3 - 6.0p 0.3 - 6.0p 0.1p BLPS-15 0 - 1030m 70m - 950m 0 - 410m...

  • Page 19: Wiring Pressure And Temperature Sensors

     MOUNTING TEMPERATURE SENSORS The immersion style temperature sensors have a ½” NPT mounting for the 2", 4", and 8" thermowell probes, and a ½” conduit fitting for electrical connections. WARNING: Location of the temperature sensor to monitor boiler water temperature of a steam boiler is critical.

  • Page 20: Servo Motor Setup And Wiring

     SERVO MOTOR SETUP AND WIRING The PPC4000 must have a “master servo” in order to generate a valid modulation curve. In a typical setup, without VFD, the AIR servo is selected as the master servo; if a VFD is used, the first fuel servo is then selected as the master servo.
  • Page 21 Cables and Connectors Cord sets having female connectors on both ends are available in 6 and 40 foot lengths. Field wire- able connectors are available in kit form, 129-192. Fireye recommends cable part number 59-565 to be used for servo wiring.

  • Page 22: Nxceso2 Oxygen Probe

    70°C (158°F) and turn off when the temperature drops below 45°C (113°F). The O2 probe mounts in the stack using Fireye mounting flange kit 35-381-2. See 133-750 for mounting dimensions and instructions. Recommended Oxygen Probe Mounting Positions The probe must be mounted in a manner that ensures that the flue gases pass into the gas tube at its open end and out of the tube at the flange end.
  • Page 23 EAR T H D GN D +24 V Baud rate selector. In is 57600 (PPC4000), Out is 19200 RS485 termination resistor Heater Fuse 23-231 4A, 125V Input Fuse Type LFMX Refer to Fireye bulletin NXCESO2-1001 for complete details on the O2 probe.

  • Page 24: Nxd410 User Interface

    PPC4000 Control and connected accessories. The NXD410 provides a four line backlit LCD dis- play screen and a multi-function tactile feel keypad. The NXD410 is panel mounted and connects directly to the PPC4000 using Fireye cable 59-562-2. Explanation of NXD410 keypad The >...

  • Page 25: Navigating Through Display Menus

     The NXD410 and PPC4000 Control contain a number of Quick Keys that allow the user to access that function directly. For these Quick Keys to operate the installer or operator must first access the KEYPAD SETUP menu where the user defines if a Quick Key is used or unused. Quick Keys are also non-volatile meaning the state of the switch function is retained in memory should a power recycle occur.
  • Page 26  The HOME key is used to bring the user directly back to the top layer menu and display the default items. Any item in the top layer menu that contains a > character indicates there is a sub menu below it.

  • Page 27: Ppc4000 Control Operation

     The UP and DOWN keys are used to scroll forward and backward through the top layer menu. The menu is continuous in both directions. That is, when you reach the bottom and continue with the DOWN key, for example, the very top of the menu will be displayed on the next line. As stated ear- lier, hitting the HOME key from anywhere will bring you back to the HOME screen.

  • Page 28: Passcode

     On first application of power, with conditions as stated above, the display will indicate: > < The Operating control relay (OCRC) will remain open and the servos will remain at their respective installed positions. For PASSCODE protected parameters, if the passcode is not enabled, the user will be automatically directed to the PASSCODE setup screen.

  • Page 29: Servo Setup

     The PPC4000 uses 12 hour format only, AM / PM. If the clock and date need adjustment, the NEXT key is pressed to move to the DATE / TIME SETUP submenu. < > < Use the UP / DOWN keys to position the item to be modified between the > < marks and use the MDFY/SAVE key to modify and save the new value.
  • Page 30 FX04-1 FX20-1 Fireye “D” hole couplings should be used in order to assure a secure connection to the driven mem- ber. Set screws alone are not recommended as they can come loose resulting in a potentially unsafe condition. Motor shafts are hardened generally preventing set screws from “biting” in and thus loos- ening after commissioning.

  • Page 31: Sensor Setup

     the servo, press MDFY and using the UP and DOWN keys, set the target position. In this example set the target position to 10.0 degrees. Press SAVE and the display will indicate the original position and change as the servo is moving toward its target position. The final display for servo 1 should look like the following: <...

