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Fireye PPC6000 Series Programming Manual

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DESCRIPTION:
This document supplies the commissioning engineer with sufficient information to make
appropriate setup and changes to the commissioning of the PPC6000.
NOTE: For additional information on Installation and Wiring information, please
For ease of navigation (see section 1.3.1), the symbols below will be used throughout
the Commissioning Process in this manual to indicate the correct application for each
commissioning OPTION, for use by the Commissioning Personnel.
A convenient check box has been added to the beginning of the symbols so that the
Commissioning Personnel can mark each appropriate option as it is completed.
SYMBOL
refer to the complete installation manual - Fireye bulletin PPC-6001
MEANS:
Commissioning Personnel MUST execute this option
For Customers with O2 TRIM option, Commissioning
Personnel MUST ALSO execute this option
For Customers with VFD options, Commissioning Personnel
MUST ALSO execute this option
PROGRAMMING
After each appropriate option parameter is
complete, CHECK THE BOX!
NXPG-6001
APRIL 8, 2013
GUIDE
FOR
PPC6000
SERIES

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Summary of Contents for Fireye PPC6000 Series

  • Page 1 PPC6000. NOTE: For additional information on Installation and Wiring information, please refer to the complete installation manual - Fireye bulletin PPC-6001 For ease of navigation (see section 1.3.1), the symbols below will be used throughout the Commissioning Process in this manual to indicate the correct application for each commissioning OPTION, for use by the Commissioning Personnel.

  • Page 2: Table Of Contents

    The following items are covered in this manual: COMMISSIONING THE CONTROL......................5 General ..............................5 Commissioning data ..........................6 1.2.1 Option parameters ......................... 6 1.2.2 Setpoints............................6 The Commissioning process........................6 1.3.1 Navigation............................. 6 Using option set mode ..........................7 1.4.1 Option parameter list ........................
  • Page 3 Option 18.1 to 18.4 – Low Voltage Fail-safe Alarm / Lockout Inputs (0 – 360) LV3......23 Option 19.1 to 19.4 – Fail-safe Alarm / Lockout Display Messages LV3..........24 Option 20.0 – Set-point Select input (0 - 16) LV3 .................. 25 Option 20.1 –...
  • Page 4 Options 32.1 to 32.4 - Trim limits (0.0 – 25.0) LV3 ................36 Options 33.1 to 33.4 - Trim integral gain (0.0 – 99.9%) LV3..............37 Option 34.0 - Trim proportional gain default (0/1) LV3 ................37 Options 34.1 to 34.4 - Trim proportional gain (0.0 – 99.9%) LV3 ............37 Option 34.5 - Calculating and entering the flow values manually –...

  • Page 5: Commissioning The Control

    1 Commissioning the control. WARNING This manual may cover more than one model from the PPC6000 series. Check for additional information at the end of this chapter. While the control is operating in commissioning mode or adjust ratio mode certain safety checks cannot be performed by the control and therefore the safety of the system operation is the sole responsibility of the commissioning engineer.

  • Page 6: Commissioning Data

    1.2.1 Option parameters The PPC6000 series is configured by programming Option Parameters (memory registers), which describe the configuration of the burner and the boiler. Option parameters are set and adjusted in Option Set mode, but it may not be possible to adjust all of them if the burner is on.

  • Page 7: Using Option Set Mode

    1.3.1.1 Entering commission ratio mode To enter commission ratio mode, turn the burner off. Once the burner has completely shut down, press the key labeled COM and select the supplier passcode value using the UP/DOWN keys. The supplier passcode is normally 2 sets of three numbers and is entered as shown below.

  • Page 8: Option Parameter List

    Option 00.4 – User program select (0 / 1) LV1 This parameter may not be available. Where it is available, it allows the user to de-select the Fireye’s standard modulation program, and select a user program. The user program may be modified using PC software to change the controls behavior for non-standard applications.

  • Page 9: Option 00.5 - Language Select (0 / 1) Lv1

    some Input / Output settings (see option parameters 20.0 to 29.9) Run user program, if available. Option 00.5 – Language select (0 / 1) LV1 DEFAULT: 0 This parameter may not be available. Where it is available, it allows the user to change the language used for the display.

