Page 1 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.
Page 2 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 Fireye. Installation, commissioning or adjustment of this product MUST be carried out by suitably trained engineers or personnel qualified by training and experience.
Page 3: Table Of Contents
1.14 Fireye NXC04, NXC12, NXC20, NXC40 Servo Motors 1.15 Fireye NXO2INT Oxygen Probe Interface Unit (optional) 1.16 Fireye NXIATS Ambient Air Temperature Sensor (optional) 1.17 Fireye NXDBVSD Variable Speed Drive (VSD) Daughter Board (optional) 1.18 Approvals 1.19 Parts List with Description 2.
Page 4 2.6.5 RS485 serial communications termination resistor (NX6100) 2.6.6 Isolated (MODbus) RS485 serial communications termination resistor (daughter board) Wiring 2.7.1 General 2.7.2 Grounding cable screens. 2.7.3 GROUND (EARTH) connection 2.7.4 Ground (earth) Connection (display unit) 2.7.5 Ground (earth) Connection (oxygen probe interface) 2.7.6 Ground (earth) Connection (servo motors and sensors) 2.7.7...
Page 5 5. Commissioning the control General Commissioning data 5.2.1 Option parameters 5.2.2 Setpoints The Commissioning process 5.3.1 Navigation Description of Touchscreen operation. 5.4.1 The Touchscreen 5.4.2 Touchscreen Power on. 5.4.3 The Operation Mode line and Status messages 5.4.4 Touchscreen Overview display. 5.4.5 Touchscreen Lockout Reset (Alarm Mute) Function.
Page 6 Option 07.6 – Main Ignition Time (t6) (1 to 10 seconds) LV3 Option 07.7 – Ignition Hold Time (t7) (1 to 30 seconds) LV3 Option 07.8 – Low Fire Hold Time (t8) (0 to 999 seconds) LV3 Option 07.9 – Post Purge Time (t9) (0 to 999 seconds) LV3 Option 08.0 –...
Page 7 Option 15.7 – Bumpless Transfer (0 or 1) LV3 Option 15.8 – Low before Off (0 or 1) LV3 Option 15.9 - reserved Option 16.2 – Allow profile swap (0 to 16) LV3 Option 16.3 – High voltage Input 12 Alarm / Lockout Function (0 - 360) LV3 Option 16.4 –...
Page 8 Option 24.1 -24.3 Priority Number(s) LV1 Option 24.4 – Lead OFF Time LV1 Option 24.5 – Lead (master) Boiler Select Method LV1 Option 24.6 – lag (slave) On Rate (0-100%) LV1 Option 24.7 – lag (slave) On Delay (0-999 minutes) LV1 Option 24.8 –...
Page 9 Options 40.1 to 40.4 - Oxygen high alarm values at low fire (0.0 – 99.9%) LV3 Options 41.1 to 41.4 - Oxygen high alarm values at high fire (0.0 – 99.9%) LV3 Option 42.0 – Second Oxygen probe interface serial number LV3 Option 42.1 –...
Page 10 Troubleshooting inverter problems PID Tutorial Combustion Profile Setup Guideline Fireye NX6100 Efficiency Calculations Typical Wiring Diagrams Fireye EP and YP Series Programmer Equivalents 10. Function Block Programming Details Introduction to Fireye’s Abacus Programming Software 1.1. Introduction 1.4. The schematic toolbar 1.5.
Page 11: Technical Specification
1. Technical specification General Supply voltage 120/230Vac +10% - 15% Power consumption Approx. 60VA Supply frequency 50/60 Hz ±5% Ambient temperature range 0 to 60°C (32 to 140°F) Control unit protection category IP20. The control must be situated in a P1 or P2 environment according to EN6730-1.
Page 12: Digital Outputs (Nx6100 And Optional Daughter Board - P/N - Nxdbvsd)
Digital outputs (NX6100 and optional daughter board – P/N - NXDBVSD) Alarm, ignition, Limit alarm & Fault mute retransmission. Type On-off relay, de-energies for off. Minimum current 200mA rms Maximum current (per output) 4A rms (power factor > 0.6) Fuse requirement 4A maximum Maximum voltage 250Vac rms...
Page 13: Alarm Output (Nx6100)
Alarm output (NX6100) Alarm Type On-off relay, de-energize for off. Minimum current 200mA rms Maximum current (per output) 4A rms Maximum voltage 250Vac rms Digital inputs Low Voltage digital inputs 1 to 7. Digital, Switching 0V to 5V pulsed. Feed must be taken from the correct terminal as indicated in this manual.
Page 14: Pressure/Temperature Input
Burden (load) resistor 220 Ohm nominal Input accuracy (typical) ±1.0% Input accuracy (as specified by EN12067) ±1.1% Fireye NX103x boiler pressure sensor See sensor specifications. See Sections 1.11 and 1.12. Fireye NX104x boiler temperature sensor Auxiliary Analog Inputs 0-5V 4-20 mA - externally powered –...
Page 15: Flame Sensing Devices
2-wire RS485 plus ground, with termination resistor selected using a link. See Section 2.6.5 An isolated 2-wire RS485 interface is available as an option. See Section 2.6.6 See MOD-6101 (FIREYE serial communications protocol manual) for details. 1.11 Fireye NX1020-1,-2 gas pressure sensor 30Vdc ±10%...
Page 16: 1.12 Fireye Nx1030-1,-2 And Nx1034-1,-2 Steam Pressure Sensors
1.12 Fireye NX1030-1,-2 and NX1034-1,-2 steam pressure sensors 30Vdc ±10% Supply voltage Approximately 10mA Supply current 0 – 25 bar Working range (zero – span) 0 to 70°C (32 to 158°F) Ambient temperature range IP44 Protection category 44mm dia. x 85mm long (excluding connector) Dimensions G ¼"...
Page 17: 1.14 Fireye Nxc04, Nxc12, Nxc20, Nxc40 Servo Motors
1.14 Fireye NXC04, NXC12, NXC20, NXC40 Servo Motors Interface to NX6100 CANbus Speed 30 seconds for 90 degrees. Microswitches Open & close positions Torque Driving Holding NXC04 4Nm/ 3 ft/lb NXC12 12Nm/ 9 ft/lb 18Nm NXC20 20Nm/ 14.7 ft/lb 18Nm...
Page 18: Fireye Nxiats Ambient Air Temperature Sensor (Optional)
Protection category Unit dimensions Weight FIREYE specific CANbus. Interface to PPC6000 / NX6100 1.17 Fireye NXDBVSD Variable Speed Drive (VSD) Daughter Board (optional Ambient temperature range 0 to 60°C (32 to 140°F) Protection category Not applicable (fits inside NX6100 unit).
Page 19: 1.19 Parts List With Description
NXDBVSD counter inputs, two programmable relays, isolated RS485 – Modbus RTU NXO2INT CANbus O2 interface module with Fireye and generic (4-20mA) probe inputs. O2 PROBES FOR NX6100 ONLY O2 probe assembly (for flues 300mm to 1000mm). Includes NXIATS CANbus NXO2PK4 ambient temperature sensor, flange kit.