  • Page 32: Sensor Setpoint Setup

     For this application, at SENSOR TYPE press MDFY. Use the UP or DOWN keys to select STEAM and press SAVE. At SENSOR RANGE, press MDFY and use the UP or DOWN keys to select 15 PSI and press SAVE. The display will be as follows: <...
  • Page 33  Definitions: LIMIT TYPE DEV - Values that deviated from setpoint. The advantage is these values will float with the setpoint. SETPOINT - The target pressure or target temperature the control will maintain. CUT IN (Cut In Value) - Determines the point in which the steam pressure (or water temperature) must reach to start a burner cycle.
  • Page 34  HIGH LIMIT - When this is exceeded, the PPC4000 will proceed to lockout. The user programs both HIGH MARGINAL and HIGH LIMIT for the temperature or pressure sen- sors based on the input signal received. The HIGH MARGINAL cannot be set higher than the HIGH LIMIT nor can either be set lower than the sum of SETPOINT plus CUT OUT.

  • Page 35: Profile Setup

     PROFILE SETUP In the top layer scroll to PROFILE SETUP and press NEXT to enter this sub menu. This menu pro- vides the means to name the profile, set the maximum modulation rate for this profile and when nec- essary erase the profile setpoints.

  • Page 36: Keypad Setup

     The list of general purpose functions for all digital inputs is as follows: > < If DIGITAL INPUT 1 (DI1) is to be set as BURNER CONTROL, at DI1 press the NEXT key to dis- play the following: < >...

  • Page 37: Variable Frequency Drive

     VARIABLE FREQUENCY DRIVE In addition to using a precision servo motor to control the air flow into a combustion chamber, the PPC4000 can control one or two variable frequency drives (VFD/VSD) with the result being better control over air flow and improvements in combus- tion.
  • Page 38  Each VFD channel has its own separate and independent sub menu. The following assumes that VFD2 is moved between the two tick marks and the NEXT key is pressed to display the following configura- tion menu. < Explanation of VFD parameters: 2.
  • Page 39  b. Integral is the time between error corrections or updates to the VFD. A high rate of updates (short integral time) to the VFD can result in unstable operation. Conversely too few updates (long integral time) to the VFD can result in large deviations from setpoint. Update time to the VFD output is done at ¼...
  • Page 40  4. Making modifications to any of the VFD parameters in the servo setup submenu, requires the Com- missioning pass code to be enabled. 5. Attempting to change a VFD channel to a value other than UNUSED in the ANALOG OUT sub menu while its ASSIGNMENT >...

  • Page 41: Commissioning With Vfd

     COMMISSIONING WITH VFD The VFD is commissioned like any servo motor and must have a position for every profile setpoint for the commissioned profile. < The VFD can be commissioned during the initial commissioning process or added to the current commis- sioning profile.

  • Page 42: Oxygen Probe Setup

     OXYGEN PROBE SETUP The NXCESO2 oxygen probe provides continuous oxygen (O2) content and stack temperature read- ings from the stack. When properly connected and configured to the PPC4000, it allows the PPC4000 to trim the air or fuel servo to achieve optimum combustion. Refer to earlier sections of this bulletin for information regarding installation and wiring of the NXCESO2.
  • Page 43  Menu item Value Description HEAT LOSS 0.0% Used to calculate boiler efficiency. Percentage of boiler output lost through the shell of the boiler at high fire. The default is 0% and ranges to 9.9% in 0.1% increment. The PPC4000 will calculate the heat loss at all firing rates and is dependent on burner turndown ratio.

  • Page 44: Setting Trim Limits

     Menu item Value Description O2 LO ALM@LO (X) LO refers to O2 level alarm limits below the O2 curve. HI O2 LO ALM@HI (X) refers to O2 level alarm limits above the O2 curve The O2 HI ALM@LO (X) values entered are the deviation from the current target O2 HI ALM@HI (X) value.

  • Page 45: General Rules For O2 Alarm Notification

     At lower firing rates, a small movement of the servo is required to cause a significant change in the air/fuel ratio as compared to high fire. It is the responsibility of the installing and operating personnel to ensure the trim limits selected do not allow a hazardous combustion condition to occur.