  • Page 10: Option 01.2 - Fault Mute Input Enable (0 - 2) Lv3

    It is possible to enable/disable the auto/man facility from the keyboard. Selecting a 0 will disable the operation of the ‘auto/man’ function from the keyboard. Selecting a 1 will enable the operation of the ‘auto/man’ function from the keyboard. Option 01.2 – Fault Mute Input enable (0 - 2) LV3 The Fault Mute function is available via Comfire 2, on the keyboard and can also be selected to be from a digital input.

  • Page 11: Option 02.X - Drive Name Lv3

    Option 02.x – Drive Name LV3 CAUTION The total electrical load for all connected servo motors must not exceed 40VA. Each Drive connected to the system can be given a name which will than be shown on the text display, The are a maximum of 10 drives (0 –...

  • Page 12: Option 03.X - Drive Serial Number Lv3

    Option 03.x – Drive Serial Number LV3 CAUTION The total electrical load for all connected servo motors must not exceed 40VA. Each Drive connected to the system has a unique serial number allocated to it during production testing. This number cannot be changed and is used to uniquely identify each drive.

  • Page 13: Option 04.X - Drive Usage Information Lv3

    Option 04.x – Drive Usage Information LV3 The system will allow a maximum of four fuel / air profiles to be entered. Each drive (servo or VFD) can be selected to operate for any, all or none of these profiles. This way the system can be programmed to use the ‘gas’...

  • Page 14: Options 06.1-06.4 - Profile Naming Lv3

    This parameter is used to specify direction for each servo drive. This parameter has no effect for variable speed drives (VFD). If this parameter is changed, affected profiles must be re-commissioned by a qualified engineer. Number entered in parameter 5.X Drive Options Drive moves counter-clockwise (looking at output shaft).

  • Page 15: Option 09.2 - Inverter Closed Loop Gain (15 - 125%) Lv3

    Option parameter 09.1 Meaning value Small tolerance (normal setting). The control will perform a non-volatile lockout if the inverter positioning error exceeds 30 for 15 seconds or 55 for 3 second (units conform to those seen on the display). Large tolerance. The control will perform a non-volatile lockout if the inverter positioning error exceeds 55 for 3 seconds (units conform to those seen on the display).

  • Page 16: Option 09.6 - Vfd2 Speed Encoder Scaler (255 - 999) Lv3

    The value may need adjustment once the unit has been tested. Specifically, it must be ensured that the feedback received never exceeds this value. In practice this may mean adding 2% to 5% to this value. Option 09.6 – VFD2 Speed Encoder Scaler (255 - 999) LV3 When using encoder feedback for VFD2, this option should be programmed to ensure that the feedback signal gives between 950 and 995 when the motor is at maximum speed (drive signal at 20mA).

  • Page 17: Option 14.1 - Limit Relay (0-8) Lv3

    These relays MUST NOT be used to provide a safety function. A relay can be used to indicate any combination of fault conditions from 14.0, 14.1 and 14.2 – this means that one relay could be used for all faults. When used for an alarm function, the relay will de-energize when in the fault condition, so an alarm bell would be wired in series with the normally closed contacts.

  • Page 18: Option 15.0 - Modulation Sensor Input Type (0 - 1) Lv3

    Option parameter 14.2 Meaning Connection Details value Flue Limits not assigned to any relay. Flue Limits assigned to relay 1 Display, PR3(COM), PR1(NO), PR2(NC). Low voltage or line voltage. Flue Limits assigned to relay 2 Display, PR7(COM), PR5(NO), PR6(NC). Low voltage or line voltage.

  • Page 19: Option 15.1 - Modulation Input Decimal Places (0 To 2) Lv2

    Option parameter Meaning 15.0 value 0 - 5V operation. Set the JP1 link to ‘OUT’. Set the JP3 link as required. This option is used to provide a 0 to 5 volt tracking input only. The burner modulation will track the voltage applied, going to high fire for 5 volts.

  • Page 20: Option 15.4 - Setpoint Control Units (0 - 3) Lv3

    Option 15.4 – Setpoint control units (0 – 3) LV3 This option selects the displayed units for setpoint and measured value. Option parameter Meaning 15.4 value Show measured value as ‘PSI’. Show measured value as ‘bar’. Show measured value as ‘°F’ Show measured value as ‘°C’...