Page 20 COMMUNICATION INTERFACE GATEWAY "Modbus RTU" interface card for PPC6000 / NX6100. Networks up to NXDBMB 15 Fireye Nexus Systems – one card per control... VSD interface daughter board with two VSD channels, one analog output, two NXDBVSD counter inputs, two programmable relays, isolated RS485 – Modbus RTU F O R A D D I T I O N A L P A R T S S E E F I R E Y E P R I C E B O O K C G - 1 4 S O M E F E A T U R E S I N C L U D E D O N N XT S D M A N U F A C T U R E D A F T E R M A Y 2 0 1 1 .
Page 21: Installation
2. Installation This section contains basic installation information concerning choice of control and servomotor environment, wiring specification and connection details. WARNING EXPLOSION OR FIRE HAZARD CAN CAUSE PROPERTY DAMAGE, SEVERE INJURY OR DEATH To prevent possible hazardous burner operation, verification of safety requirements must be performed each time a control is installed on a burner, or the installation modified in any way.
Page 22: Mechanical Mounting Details For The Nx6100
Mechanical mounting details for the NX6100 A Template for mounting is provided at the end of this manual for convenience. See Section 11. There are two versions of the control, one that is intended to be mounted inside of a burner control cabinet, the other which has provision for conduit storage of field wiring etc.
Page 23: Mounting Details For Optional Oxygen Probe Interface Unit
Mounting details for optional Oxygen Probe Interface unit A Template for mounting is provided at the end of this manual for convenience. See Section 11.7. The optional oxygen probe interface unit is designed to be fitted either within a control cabinet or without a control cabinet;...
Page 24: Mounting Arrangements For Temperature, Gas Pressure And Steam Pressure Sensors
The ambient operating temperature range is 0 to 70°C (0 to 158°F). The unit MUST be grounded to maintain electrical safety and ensure reliable operation. The conduit connection for gas pressure sensors is PG9, an adaptor for ½” NPSL is available. Fireye ½” Conduit Adaptor PN35-371.
Page 25: Steam Pressure Sensors
The ambient operating temperature range is 0 to 70°C. The unit MUST be earthed to maintain electrical safety and ensure reliable operation. The conduit connection for steam pressure sensors is PG9, an adaptor for ½” NPSL is available. Fireye ½” Conduit Adaptor PN35-371.
Page 26: Oxygen Probe Description
2.4.4 Oxygen probe description The oxygen trim / monitoring function is designed to be used with either an NXO2PK4, NXO2PK6, or NXO2PK8 oxygen probe. The probe offers fast, accurate response and good reliability when mounted in accordance with the guidelines in this section. The probe is available in three different sizes.
Page 27: Installation Of Oxygen Probe
Installation of oxygen probe 2.5.1 Mounting the oxygen probe The probe must be mounted in a manner that ensures that the flue gases pass into the gas tube at its open end and out of the tube at the flange end. Furthermore, if possible, the flange should be vertical with the gas tube angled downwards to ensure that particulates do not build up within the sample tube.
Page 28: Option Link Selection (Nx6100)
DIRECTION OF DIRECTION OF PART A PART B FLUE GAS FLOW FLUE GAS FLOW 3 (1/8") FILLET WELD MOUNTING ALL ROUND PLATE FLUE WALL FLUE WALL Ø M6x25 ST.STL. BE220069 SCREW - TAP FLUE WALL IN 6 POS'NS ON 80 30¦...
Page 29 Bussman S504 series P/N GMA-1 1 AMP (Fast Acting) ( to protects 5V DC circuit) Alternate Source: Mouser Electronics PnN 504-GMA-1 Bussmann - S504 series P/N GMD-630 (TIME Delay) for 115V P/N GMD-315 (TIME Delay) for 230V ( to protect 24V circuit Alternate Source:: Mouser Electronics AH221833...
Page 30: Line Supply Voltage (Lk1 - 4) (Nx6100)
2.6.2 Line supply voltage (LK1 - 4) (NX6100) WARNING Incorrect setting of the Links WILL damage or destroy the unit. The possible supply voltages are shown below, together with the necessary fuse rating. Incorrect setting of the ‘supply selection links’ will cause damage to the unit. The correct fuse (type and rating) must be fitted;...
Page 31: Remote Setpoint (Nx6100)
2.6.4 REMOTE SETPOINT (NX6100) If the remote setpoint or track signal is being used, link JP2 must be set to suit the type of signal. For example: • For a current input set JP2 to IN position to ensure burden resistor is connected. •...
Page 32 CAUTION Disconnect the power supply before beginning installation to prevent electrical shock, • equipment and/or control damage. More than one power supply disconnect may be involved. Wiring must comply with all applicable codes, ordinances and regulations. • • Loads connected to the PPC6000 series, optional daughter board and optional oxygen probe interface must not exceed those listed in the specifications as given in this manual.
Page 33 All low voltage circuits and communication wire must be fully shielded braided (screened) type wire of the specified gauge and number of conductors. Error! Reference source not found. provides the only approved wire for this application. No “or equal” is provided. Use of wire not approved by Fireye may VOID warranty.
Page 34 0.020 0.51 0.20 7 x .008 7 x .2 Table 2.7.1-C CONDUIT CONNECTOR ADAPTERS Metric to ½ inch NPSL Female Device Fireye Part Number NXC04 Servomotor 35-321 NXC12 Servomotor 35-321 NXC20 Servomotor 35-322 NXC40 Servomotor 32-372 NXIATS Inlet Air Sensor...
Page 35: Grounding Cable Screens
2.7.2 Grounding cable screens. Two screen termination clamps are provided on the NX6100 for termination of cable screens (copper braid type) where necessary, if the unit is used with a daughter board the screens of these cables MUST also be terminated to the cable clamps and the screen and associated insulation left on the cable until as close as possible to the terminals to which they are connected.
Page 36: Ground (Earth) Connection
2.7.3 GROUND (EARTH) connection The main unit MUST be connected to ground (earth); the connection should be made at the stud with the tag showing the Ground (earth) symbol. This connection is required to maintain the overall electrical safety of the installation and ensure the EMC performance of the equipment;...
Page 37: Terminal Designation
2.7.7 Terminal Designation All terminals within the system have ‘unique’ terminal designations to reduce the possibility of wiring errors. This information is tabulated below: Terminal Number Location Function Voltage Range NX6100 24Vac Supply for Servos, Display etc. 24 – 40Vac NX6100 24Vac Supply for Servos, Display etc.
Page 38 Terminal Number Location Function Voltage Range NX6100 Isolated comms ground 0 – 5V (daughterboard) NX6100 Isolated comms - (daughterboard) 0 – 5V NX6100 Isolated comms + (daughterboard) 0 – 5V NX6100 RS485 ground NX6100 0 – 5V NX6100 RS485 B (-) NX6100 0 –...
Page 39 Terminal Number Location Function Voltage Range NX610/NX6110 Display Relays – General Purpose Shown For Alarm, see Section 5.5.1 Option 17.x Table A Display Unit Relay output 1 normally open 0 – 250V Display Unit Relay output 1 normally closed 0 – 250V Display Unit Relay output 1 common 0 –...