  • Page 46: Flue Temperature Alarm Limits

     FIGURE 8. Level Alarm Limits Hi ALM @ LO O2 ALM@Hi O2 Level O2 ALM@Lo Lo ALM @ LO Hi ALM @ HI Lo ALM @ HI Firing Rate Each profile will have its own set of alarm level values. The alarm value for each succeeding profile setpoint is interpolated from these inputs.

  • Page 47: Gain Terms

     FIGURE 9. Flue Temperature Limits Acceptance Zone Flue Temp Flue Temp Lo Flue Temp Hi Firing Rate Note: The PPC4000 requires the flue temperature to be above the high limit or below the low limit for 30 seconds before action takes place. GAIN TERMS O2 trim is performed using the current O2 level, the current saved target value and the boiler trans- port delay.
  • Page 48  alarm relay will be energized. Lockouts are non-volatile and require a manual reset. Warnings are dynamic and will self-remove when the condition causing the warning no longer exists. The message O2 FAULT eXX contains the error message causing the lockout or warning event. The error message 'eXX' is described in the following table: e-code VALUE...

  • Page 49: Commissioning Procedure

    OEM to know the do's and don'ts of their particular burner and to have relevant experi- ence in the theories and practices of combustion control. Fireye cannot accept any liability for any consequences resulting from inappropriate, negligent or incorrect installation, commissioning or adjustment of operating parameters of the equipment.

  • Page 50: Commissioning Rules

     COMMISSIONING RULES 1. Commissioning mode is used for entering new setpoints in a profile. 2. Existing setpoints can be modified in commission mode or adjust ratio mode. 3. Only commissioning mode can be used to modify setpoints P00, P01 and P02. 4.
  • Page 51  If a control was previously commissioned then the currently stored profile will be loaded and be used as the base setpoints. Note: this can only occur when a profile is actually selected. If not com- missioned (out of the box condition) then the succeeding Pxx point should be the same as the preced- ing Pxx point.
  • Page 52  switch, the operating control relay (OCRC) remains open. When the user has finished setting the P00 position for all servos, P00 is complete and the user will press the NEXT key to set up P01. At this point a profile will need to be selected requiring the operating control relay to become closed. If the burner control switch is closed, the keypad BURNER ON/OFF pressed and LED illuminated and all other startup permissives are met (i.e.
  • Page 53  When all servos are at the desired ignition light-off position, the user presses the NEXT key and the PPC4000 outputs to the YB110 controller the low fire start signal on terminal D. The YB110 control- ler will advance into PTFI only if the low fire start purge timer has expired and the low fire start switch is closed (terminal D).
  • Page 54  It will be up to the user as to how many setpoints are entered. As a minimum, P03 must be entered and P23 is the maximum. The more setpoints entered the better the interpolation between each set- point and the smoother the firing rate curve. Ending Commissioning Mode: Pressing the C-MODE key ends the Commisioning Mode and saves all changes to the current pro- file.
  • Page 55  Graph 2 shows the same commissioned actuator positions for both the AIR and FUEL servos as shown graph 1 but with the FUEL actuator used as the master because a VFD is used. Notice how different the modulation curve appears. Because the FUEL's p03 position is 10 degrees and the p13 position is 40 degrees, the 50% position occurs at ((40-10) X 50%) + 10 = 25 degrees.

  • Page 56: Commissioning O2 Trim With The O2 Probe

     For AUTO modulation: > < ° ° For MANUAL modulation: > < ° ° To adjust the modulation rate, the user will press MDFY and use the UP and DOWN keys. The mod- ulation will change with the UP and DOWN arrows. When complete the user presses the SAVE key to save the current position.

  • Page 57: Operation With O2 Trim

     At each profile setpoint the target value is saved to interim memory by first using the MDFY key to position the air or fuel servo to their appropriate positions and pressing the SAVE key. After a suffi- cient wait time to achieve a reliable O2 reading the NEXT key is pressed to save the target value to the setpoint table and move forward to the succeeding profile setpoint.

  • Page 58: Adjust Ratio Procedure

     With good PID control the user should set both P-BAND and INTEGRAL to provide the wanted per- formance yet avoid large firing rate changes. While THERMAL SHOCK is active, O2 trim is disabled. ADJUST RATIO PROCEDURE Adjust ratio is used after the profile has been commissioned and all setpoints have been entered. Adjust ratio mode is used only for modifying an existing profile from low fire (P03 through P23) through high fire.