  • Page 21: Option 15.8 - Low Before Off (0 Or 1)* Lv3

    Option 15.8 – Low before Off (0 or 1)* LV3 When set to 1, this parameter will change the way a normal controlled shutdown works. Option parameter Meaning 15.8 value The burner will turn off immediately when it is expected / required to. The burner will modulate down for up to 30 seconds (or until low fire is reached) and then turn off.

  • Page 22: Option 16.2 - Allow Profile Swap (0-16) Lv3

    Option 16.2 – Allow profile swap (0-16) LV3 This option performs exactly the same as 16.1 above except that when the control is at the pilot position, it will allow a fuel profile change without forcing the burner to go off. When the fuel profile selection changes, the ignition-prove output (LFS) will go off and the control will move all drives to the ignition (P2) positions on the new fuel profile.

  • Page 23: Option 18.1 To 18.4 - Low Voltage Fail-Safe Alarm / Lockout Inputs (0 - 360) Lv3

    Option 18.1 to 18.4 – Low Voltage Fail-safe Alarm / Lockout Inputs (0 – 360) LV3. These functions are all fail-safe and may be used to lockout or shutdown the burner. The fault number generated always relates directly to the input that caused the fault (by going open circuit). Thus F1 comes from input 1, F2 comes from input 2 and F4 comes from input 4.

  • Page 24: Option 19.1 To 19.4 - Fail-Safe Alarm / Lockout Display Messages Lv3

    Option Digital Input Number / Terminals Fault number parameter number 18.1 Input 1 - PA5 to PA11, LOW VOLTAGE F1 or L1 18.2 Input 2 – PA6 to PA11, LOW VOLTAGE F2 or L2 18.3 Input 3 – PA7 to PA11, LOW VOLTAGE F3 or L3 18.4 Input 4 –...

  • Page 25: Option 20.0 - Set-Point Select Input (0 - 16) Lv3

    CAUTION The product allows for customization of various non-safety critical functions including the modulation control. The option parameters shown below relate to the default modulation control function programmed in the control at the factory. To verify this has not been replaced by an application specific function check with the equipment supplier and / or check option parameter 00.4, if available.

  • Page 26: Option 20.4 - Ignition Wait Input (0 - 16)

    Option 20.4 – Ignition Wait input (0 - 16). A high level on the input specified here will prevent the burner from igniting. The drives stay at their ignition positions, but the light up sequence will not start until this input is removed. The input numbers are as specified in option parameter 20.0 above.

  • Page 27: Option 21.2 -Set-Point 1 Proportional Band (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) Lv1

    This is the control value used in the PID control loop for setpoint 1. When the control is in auto mode, the PID control loop will modulate the boiler to maintain the measured value at the same level as set by this parameter. Option 21.2 –Set-point 1 proportional band (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 This is the width of the proportional band that is used by the PID control loop for setpoint 1.

  • Page 28: Option 21.6 - Setpoint 1 Low Limit Control Value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) Lv1

    Option 21.6 - Setpoint 1 low limit control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 If the boiler is off due to a controlled shutdown, this parameter defines the measured value at which the boiler will be turned on again.

  • Page 29: Option 22.5 - Setpoint 2 Control Limit Type (0 - 2) Lv3

    Derivative control is seldom needed for boilers, but can improve the response of the modulation system to sudden load changes. Too much can cause control instability. Option 22.5 - Setpoint 2 control limit type (0 - 2) LV3 This option parameter defines the control limit type for setpoint 2. The control limits are used to automatically turn the burner off when it is not needed, and bring it back on when it is needed.

  • Page 30: Option 23.2 - Warming Time (0 To 999 Minutes) Lv1

    control will hold the boiler at low fire (in status 15) indefinitely unless a non-zero time has been entered in option parameter 23.2. Note : If during normal modulation, the measured value falls below this limit having once been above it, the warming function will not be re-applied.

  • Page 31: Option 24.0 Sequence Slaves (Number Of Boilers) (0-3) Lv3

    2. Setting option parameter 22.1 to the desired setpoint value when in stand by. 3. Setting option parameter 22.5 to 1 (Absolute Value) 4. Setting option parameter 22.6 to the desired cut in value when in stand by. 5. Setting option parameter 22.7 to the desired cut out value when in stand by. For example: If the normal operating setpoint is 100 PSI, and the desired stand by pressure is 75 PSI.