Page 40 0 – 40V NOTES: - Fireye self test sensors NX103x / NX104x - Fireye self test NX103x / NX104x and externally powered 4-20 mA sensors - Fireye Approved Integrated scanners Type: Phoenix series 85xxx-1WR, or Insight series 95xxxx with “WR cable”...
Page 41 STATUS LED BLOCK BLOCK Blinking = OK BLOCK BLOCK BLOCK BLOCK...
Page 42: Live And Neutral Supply (Nx6100)
2.7.8 LIVE and NEUTRAL supply (NX6100) WARNING Incorrect setting of the Supply Voltage Links WILL damage or destroy the unit. The LINE and NEUTRAL supplies must be connected using multi-strand single conductor (core) PVC insulated MAX 8A 16 AWG (19/0.3mm) wire. The live connection MUST be LIVE LIVE PE 1 fused with a maximum rating as shown.
Page 43: Auxiliary Relay Outputs (Display)
2.7.11 Auxiliary Relay Outputs (display) Fuses not exceeding 4A must protect all relay outputs. Fit a 4A fuse to the Burner Panel Supply, relay common or, where the total RELAY 1 NORMALLY OPEN PR 1 current exceeds 4A, fit a separate fuse on each relay output to achieve this.
Page 44: Fuel And Profile Select Inputs (Optional) (Nx6100)
READ THIS FIRST!!!! There are numerous mentions of “….overall braided shielded (screened) wire” throughout this manual. This is an important aspect to reliable operation. Error! Reference source not found. lists the only approved wire for this control. While one of the specifications relating to shielded wire indicates the amount of coverage (0-100%), this is not the only factor in selecting wire.
Page 45: Low Voltage Digital Inputs 1 To 7 (Nx6100)
other cable connected to the control or run in the same conduit. Note that these inputs expect dynamic low voltage (0/5V) signals and must be taken from the terminals provided. Under no circumstances should these input/outputs be connected to mains potential. Connection of any voltage above 5 volts to these terminals will damage or destroy the unit.
Page 46 There are 2 sets of terminals available for the CANbus connection; both sets are identical. 24Vac PA 1 / PB 1 24Vac PK 1 / PT 1 24Vac PA 2 / PB 2 24Vac PK 2 / PT 2 CANbus + PA 3 / PB 3 CANbus + PK 3 / PT 3 NOTE: Terminals PA &...
Page 47: 2.7.17 Pressure Sensor Screen Termination
Connect the braided shielded (screened) cable SENSOR SUPPLY PA 20 to the control with the screen termination clamp. In the case of the Fireye NX103x or Fireye body NX104x sensors, the braided shielded (screened) cable must also be connected a the...
Page 48: Gas Pressure Sensor Input (Nx6100)
For the Fireye NX104x, form a ‘tail’ from the cable screen and use of a ring crimp terminal connected to the sensor body. For the Fireye NX103x use the screen termination clamp. Make all connections at the sensor/transmitter first.
Page 49: Remote Setpoint (Analog Input 5) (Nx6100)
Fireye Approved Integrated scanners Type: Phoenix series 85xxx-1WR, or Insight series 95xxxx with “WR cable.” Reference table in section 2.7.7. 2.7.22 Remote Setpoint (Analog Input 5) (NX6100)
Page 50: Rs485 Interface (Nx6100)
2.7.24 RS485 interface (NX6100) The RS485 interface included in the basic control is intended to be used for interconnection of several Fireye units or connection of a ‘lap-top’ computer during commissioning if it is intended to make a permanent connection to a PC or non-Fireye equipment the optional isolated RS485 daughter board should be installed.
Page 51: 2.7.25 Variable Speed Drive Selection
2.7.25 Variable Speed Drive Selection: The NX6100 may have an optional daughter board within the main enclosure to allow control of 1 or 2 inverter drives. Optionally the daughter board is also available to allow feedback to be taken from directly from encoders measuring the speed of the relevant motor, fan or pump shaft.
Page 52: 2.7.26 Variable Speed Drive Daughter Board P/N Nxdbvsd
2.7.26 Variable Speed Drive Daughter Board P/N NXDBVSD. See Section 5.4.1 Option 03.x for setup details CAUTION Due to the possibility of High Frequency electrical noise, BOTH ends of the shielded signal wire to the VSD must be grounded. 4-20mA Output Channel 1 – ve PZ 1 The cabling for all of these terminals MUST be 2-core overall braided 4-20mA Output Channel 1 +ve PZ 2 shielded (screened) PVC insulated 24 AWG (7/0.2mm).
Page 53: 2.7.27 Live And Neutral Supply External Interface - P/N Nxo2Int
4 + 20mA (+) see note PL 5 N/A future use PL 4 CANbus – PL 3 CANbus + PL 2 Neutral PL 1 Live Ground (Earth) (screw) NOTE: 4-20mA O input from non-Fireye O probe. See sections 30.1 and 30.2...
Page 54 CAUTION Disconnect the power supply before beginning installation to prevent electrical • shock, equipment and/or control damage. More than one power disconnect may be involved. Wiring must comply will all applicable codes, ordinances and regulations. • • Wiring where required, must comply with NEC Class 1 (Line Voltage) wiring. The cabling between the unit and the probe consists of the following: Cable Specification...
Page 55: Inlet Temperature Sensor (Optional)
0. DO NOT connect the screens at the probe. Incorrect connection may damage or destroy the units being connected. 2.7.29 Inlet temperature sensor (optional) The system allows direct connection of an FIREYE inlet temperature sensor. The unit is connected via CANbus 24Vac PA/PB 1...
Page 56: Final Checks
Shield CANbus - CANbus + 24 VAC 24 VAC NXIATS Inlet Air Temperature Sensor NOTE: When wiring the shield wire to terminal 5 be sure to insulate to prevent grounding against pins located on the circuit board. Final checks WARNING Incorrect setting of the Supply Voltage Links WILL damage or destroy the unit.
Page 57: Servo-Motor Selection And Calibration
3.1.1 Motor requirements Only servo-motors supplied by FIREYE may be used with this equipment, various servo-motors are available, to suit differing applications. The information below is intended as a general guide only; ensure that when installing or adjusting the servo-motors fitted to the appliance that reference is made to the correct instruction manual.
Page 58: Important: Servo-Motor Direction Warning
The flat (facing the shaft) will now be in the 6-9 O’clock position. At this point the mechanical connection to the driven device can be made up. Fireye “D” hole couplings should be used in order to assure a secure connection.
Page 59: Locking The Servo-Motor To The Valve Shaft
It is essential that the motor and valve remain securely connected to ensure safe • operation of the equipment, since feedback is only taken from the servomotor. A variety of “D” hole couplings are available. Contact your Fireye Distributor, or Fireye, Inc., for assistance. Feedback potentiometer...
Page 60: Adjusting Microswitch Positions
For each motor, it is necessary to adjust the servo-motor position relative to the shaft it is driving (e.g. gas valve) in order to obtain the correct open and closed positions on the display. To do this, follow the procedure below: 1.
Page 61: Servomotor Replacement
Servomotor Replacement After a system has been commissioned replacing an undersized or failed servomotor requires the following considerations: First determine the direction the motor travels as the replacement will have to be set the same way. This can be found in Option Parameter 5.x (x being the number of the drive. E.g. 5.3 is drive 3).