  • Page 59: Boiler Efficiency

     If entering adjust ratio mode while the burner is in AUTO (modulating) the displayed setpoint will be the closest setpoint to the actual firing rate of the burner. If the calculated modulation point is between two setpoints, the burner will move to the lower setpoint. While in adjust ratio mode and in STANDBY, s01, the burner can be made to turn on and will cycle through its normal sequence.

  • Page 60: Cold Start Thermal Shock Protection

    Sensors 3, 4 and 5 are provided to connect an inlet air temperature to be used for the boiler efficiency calculation. Fireye provides 3 ranges of inlet air temperature: -50°F to 300°F (-45°C to 149°C), -40°F to +140°F (-40°C to 60°C), 32°F to 350°F (0°C to 176°C).
  • Page 61  SOR USAGE submenu. The thermal shock algorithm needs to know only the type and range of the sensor. THERMAL SHOCK SETUP should be accessed only after all sensor and setpoints have been setup. LOW FIRE METHOD: This method of cold start thermal shock protection is generally used on Water Tube Boilers.

  • Page 62: Communications Setup

     of one segment and repeats the process. The PPC4000 steps the firing rate until the steam pressure (or water temperature) reaches the Thermal Shock Exit Point (THERMAL EXIT). At that point, the firing rate is at the high fire position, and will remain at the high fire position until the steam pressure (or water temperature) breaks into the proportional band.

  • Page 63: Setback Operation

     SETBACK OPERATION With the real time clock in the PPC4000, scheduled setback operation can be implemented to allow the system to operate to an alternate steam pressure or water temperature during off peak times. The scheduled setback time applies to every day of the week. That is, there are not individual setback times for each day of the week.

  • Page 64: Standby Water

     If the modulation rate is greater than 25% at the Begin Setback period (BEGIN STBCK) when the PPC4000 is scheduled to operate according to the reduced setback setpoints, the PPC4000 will delay opening the operating control output until the servo motors reach the low fire position, P03. SETBACK OVERRIDE: In addition, the PPC4000 provides the ability to program a digital input to override the setback mode of the PPC4000 control for a programmed period of time from 1 to 8 Hours (OVERRIDE HOURS).

  • Page 65: Track Modulation

     All other parameters are set to for SETPOINT 2 are user selectable based on need. Note: If the boiler is set up as a sequencing slave and is being commanded to be off by the master, the Standby Water function will override that and allow the slave boiler to run to maintain the Standby Water setpoint.
  • Page 66  Name PPC4000 YB110 Description P15.3 From YB110: Indicates to PPC4000 that purge is complete and go to ignition position. While in AUTO directs PPC4000 to low fire position (P03). HIGH P15.2 From YB110: Indicates to PPC4000 to move servos to purge position.
  • Page 67 ...

  • Page 68: Sequence Of Operation

     Unit powered, setup and commissioned PPC4000 Revision 1.4 State 01 Sequence of Operation Servos in closed position, P00, operating control relay open, safety relay can be closed, low fire output on STANDBY burner switch closed? After State 01 and pcv less than throughout the cycle –...
  • Page 69  From page 1 When low fire purge is IGNITION completed by flame State 11 – State 14 safeguard, PTFI begins reserved for future – ignition and main light off sequence (PTFI, PILOT, MTFI, MFEP) Wait for AUTO signal from flame safeguard State 15 Move to LOW FIRE position...