  • Page 32: Option 24.5 - Lead (Master) Boiler Select Method Lv3

    Option 24.5 – Lead (master) Boiler Select Method LV3 This option parameter selects the lead (master) boiler via the keypad, digital input or communications (Comfire 2). The values are: 0 = Not lead, operates on own PID or as commanded by master (lead) 1 = lead (master) via Keypad 2 = lead (master) via digital input.

  • Page 33: Option 30.0 - Oxygen Probe Interface Serial Number Lv3

    Option 30.0 – Oxygen probe interface serial number LV3 Each CANbus device connected to the system has a unique serial number allocated to it during production testing. This number cannot be changed and is used to uniquely identify each device. When the system is in commissioning mode the serial number of all the connected devices is read by the main unit and displayed as a ‘list’...

  • Page 34: Option 30.5 - Oxygen Input Function (0/1) Lv3

    Closed loop trim. The oxygen value is used to provide both a display of the measured oxygen level and a feedback signal for closed loop trim control function of the PPC6000 series control. Option 30.6 - Oxygen probe calibrate enable (0 – 2) LV3 This option parameter is only available if option 30.0 is non-zero.

  • Page 35: Option 30.8 - Reset Oxygen Trim Profile (0/1) Lv3

    Option 30.8 - Reset oxygen trim profile (0/1) LV3. This option parameter allows the learnt trim profile to be reset. If the option is set to 1 any learnt profile currently held in memory will be reset and the trim drives will return to their commissioned positions for the corresponding modulation position.

  • Page 36: Options 31.1 To 31.4 - Trim Type For Profiles 1 To 4 (0 To 2) Lv3

    Option parameter Meaning 31.0 value Modulation not limited. Burner modulates from P to P Oxygen trim works over full range from P to P , but may not be able to apply trim at high fire, or low fire – depending on trim direction. The burner always modulates to the desired modulation rate, which may limit the system’s ability to maintain the desired oxygen value.

  • Page 37: Options 33.1 To 33.4 - Trim Integral Gain (0.0 - 99.9%) Lv3

    If option 32.0 is set to 0, the default trim limit will be ±5.0% for all profile selections. Option parameters 32.1 to 32.4 will not be available. If option 32.0 is set to 1, it is possible to individually adjust the trim limit for each profile selection using option parameters 32.1 to 32.4.
  • Page 38 3. Record the excess air value at location x in the table. For single fuel profiles, this value may be found using the Engineer’s Key parameter EK48 (provided the hydrocarbon ratio has been entered into the appropriate option parameter (35.1 - 35.4) for this fuel). For multiple fuel profiles, Refer to NOTE under section Options 35.1 to 35.4.
  • Page 39 Example of table completed for A10 (high fire) to A8. In practice, the table must be filled out down to A3 (low fire). Profile Excess Air Ex. Air + 100 Ratio Airflow Fuelflow position y = x + 100 c = a + 100 d = b + 100 High fire = A10...
  • Page 40 Table: Flow calculation table Ex. Air + 100 Profile Excess Air y = x + 100 Ratio Airflow Fuelflow position c = a + 100 d = b + 100 High fire 1 = A e 1 = c 1 /d 1 f 1 = e 1 (99.9) g 1 = f 1 (y/c 1 ) 2 = A...

  • Page 41: Option 35.0 - Inlet Temperature Sensor Serial Number Lv3

    Option 35.0 – Inlet temperature sensor serial number LV3 Each CANbus device connected to the system has a unique serial number allocated to it during production testing. This number cannot be changed and is used to uniquely identify each device. When the system is in commissioning mode the serial number of all the connected devices is read by the main unit and displayed as a ‘list’...

  • Page 42: Option 35.9 - Boiler Radiated Heat Loss (0.0 - 9.9%) Lv3

    Fuel Gross calorific value Net calorific value Hydrocarbon ratio (x10) 52.8 47.6 3.20 Light oil 45.6 42.8 1.57 Medium oil 43.1 40.8 1.35 Heavy oil 42.9 40.5 1.28 Option 35.9 - Boiler radiated heat loss (0.0 – 9.9%) LV3 This option parameter is only available if option 35.0 (inlet temperature sensor) is not set to zero. If this option parameter is set to zero the unit will calculate the net efficiency, if non-zero it will calculate gross efficiency.