Page 62: Description Of Operation
4. Description of operation There are two (2) types of Displays available for the NX6100. The first is the standard 12-key keypad shown below and the second is the optional 10.4” touchscreen (NXTSD104) described in section 5.4. Both displays rely on the information in this section, and the manual reads as though the standard display is being used, so please read this entire section regardless of the type of display in the configuration being used.
Page 63: Start-Up Sequence
Reset * The Fuel key will have no function when used with the Fireye PPC6000,. Start-up sequence When a fuel selection is made and the ‘burner select’ (PE6) signal is given to start up the burner, the control runs through the sequence described below.
Page 64 Stage Stage name Description Prove closed If gas is selected, the gas valve proving sequence begins. In all positions profiles, the fuel and air motors are moved down until they stop. The final positions are compared with the closed positions stored in memory.
Page 65 Stage Stage name Description Wait for flame When the second safety time t6 has expired, the pilot valve output is established turned off. If permanent pilot is selected and the burner is firing on gas the pilot will remain open with the main valves. Main interval time t7 is initiated.
Page 68: Gas Safety Valve Proving Sequence (Vps)
Gas safety valve proving sequence (VPS) If the gas valve proving is enabled and a gas profile is selected, the control will begin 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 control will perform a non-volatile lockout and lockout the burner.
Page 69: Closedd
The control has 2 modes of operation using the standard Fireye PID modulation function, Remote and Local. The mode of operation is set via the keypad by pushing the “Burner ON/OFF” key and selecting the mode. Using the programmable block function (option) within the control it is possible for the modulation control to be generated with alternate options, these are not covered in the standard manual as they may be generated by the user.
Page 70: Commissioning The Control
5. Commissioning the control WARNING This manual may cover more than one model from the NX6100 series. Check for • additional information at the end of this chapter. While the control is operating in commissioning mode certain safety checks • cannot be performed by the control and therefore the safety of the system operation is the sole responsibility of the commissioning engineer.
Page 71: Commissioning Data
Commissioning data 5.2.1 Option parameters The NX6100 series is configured by programming Option Parameters (memory registers) that describe the configuration of the burner and the boiler. Option parameters are set and adjusted in Option Set mode, but it may not be possible to adjust all of them if the burner is on. 5.2.2 Setpoints Setpoints contain information about required motor positions.
Page 72 There are two (2) types of Displays available for the NX6100. The first is the standard 12-key keypad shown below and the second is the optional 10.4” touchscreen (NXTSD104) described in section 5.4. Both displays rely on the information in section 4, and the manual reads as though the standard display is being used, so please read the entire section 4 regardless of the type of display in the configuration being used.
Page 73: Description Of Touchscreen Operation
Five (5) seconds after power is applied the Fireye splash screen (shown below) will be displayed for 6 seconds, after which a period of 5 seconds of a blank white screen will show.
Page 74 Dedicated ‘buttons’ at the lower edge of the screen perform the following functions: Mute / Reset – used to reset a burner lockout, mute alarms or to test audible alarms. If an alarm is present the button is yellow and the text on the ‘button’ changes to Alarm Mute. Burner Start/Stop –...
Page 75: Touchscreen Overview Display
Icon Description Details Indicates commissioning Displays when the control is operating in mode commissioning mode. Indicates HAND Displays when the control is operating in HAND modulation mode. modulation mode. AUTO Indicates AUTO Displays when the control is operating in AUTO modulation mode.
Page 76: Touchscreen Lockout Reset (Alarm Mute) Function
Once the sequence is complete then the display will return, after a short delay, to the overview screen. 5.4.5 Touchscreen Lockout Reset (Alarm Mute) Function. The Reset (Alarm Mute) ‘button’ on the touchscreen is multi-functional. In normal operation it may be used to test the alarms, this is achieved by holding the button for in excess of 10 seconds after which the alarm relays will activate.
Page 77: Touchscreen Fuel/Profile Select
5.4.7 Touchscreen Fuel/Profile Select. Once the Fuel soft-button is pressed, a pop-up window appears on the right giving the user a choice of available fuels/profiles. The NX6100 allows for a maximum of four profiles. Any profiles, which are not programmed and therefore not available, will be ‘grayed-out’.
Page 78: Touchscreen 'Control' Screen
5.4.8 Touchscreen ‘Control’ screen. Once the Control button is pressed, a window appears giving the user a choice of options. If an option is unavailable it will be ‘grayed out’, for example Manual Modulation may be disabled during commissioning. If the burner is firing, then the modulation percentage will be displayed in a window between the ‘Burner off’...
Page 79: 5.4.10 Touchscreen 'Burner Settings' Button
5.4.10 Touchscreen ‘Burner Settings’ button. Once the Burner Settings button is pressed, a window appears giving the user a choice of data types by Tab. Selecting, by touching a tab, it as possible to view a variety of data, in the example here the Option Parameters are available.
Page 80: 5.4.11 Touchscreen 'Fault/Event Log' Button
Fault data only, Events data only or a combined history as shown in this example. For more information on fault codes and fault finding refer to the Fault Finding section of the NX6100 manual – Fireye bulletin NEX-6101. 5.4.12 Touchscreen ‘Screen Configuration’ button.
Page 81: 5.4.13 Cleaning The Touchscreen
Highlight the profile for which a name is to be entered or modified and press the Modify button. This will cause a window to appear allowing the required name to be entered using the button pad. Once the name is displayed against the required profile the mode can be exited by pressing the ‘X’ in the top right corner of the Touchscreen Configuration window.
Page 82: 5.4.14 Touchscreen Commission Mode
When cleaning the touchscreen ensure the correct LCD screen cleaner is used. Use of any other cleaning fluid or water may damage the screen. There are designated commercial cleaning solutions on the market for touchscreens only. Also, these products are recommended to be used only with a very soft cloth. Please note the directions and the warnings on the product.
Page 83 CAUTION • Use extreme care while commissioning the system. While operating in commissioning mode the safety of the system is the sole responsibility of the commissioning engineer. • Ensure a pre-purge position is entered for the relevant drives. • Incorrect positioning of either fuel or air could cause a hazardous situation to occur.
Page 84: Using Option Set Mode
To enter or adjust Drive positions it is necessary to select the relevant Drive to be set, and then use the up/down arrows to move the drive to the required position. Set all the drive positions for each profile point before using the ENTER button to store the values and move to the next profile point (if already entered) then repeat the procedure for this point and any others required up to high fire.
Page 85: Option 00.3 - Reset Hours Run (0 - 1) Lv3
Option 00.4 – User program select (0 / 1) LV1 This parameter may not be available. Where it is available, it allows the user to de-select the Fireye’s standard modulation program, and select a user program. The user program may be modified using PC software to change the controls behavior for non-standard applications.
Page 86: Option 00.8 - Modbus Communications Speed (0 - 3) Lv3
Option 00.8 – MODBUS communications speed (0 – 3) LV3 Default value 0 NOTE: Only available with NXDBMB (modbus) on NXDBVSD (variable speed drive) daughterboard installed. This option sets the MODBUS communications speed in each controller as follows: Option 00.8 Speed, value bits/s...