  • Page 70: Ppc4000 System Wiring Diagram

     System Wiring Diagram (Burnerlogix)YB110 FIGURE 10. NXD410 (front) Consult the NXTSD-4001 TDB- bulletin for connection to TDB+ a touchscreen. 24 Vdc Return (Bla 24Vdc (Red) 24 Vdc (Red) NXD410 (rear) 24Vdc Return (Black) Touchscreen/ Modbus Boiler Sequencing Twisted Pairs Display Tx (Yellow) Display Ty (Blue) Display Rb (Brown)
  • Page 71  TDB- TDB+ Drain 4 Vdc Return (Black) 24 Vdc (Red) NXCESO2 Non-Recycling Running Interlocks Disconnect Means and Overload Protection Required. A Good Earth Ground is Essential. Fuel Valve End Switch BURNERLOGIX SYSTEM CONFIGURATION (YB110) YP1XX SERIES PROGRAMMERS ALARM OCRC PILOT PILOT MAIN...
  • Page 72  System Wiring Diagram (E110) FIGURE 11. NXD410 (front) Consult the NXTSD-4001 TDB- bulletin for connection to TDB+ a touchscreen. 24 Vdc Return (Bla 24Vdc (Red) 24 Vdc (Red) NXD410 (rear) 24Vdc Return (Black) Touchscreen/ Modbus Boiler Sequencing Twisted Pairs Display Tx (Yellow) Display Ty (Blue) Display Rb (Brown)
  • Page 73  TDB- TDB+ Drain 4 Vdc Return (Black) 24 Vdc (Red) NXCESO2 Non-Recycling Running Interlocks Fuel Valve End Switch Disconnect Means and Overload Protection Required. A Good Earth Ground is Essential. FLAME MONITOR SYSTEM CONFIGURATION (E110) EP1XX SERIES PROGRAMMERS ALARM OCRC PILOT PILOT...

  • Page 74: Boiler Sequencing

     BOILER SEQUENCING Sequencing is used in a multiple boiler (2-6) environment where a master boiler, during normal oper- ation, is established to control the remaining slave boilers in order to achieve the desired setpoint as set in the master boiler. Any boiler can be a master, and in a sequencing operation, only one boiler can be the master at a time.
  • Page 75  MASTER SELECT METHOD This parameter provides for the selection of the master boiler via the keypad, digital input or communications. The available selections are: UNUSED: No SEQUENCING selected, operates on own PID. KEYPAD: Master selection via the Keypad - the LEAD/LAG button is used to select the master.
  • Page 76  When configured, SETPOINT 2 is used as the STANDBY WATER setpoint. Although commanded to remain off by the master, each slave is to maintain the STANDBY WATER setpoint which is typi- cally the 'warm' state. When commanded to be on by the master boiler, the slave's SETPOINT 2 set- point values are ignored because its operation and firing rate is controlled by the master boiler.
  • Page 77  OPERATION NOTES: If the master boiler is turned off, fails to come on within 30 seconds, or goes to lockout while operat- ing as the master, it will stop communicating and sequencing will be disabled. All slave boilers will revert to their own PID settings.

  • Page 78: Sd Card Operation

     SD CARD OPERATION The PPC4000 provides the means to backup and restore settings and profile data using a secure digi- tal (SD) memory card. The front of the PPC4000 contains a slot where the SD card is inserted and removed.
  • Page 79 SETPddmmyyhhmm.ext SETP2206110923.SPD The BACKUP files are stored on the SD card in a folder named FIREYE. If the folder does not exist, it will be created automatically during the first BACKUP operation. If necessary, any of the files stored on the SD card can be renamed using a PC and a file explorer utility. A unique name of the user's choosing may better describe the application.

  • Page 80: Restore Operation

     The PPC4000 performs a read back of the file written to the SD card and if found to be incorrect the display will indicate the failure: < > < Note: only the single reason for failure is indicated. The SD card can be removed by pressing lightly on the SD card and then releasing. The SD will eject upward where it can be lifted out of its slot.

  • Page 81: Delete Operation

    The purpose of DELETE is to allow the user to remove files from the SD card. The files to be removed are files located on the SD card in the FIREYE folder pertaining to the PPC4000 and are identified by the various extensions used.

  • Page 82: Format Operation

     At this time the user can press the BACK key to remain in the BACKUP selection sub menu or press the HOME key to exit SD operations. FORMAT OPERATION The PPC4000 can be used to format the SD card. The formatting method will only be FAT32. At the FORMAT on the SD OPS SETUP sub menu press NEXT to display the following: <...