  • Page 43: Option 38.0 - Oxygen Alarm Select (0 - 2) Lv3

    Option 38.0 - Oxygen alarm select (0 – 2) LV3 Option parameter 38.0 is only available when option 30.5 (oxygen input select) is not set to zero and the optional oxygen probe interface unit is connected. Since the oxygen alarm values relate to the oxygen setpoint values, oxygen setpoint values must first be entered in adjust ratio mode.

  • Page 44: Option 42.0 - Second Oxygen Probe Interface Serial Number Lv3

    Enter this value to disconnect the specified device from any hardware. The FIREYE oxygen probe and associated electronics are not fail-safe. It is for this reason that the maximum amount of oxygen trim allowed must be limited by the commissioning engineer using option parameter 32.1 to 32.4 .

  • Page 45: Option 42.3 - Second Oxygen Probe Calibrate Enable (0 - 2) Lv3

    Option 42.3 – Second Oxygen probe calibrate enable (0 – 2) LV3 This option parameter is only available if option 31.0 is non-zero. This option parameter must be used when calibrating the second FIREYE oxygen probe. There are three possible values.

  • Page 46: Option 45.0 - Erase / Restore Enable (0 - 1) Lv3

    Option 45.0 - Erase / Restore enable (0 - 1) LV3 CAUTION If this value is displayed as a ‘2’, the option parameter data has been ‘up- loaded’ into the control, ensure all option parameters are set to match the requirements of the burner to which it is connected.

  • Page 47: Commission Ratio Mode

    Commission ratio mode 1.5.1 Description Commission ratio mode is used for entering a new profile or changing an existing profile. Using commission ratio mode, it is possible to step through each setpoint including close, purge and ignition. Once a setpoint has been entered, it is not possible to go back and modify it again in the same commissioning session.

  • Page 48: Leaving Commission Ratio Mode

    The procedure for entering or modifying a profile is as follows: Please see Appendix, Section 2.3 for suggestions on developing a profile. 1. Enter commission ratio mode (see section 1.3.1). P0 (close) is displayed. 2. If the close setpoint has been entered before and no change is required, press NEXT. Otherwise, move each motor to its lowest position and press ENTER.

  • Page 49: Adjust Ratio Mode

    If P3 (or higher) has been commissioned, the existing profile will be overwritten. If you do not wish the existing profile to be overwritten, disconnect the power to the control without pressing RUN and ENTER. 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.

  • Page 50: Using Adjust Ratio Mode

    1.6.3 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 positioning of any drive could cause a hazardous situation to occur. To adjust the position of a servo-motor or inverter, select the relevant drive and use the UP/DOWN keys.

  • Page 51: Leaving Adjust Ratio Mode

    To leave adjust ratio mode and return to run mode, press the key labeled RUN followed by the key labeled ENTER. Interrogating the software issue There are two methods for finding the software issue : 1. From run mode, press the COM key. 2. Use the engineer’s key. Refer to Fireye bulletin PPC-6001 section 6.6 for details.

  • Page 52: Appendix

    Terminal Designation Note: All wiring to terminals “PA & PB” are low voltage and must be braided shielded wire per table 2.6.1A of Fireye Bulletin PPC-6001. Wiring to terminals “PE” are line voltage. The maximum wire size is 16AWG (19.3mm) for all terminals.

  • Page 53: Typical Wiring Diagram / Burnerlogix

    Typical Wiring Diagram / BurnerLogix...
  • Page 54 Typical Wiring Diagram / E110 Flame Monitor...

  • Page 55: 2.3 Combustion Profile Setup Guideline

    This is normal and due to the difference between wet and dry samples. Bear in mind the PPC6000 will trim to the value of the Fireye probe, not to the value of a portable analyzer. For example:...
  • Page 57 Fireye shall be limited exclusively to the right to replacement or repair as above provided. In no event shall Fireye be liable for consequential or special damages of any nature that may arise in connection with such product or part.

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