Page 87: Option 01.3 - External Profile Select Enable (0 - 2) Lv3
Number entered in parameter 01.2 Fault mute from: Keyboard / comms only. Input 1, PB9 to PB10 Low Voltage Input 2, PB9 to PB11 Low Voltage Input 3, PB9 to PB12 Low Voltage Input 4, PB9 to PB13 Low Voltage Input 5, PB14 to PB15 Low Voltage Input 6, PB14 to PB16 Low Voltage Input 7, PB14 to PB17 Low Voltage...
Page 88: Option 01.5 - Oil Valve Proof Of Closure Select (0 - 13) Lv3
Number entered in Gas valve monitored Digital Input used parameter 01.4 NONE NONE. Input 1, PB9 to PB10 Low Voltage Input 2, PB9 to PB11 Low Voltage Input 3, PB9 to PB12 Low Voltage Input 4, PB9 to PB13 Low Voltage Input 5, PB14 to PB15 Low Voltage Input 6, PB14 to PB16 Low Voltage Input 7, PB14 to PB17 Low Voltage...
Page 89: Option 01.7 - Safety Time Configuration Set (0 - 1)
This parameter allows the selection of a second airflow-monitoring switch. This might be used for a flame- shaping (sometimes called primary air) function. Selecting a non-zero value will enable the operation of the ‘Primary Airflow’ function from digital input 6 (low voltage). If digital input 6 is used for this function, ensure it is not selected for any other function (option parameters 1.x, and 18.6).
Page 90: 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, there are a maximum of 10 drives (0 –...
Page 91: 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. • Due to the possibility of High Frequency electrical noise, BOTH ends of the • shielded signal wire to the VSD MUST be grounded Each Drive connected to the system has a unique serial number allocated to it during production testing.
Page 92: Option 05.X - Drive Options Lv3
Number entered in parameter 4.X Drive X used for profile(s) NONE 3+2+1 4+2+1 4+3+1 4+3+2 4+3+2+1 (ALL) If these parameters are changed after the burner has been commissioned, any profiles affected will need to be re-commissioned. A ‘profile invalid’ fault (see FAULT 64) will lock the burner out on an attempt to fire a profile which has had a previously commissioned drive removed.
Page 93: Option 07.0 - Fan On Early Time (0 To 120 Seconds) Lv3
*selection 3 allows combined gas and oil firing. This selection may not be available on certain versions of this product. In addition, for special applications further options may be allowed – again the availability depends of product version. Option 07.0 – Fan On Early Time (0 to 120 seconds) LV3 DEFAULT: 1 During the burner start-up it is possible to start the fan before starting to open the main damper this reduces the load on the F.D.
Page 94: Option 07.4 - Pilot Ignition Time (T4) (1 To 10 Seconds) Lv3
A flame should not be seen during the pre-ignition time (t3), as this would cause a safety shutdown to occur. If option 08.0 = 1 the control will monitor the ignition relay output terminals and will not care if a flame is present or not during this pre-ignition time.
Page 95: Option 07.7 - Ignition Hold Time (T7) (1 To 30 Seconds) Lv3
Extended Oil Pilot time will essentially extend this time for use with heated (heavy) fuel oil only. See option parameter 14.8. Late or returning spark termination will cause the ignition transformer to be ON during the main ignition time (t6). See option parameter 14.6. Option 07.7 –...
Page 96: Option 08.0 - Ignition Spark Output Check (0 - 1) Lv3
time will then start. If the burner has turned off because the fuel profile selection has been removed (i.e. set to NONE), no post-purge will be performed. If the burner locks out at or after ignition, and a post-purge time has been entered, the controller will also attempt a post purge.
Page 97: Option 09.0 - Inverter Control Accuracy (0 / 1) Lv3
The false flame response time can be set using this option parameter. Number entered in parameter 08.2 False flame lockout time (seconds) 3 seconds 30 seconds The value entered will be 0 or 1, corresponding to 3 or 30 seconds after the detection of a flame (when a flame should not be present) for a safety shutdown to occur (all fuel valves closed etc).
Page 98: Option 09.3 - Inverter Stop Time (0 - 100 Seconds) Lv3
For normal operation, use 100%. If the inverter control is unstable, reducing this value has the effect of damping the inverter’s response as its speed approaches its setpoint. Option 09.3 - Inverter stop time (0 – 100 seconds) LV3 V S D V S D V S D V S D...
Page 99: Option 09.7 - Reserved
Option 09.7 – Reserved Option 09.8 – Reserved Option 10.0 - Gas pressure select (0 - 4) LV3 If a Fireye NX1021-x gas pressure sensor is connected to the system, it’s type and units must be entered here. Option parameter 10.0...
Page 100: Option 10.1 - Gas Pressure Sensor Span (Mbar, Bar, Inches Of Water, Psi) Lv3
Option 10.1 - Gas pressure sensor span (mbar, bar, inches of water, PSI) LV3 This is the gas pressure (above atmospheric) measured by the sensor at its maximum output. The units and number of decimal places depend on option parameter 10.0. Option 10.2 - Gas pressure nominal (mbar, bar, inches of water, PSI) LV3 This is the nominal governed line pressure of the gas supply delivered to the burner.
Page 101: Option 12.0 - Flame Detection Device I.r. Or Direct Coupled (0 - 2) Lv3
Photocell / IR input not used. The flame monitoring must be done via the UV input. Allows flame detection to be performed by Fireye FM approved integrated scanners via internal scanner relay. This option may only be used with the following Fireye scanners; Phoenix 85XXXX-XWR or Insight Scanners with cable 59-XXX-WR.
Page 102: Option 12.1 - Pilot Flame Threshold Photocell Or I.r. (1 -100) Lv3
When this is done, the control must not see a flame on either input when the flame should be OFF. When the flame should be ON, a flame must be seen on BOTH inputs. When using an integrated flame scanner, such as a Fireye Phoenix 85 series, this option must be set to zero.
Page 103: Option 13.1 - Pilot Flame Threshold U.v. Or Shuttered U.v. (0 - 100) Lv3
Option 13.1 – Pilot Flame Threshold U.V. or Shuttered U.V. (0 – 100) LV3 DEFAULT : 20 If option parameter 13.0 has been set to select a U.V. or shuttered U.V. flame sensor, this option parameter must be set to a value for the flame threshold to validate the pilot flame. Once a value is set, the flame signal detected during pilot ignition should be monitored and the level adjusted, if necessary, to ensure safe and reliable operation.
Page 104: Option 14.2 - Oxygen And Flue Temperature Limit Relay (0 - 8) Lv3
Option parameter 14.1 Meaning Connection Details value Limits not assigned to any relay. Limits assigned to relay 1 Display, PR3(COM), PR1(NO), PR2(NC). Low voltage or line voltage. Limits assigned to relay 2 Display, PR7(COM), PR5(NO), PR6(NC). Low voltage or line voltage. Limits assigned to relay 3 Display, PR7(COM), PR9(NO), PR8(NC).
Page 105: Option 14.3 - Permanent Gas Pilot Select (0 - 1) Lv3
A relay can be used to indicate any combination of fault conditions from 14.0, 14.1 and 14.2 – this means that one relay could be used for all faults. When used for an alarm function, the relay will de-energize when in the fault condition, so an alarm bell would be wired in series with the normally closed contacts. Option 14.3 –...