  • Page 83: Profile Setup Work Sheet

     Profile Setup Work Sheet Commissioning Date ______________________ Location ___________________ Profile# ______________________ Profile Drive # VFD# OXYGEN STACK Net Eff Setpoint Name LEVEL TEMP CNTS ENCODE °F / °C (°) (°) (°) (°) Notes: Setpoint Boiler Manuf. Cut-in Boiler Type Cut-out Boiler Size P-Band...
  • Page 84  Profile Setup Work Sheet Commissioning Date ______________________ Location ___________________ Profile# ______________________ Profile Drive # VFD# OXYGEN STACK Net Eff Setpoint Name LEVEL TEMP CNTS ENCODE °F / °C (°) (°) (°) (°) Notes: Setpoint Boiler Manuf. Cut-in Boiler Type Cut-out Boiler Size P-Band...

  • Page 85: Lockouts

     LOCKOUTS: When a safety shutdown occurs, the control will indicate the reason for the lockout through the Alarm/Status LED and also describe the lockout on the User Interface. The alarm relay located on terminals P4.1 to P4.2 will be energized. The non-volatile memory will remember the status (Run or Lockout) of the control even if a power failure occurs.
  • Page 86 Replace Z Board Z BOARD Z Board internal error Replace Z Board PPC4000 FAULT PPC4000 Internal Error Replace PPC4000 (notify Fireye about this error) PPC4000 FAULT PPC4000 Internal Error Replace PPC4000 (notify Fireye about this error) PPC4000 FAULT PPC4000 Internal Error...
  • Page 87 Replace O2 Probe cartridge O2 FAULT O2 Probe Sensor warming up This could be normal operation O2 FAULT O2 Probe sensor in standby Replace O2 Probe cartridge Unused Unused PPC4000 FAULT PPC4000 Internal Error Replace PPC4000 (notify Fireye about this error)
  • Page 88 Helper CPU has detected an internal error Replace PPC4000 PPC4000 FAULT e103 PPC4000 FAULT PPC4000 Internal Error Replace PPC4000 (notify Fireye about this error) e121 Check servo address selection, check e122 SERVO 1 LOST Communications to the servo has stopped wiring.
  • Page 89  Error Code Displayed Reason for error Possible remedy Expected shaft movement does not equal measured In this order: Excessive torque, servo hitting hard e144 SERVO 3 STUCK shaft movement stop, defective servo. Expected shaft movement does not equal measured In this order: Excessive torque, servo hitting hard e145 SERVO 4 STUCK...
  • Page 90  Error Code Displayed Reason for error Possible remedy Insufficient voltage to servo under load or defective e204 SERVO 3 VOLTAGE Voltage supply to servo is below 21.4V servo Insufficient voltage to servo under load or defective e205 SERVO 4 VOLTAGE Voltage supply to servo is below 21.4V servo Insufficient voltage to servo under load or defective...
  • Page 91 P0 NOT COMMISSIONED p00 not commissioned Commission the p00 servo positions e284 PPC4000 FAULT PPC4000 main CPU timing error Replace PPC4000 (notify Fireye about this error) e285 PPC4000 FAULT PPC4000 main CPU timing error Replace PPC4000 (notify Fireye about this error) e286...
  • Page 92 Reason for error Possible remedy e289 PPC4000 FAULT PPC4000 main CPU timing error Replace PPC4000 (notify Fireye about this error) e290 PPC4000 FAULT PPC4000 main CPU timing error Replace PPC4000 (notify Fireye about this error) Less than 2 servos have been assigned to the current...
  • Page 93  Error Code Displayed Reason for error Possible remedy Pressing RESET will restore values from stored e375 “profile 2 data” is corrupted PPC4000 FAULT memory Pressing RESET will restore values from stored e376 “profile 3 data” is corrupted PPC4000 FAULT memory Pressing RESET will restore values from stored e377...
  • Page 94  Pressing RESET will restore values from stored e398 "User Output data" is corrupted PPC4000 FAULT memory Pressing RESET will restore values from stored e399 "CO Setup data" is corrupted PPC4000 FAULT memory e400 Unused Unused e419 Inspect Servo for button e420 Manual move button pressed on servo 1 SERVO FAULT...
  • Page 95  O2 Probe field calibration instruction It's important to calibrate the O2 Probe periodically in order to achieve accurate oxygen measure- ment and maintain optimum combustion efficiency. Calibration of the probe can be accomplished by the following steps: 1. Start a burner cycle. 2.

  • Page 96: Marginal Alarms

    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.

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