Page 106: Option 14.7 - Aux / Oil Pump Relay Function. (0 - 6) Lv3
If a 4.20mA sensor (Fireye PXMSxxx) is used it is still possible to set a safety limit, but an external limit device must be fitted to protect the boiler.
Page 107: Option 15.1 - Modulation Input Decimal Places (0 To 2)
Fireye NX104x “fail safe” boiler temperature sensor. Set the JP4 link to ‘30V’ and the JP1 link to ‘OUT’. Fireye NX103x “fail safe” boiler pressure sensors. Set the JP4 link to ‘30V’ and the JP1 link to ‘OUT’. Option 15.1 – Modulation input decimal places (0 to 2) This parameter specified the number of decimal places to which the measured value and setpoint are displayed.
Page 108: Option 15.3 - Modulation Input Span Value (-999 To +999 / -99.9 To +99.9 / -9.99 To +9.99) Lv3
Option 15.5 - Boiler high safety limit (0 - 999 / 0.0 - 99.9 / 0.00 – 9.99) LV3 If a Fireye “fail safe” boiler sensor is used, model NX1030-x, NX1034-x, NX1040-1, NX1044-1, the control may be used to monitor the boiler high safety limit and perform a shutdown and lockout if the limit is exceeded.
Page 109: Option 15.9 - Reserved
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 110: Option 16.2 - Allow Profile Swap (0 To 16) Lv3
Option 16.2 – Allow profile swap (0 to 16) LV3 This option allows a digital input to be configured to allow a profile swap without turning the burner off. If this input is ON and a fuel profile selection change is made, the control will go to low fire then back to pilot ignition (P2) on the original profile.
Page 111: Option 17.0 - Relay Output Function Lv3
Option 17.0 – Relay output function LV3 This option parameter assigns ‘events’ to the relay outputs. Set option parameter 17.1 to select the function for relay output 1, option 17.2 to select the function for relay 2 etc. Option parameter Meaning 17.x value No function set from this option parameter...
Page 112 Option parameter Meaning 17.x value Relay ON status 2 onwards and during lockout post-purge (Fan on if burner on or waiting for burner select.) Burner available. Relay on status 2 to 16 inclusive. Low fire output. High fire output. 49 – 100 101 –...
Page 113 B) For NX6110, if set as General Purpose relay, connections are as follows:: NOTE: You MUST recycle power to reset relay function first Option Relay GENERAL PURPOSE Connection Detail Parameter Output 17.1 Display, Low or Line voltage Normally Open Normally Closed Common 17.2 Display, Low or Line voltage...
Page 114 C) For NXTSD104, if set as Alarm, no alarm present, at power up, relays change state as follows:: Option Relay ALARM Function Connection Detail Parameter Output 17.1 Display, Low or Line voltage Common Normally Open Normally Closed 17.2 Display, Low or Line voltage Common Normally Open Normally Closed...
Page 115 Option 18.1 to 18.9 – Low Voltage Fail-safe Alarm / Lockout Inputs (0 – 360) and option parameters 16.3 & 16.4. 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).
Page 116: 16.6. Lv3
HUNDREDS TENS UNITS (fault type) (fuel type) (burner status type) 5 to 9 are spare and can’t be All other values will work like 5 – Fault will be active after selected. selection 1 (including zero). 5 main ignition has started to 9 are spare so new (status 13 onwards).
Page 117: Option 20.0 - Set-Point Select Input (0 - 35) Lv3
Option parameter Meaning 19.X (or 16.5 / 16.6) value High Water High Gas Pressure Low Gas Pressure High Oil Pressure Low Oil Pressure High Oil Temp. Low Oil Temp. Low Atom. Media High Temperature Low Temperature High Pressure Low Pressure Panel Switch Open High Stack Temp.
Page 118 NOTE: Options 20.0 to 20.6 and 20.8 have two operational modes. In one case a “high,” level or voltage present, as would be the case of a closed switch, will result in the action specified. In the other case, a “low” level or open switch would cause the action specified.
Page 119: Option 20.1 - Boiler Shutdown Input (0 - 35). Lv3
Option 20.1 – Boiler Shutdown input (0 - 35). LV3 (0 – 15) A high level on the input specified here will cause the boiler to go off and stay off until it is removed. No fault / alarm is generated. (16 or 20) Will cause the burner to SHUT OFF permanently.
Page 120: Option 20.6 - Purge Time Start Input (0 - 35). Lv3
(21 – 35) A low level on the input specified here will prevent the burner moving on past pre-purge. The drives stay at their purge positions, until this input is switched high (ON). The input numbers are as specified in Option Table 20.0 A above. Option 20.6 –...
Page 121: Option 21.0 - Set-Point 1 Enable (0 - 1) Lv1
NOTE: For the following Options 21.x and 22.x, see Section 9.3 for PID Tutorial. Option 21.0 – Set-point 1 enable (0 - 1) LV1 This option parameter is used to select setpoint 1. Option 21.1 – Set-point 1 control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 This is the desired pressure or temperature control value used in the PID control loop for setpoint 1.
Page 122: Option 21.8 - Remote Setpoint 1 Zero (4Ma) Value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) Lv1
Option parameter Meaning 21.5 value No limits. The burner will run until another method is used to switch it off. Absolute limit. The values entered in option parameters 21.6 and 21.7 are the actual limit values. Deviation limit. The values entered in option parameters 21.6 and 21.7 represent a deviation (i.e.
Page 123: Option 22.4 - Set-Point 2 Derivative Term (0 - 100) Lv1
This is the integral time used in the PID control loop for setpoint 2. It may be set to any value from 0 to 999, seconds. If a value of 0 is entered the integral function is disabled, otherwise the time entered is the number of seconds the control will take to give an additional modulation change equal to that currently given by the proportional term.
Page 124: Option 23.0 - Warming Enable (0 Or 1) Lv1
Option 23.0 – Warming Enable (0 or 1) LV1 This parameter allows a warming function to be applied to the boiler, and makes option parameters 23.1 and 23.2 available. If zero is entered, no warming limit is applied. Option 23.1 – Warming Limit (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 If, when the burner starts up and reaches modulation, the measured pressure / temperature value is lower than that specified here, the control will hold the boiler at low fire until the value specified is reached.
Page 125 The temperature sensor must be a 4-20mA device. If this device is to be loop- powered by the NX6100, it should be connected to the 30V output, “sensor supply” on PA16. See option 25.0 – 25.5. Example: Fireye Temp. Sensor – TS350 NX6100 Sensor Terminal (1) 4-20mA NX6100 Terminal...
Page 126: Option 24.0 Sequence Slaves (Number Of Boilers) (0-3) Lv1
NOTE: When using sequencing, setpoint 2 is unavailable for use with any digital input unless the boiler is removed from sequencing completely. Option 24.0 Sequence Slaves (number of boilers) (0-3) LV1 This option is set to 1, 2 or 3 in each NX6100 to equal the number of lag “slave” boilers in the system. Once set, option parameters 24.1, 24.2, and 24.3 will become available.
Page 127: Option 24.6 - Lag (Slave) On Rate (0-100%) Lv1
1 = lead (master) via Keypad 2 = lead (master) via digital input. (Digital Input Selected via Option 20.8) 3 = lead (master) via communications such as Comfire 2. 4 - Not a lead boiler (lag only) - Same as setting "0" 5 to 7 makes lag boilers modulate in unison with the lead when commanded to be ON as follows 5 = lead (master) via Keypad...
Page 128: Option 25.1 - Water Temperature Zero Value Lv3
3 = uses analog input 3 (PA13 or PA16 supply, to PA9 input) 4 = NOT RECOMMENDED – REQUIRES EXTERNAL 220 OHM RESISTOR - uses analog input 4 (PA13 or PA16 supply, to PA12 input) 5 = uses analog input 5 (PA16 supply, to PA15 input) NOTE - If a loop-powered sensor is used, the "+"...
Page 129: Option 28.3 - Analog Input 2 Decimals (0-2) Lv3
Set the number to be displayed when the input 1 current is 20mA. Setting this parameter to a non-zero value also enables this item. NOTE: Setting the span value enables the item. On the 2-line display the values can then be seen by scrolling with the <> keys in RUN mode. They will always show up as “Analog Input 1”...
Page 130: Option 29.1 - Output1 Zero Value (4Ma Output) Lv3
Drive 8 Position Spare Drive 9 Position Spare Spare Burner modulation rate Spare Spare Measured value Spare Boiler Efficiency Spare Inlet air temperature Spare Flue gas oxygen level Gas pressure Calculated flue gas CO2 level Spare Spare Flame signal Spare Spare Spare Spare...
Page 131: Option 29.8 - Output3 Span Value (20Ma Output) Lv3
Option 29.8 – Output3 span value (20mA output) LV3 Set this option to the value which a 20mA output will represent. Commissioning Oxygen Trim CAUTION Use extreme care when entering flow values and oxygen set points. Incorrect setting of • either could cause a hazardous situation to occur.
Page 132 CAUTION When using the adjust ratio mode, it is not possible for the unit to check drive positions at all times. It is the responsibility of the engineer to check that motors and valves are responding correctly To adjust an oxygen setpoint or enter an air flow value in the firing range, use the following procedure. The manual calculation of the values to be entered here is covered in the next section.
Page 133: Option 30.0 - Oxygen Probe Interface Serial Number Lv3
Option 30.1 - Oxygen probe calibration offset value (0 – 999) LV3 This option parameter is only available if option 30.0 is non-zero. This option parameter must be set to the calibration offset value that is specified with the Fireye probe supplied.
Page 134: Option 30.4 - Flue And Inlet Sensor Temperature Units (0 - 1) Lv3
Option 30.4 – Flue and inlet sensor temperature units (0 – 1) LV3 This option parameter is only available if option 30.0 is non zero. This option parameter must be set to select the units for display of both temperatures on either °C or °F. Option parameter Meaning 30.4 value...
Page 135: Option 30.7 - Boiler Transport Delay (5 - 60 Seconds) Lv3
Option 30.7 - Boiler transport delay (5 – 60 seconds) LV3 Boiler transport delay is the time taken for 'gas' to travel from the burner to the oxygen probe. This delay varies with burner fire rate. In order for the oxygen trim control loop to be stable, this parameter must be set accurately to the transport delay of the boiler when at low fire.
Page 136 The drives are moved to the next position directly below high fire (Ph-1) and wait for the oxygen to stabilize. The unit moves the air drives up to the point above the current setpoint, leaving the fuel drive in the same position. The display will show ‘Flow calc An + 1’. When the new oxygen reading settles, the unit calculates and stores the new flow value.
Page 137: Options 31.1 To 31.4 - Trim Type For Profiles 1 To 4 (0 To 2) Lv3
Option 31.0 - Limit Modulation Range (0 to 1) LV3 By default, the control modulates the burner between the set-points P (low fire) and P (high fire), where is the last set-point entered in commission ratio mode. If oxygen trim is fitted, it is not possible for any drive position to be trimmed lower than point P (low fire) or higher than point P (high fire).
Page 138: Option 32.0 - Trim Limit Default (0/1) Lv3
Parameter value in Meaning 31.X No Trim. Do not apply oxygen trim when running on this profile. Air Trim. Trim ‘Air’ drives when running on this profile (see option parameters 2.0 to 2.9.) Fuel Trim. Trim ‘Fuel’ drives when running on this profile (see option parameters 2.0 to 2.9.) Option 32.0 - Trim limit default (0/1) LV3 0 = Default Trim Limit of ±...
Page 139: Option 34.0 - Trim Proportional Gain (0/1) Lv3
Option 34.0 - Trim proportional gain (0/1) LV3 Options 34.1 to 34.4 - Trim proportional gain (0.0 – 99.9%) LV3 Options 34.0 to 34.4 are only available if option 30.5 (oxygen input function) has been set for closed loop oxygen trim. If oxygen trim proportional gain is not required for any profile selection, set option parameter 34.0 to 0.
Page 140 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 Fuel flow position y = x + 100 c = a + 100 d = b + 100 High fire...
Page 141 Table: Flow calculation table Ex. Air + 100 Profile Excess Air y = x + 100 Ratio Airflow Fuel flow 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 142: 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 NX6100 and displayed as a ‘list’...
Page 143: 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 144: Option 38.0 - Oxygen Alarm Select (0 - 2) Lv3
Option 38.0 - Oxygen alarm select (0 – 2) LV3 CAUTION This parameter is not required, but highly recommended. Option parameter 38.0 is only available when option 30.5 (oxygen input select) is not set to zero and the optional oxygen probe interface unit is connected. Since the oxygen alarm values relate to the oxygen setpoint values, oxygen setpoint values must first be entered in adjust ratio mode.
Page 145: Option 42.0 - Second Oxygen Probe Interface Serial Number Lv3
‘0, nothing’ is displayed. Enter this value to disconnect the specified device from any hardware. The FIREYE oxygen probe and associated electronics are not fail-safe. It is for this reason that the maximum amount of oxygen trim allowed must be limited by the commissioning engineer using option parameters 32.1 to 32.4.
Page 146: 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, as seen on the following chart:...
Page 147: Option 42.7 - Air Pressure Input (0-3) Lv3
Option 42.7 – Air Pressure Input (0-3) LV3 In addition to the analog or counter feedback from a VFD, an optional loop powered air pressure sensor of a suitable range can be added. Analog inputs 1,2 or 3 can be used for this purpose. During commissioning, the value of this sensor is appended to the combustion curve (profile) and is treated as a cross reference during operation.
Page 148: Option 44.1 - Set Year (00 - 99) Lv1
Option 44.1 – Set Year (00 – 99) LV1 See “SET CLOCK” Example after Option 44.7 Option 44.2 – Set Month (1 – 12) LV1 See “SET CLOCK” Example after Option 44.7 Option 44.3 – Set Day of Month (1 – 31) LV1 See “SET CLOCK”...
Page 149: 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 150: Option 45.2 - Restore Command (0 - 999) Lv3
Comfire 2 software, all data and combustion curves will need to be entered by hand. Please refer to Fireye bulletin NEX-1502 (Comfire 2), available at www.Fireye.com. Comfire 2 will not restore the servomotor serial numbers which will need to be hand entered in Option 3.0 to 3.9 BEFORE restarting the NX6100.
Page 151: Commission Ratio Mode
This option allows the commissioning engineer to deselect the NXEXP300 by changing option 43.0 to a value of 0. After entering the value of 817, exit commissioning mode, then, without shutting the power to the control off, re-enter full commissioning mode. At this point, option 43.0 will allow a value of 0 to be entered.
Page 152: Using Commission Ratio Mode
5.6.2 Using commission ratio mode CAUTION Use extreme care while commissioning the system. While operating in commissioning mode • the safety of the system is the sole responsibility of the commissioning engineer. Ensure a pre-purge position is entered for the relevant drives. •...
Page 153: Leaving Commission Ratio Mode
NEXT. Otherwise, move each motor to its required pre-purge position and press ENTER. If the purge setpoint has not been entered before the servo-motors will remain at their respective closed (P0) positions until each motor has been moved to its required position. Once all selected motors are at the correct position press ENTER.
Page 154: Entering Adjust Ratio Mode
• Using adjust ratio mode, it is possible to modify the motor positions for any setpoint in the firing range from low to high fire (P3 and higher). • The setpoints may be chosen in any order. • It is not possible to modify any motor position so that it is higher than the high fire setpoint. •...
Page 155: Leaving Adjust Ratio Mode
There are two methods for finding the software issue: 1. From run mode, press the COM key. The Fireye version number will appear. 2. Use the engineer’s key (refer to section 6.6 for details.) and scroll up to EK200 for the current Fireye operating version.
Page 156: Faults And Fault Finding
6. Faults and fault finding The fault display The NX6100 carries out a number of internal and external checks during operation. If a fault is found, a fault number (displayed with a text description) is used to identify the type of problem. A list of fault numbers may be found later in this chapter.
Page 157: Non-Volatile Lockout
Once all faults have been diagnosed, rectified and cleared, press the FAULT MUTE RESET key for approximately three seconds to remove the fault messages and re-start the burner. The function of the MUTE RESET FAULT MUTE key may also be achieved via Comview or by using the FAULT MUTE input.
Page 158 No * Cause Description Flame Failure The flame detector did not register the presence of a flame when it should be present. Subset : burner status False Flame The flame detector registered the presence of a flame when it should not be present or when the shutter (if selected) was closed.
Page 159 No * Cause Description Optional second The primary air pressure switch registered air pressure when (primary) air it should not be present (subset : 1), or the air pressure pressure detected switch registered air pressure for more than 3 minutes after when it should not the burner was turned off (subset : 2).
Page 160 No * Cause Description Drive 0 position A drive-positioning fault has occurred, which will cause a non- fault volatile lockout of the burner. This fault has occurred for one of the following reasons: Drive 1 position 1. During ‘Close’ position prove, the measured position fault when a drive stops at a position that is outside the commissioned ‘Close’...
Page 161 No * Cause Description Oil Proof of The oil valve proof of closure signal is not responding Closure fault correctly. The fuel valve “proof of closure” switch must change state (e.g. open or close) within 7 seconds of the valve being energized or de energized. Subset : burner status.
Page 162 No * Cause Description Reset fault This fault occurs if the control receives more than 5 ‘false’ restart requests within a 15 minute period. A false restart request occurs then the fault mute key / input is held for more then three seconds when there is no fault present.
Page 163 Subset : Failed Page. Spare Boiler safety limit The boiler’s measured value has exceeded the exceeded pressure/temperature safety limit, or the Fireye pressure/temperature sensor is not responding correctly. Subset : 1 = - sensor feedback < 1V, 2 =- sensor feedback > 5V,...
Page 164 No * Cause Description EEPROM memory The EEPROM memory in the controller has been corrupted. CRC fault This memory is used to store the option parameters, • Interrupt power to the controller • Erase the system using option parameter 45.1 = 5 and re commission (or restore with option parameter 45.2).
Page 165 No * Cause Description The measured oxygen level exceeded 15.0% during auto trim Auto trim commissioning. The burner is shutdown. commissioning fault Subset : Last auto trim commission setpoint (+32 if adding air). The measured flue temperature is below the low alarm value Flue temperature for the current profile, or the flue thermocouple is faulty.
Page 166 No * Cause Description Profile Invalid This fault means that the controller can’t fire the currently selected profile because it isn’t sure it still matches the burner / site configuration. It could lead to a hazardous situation. There are three possible causes to this fault : 1 –...
Page 167 No * Cause Description Secondary relay A secondary fault has occurred with the main 1, main 2, pilot, fault vent or non-volatile lockout relays. Tests are performed once an hour. If two consecutive tests fail then the controller will Lockout and display the fault number. •...
Page 168: The Engineer's Key
The engineer's key By selecting the engineer's key it is possible to read the values of internal system variables and external input and output states. It is also possible to see the values of fault subsets, in order to obtain more detailed information about a fault that has occurred.
Page 169: Engineer's Key Parameter List
6.6.2 Engineer’s key parameter list Name Description Low Voltage Digital Input 1 PB9 – PB10 Shows the state of each input. Low Voltage Digital Input 2 PB9 – PB11 Where : Low Voltage Digital Input 3 PB9 – PB12 Low Voltage Digital Input 4 PB9 –...
Page 170 Name Description EK16 Low fire hold or warming limit active 0 - Measured value above warming limit, burner free to modulate. 1 - Measured value below warming limit, burner held at low fire if the controller is in auto or sequencing mode. EK17 Flame Detected 0 –...
Page 171 Name Description EK24 Oil warming Active The burner will not fire because the oil is not up to temperature and the oil warming function is active. EK25 CAN_TX Failures A count of the number of times the can bus controller has failed to send a message since power-up.
Page 172 Name Description EK33 Modulation mode The current modulation mode : 0 - Auto mode. +1 - Manual from keyboard / TSD +2 - Low fire hold from keyboard / TSD +4 - Local 1. +8 - Local 2. +12 - OFF from Display Ex.: 10 would be local 2, LFH.
Page 173 Name Description EK44 Oxygen measured value The current flue oxygen value as measured by the Fireye probe (if fitted). EK45 Oxygen probe status 0 – Probe OK +1 - Internal fault. +2 - Internal fault. +4 - Heater fault. Causes F50.
Page 174 Name Description EK48 Excess air (%) Excess combustion air at the current firing position. EK49 Oxygen error (%) Error between O measured value and O setpoint. EK50 Trim deviation (% flow) Deviation in air flow/airflow imposed by trim (- 25 to +25%) EK51 Gas pressure (display units as set Measured gas pressure from the gas pressure...
Page 175 Name Description EK60 Digital (relay) outputs on. The combination of digital outputs currently switched on. +1 : Digital Output 1 ON. Display, PR3(COM), PR1(NO), PR2(NC). Low voltage or line voltage. +2 : Digital Output 2 ON. Display, PR3(COM), PR5(NO), PR4(NC). Low voltage or line voltage.
Page 176 0 for OFF (open circuit) and 1 for ON. EK72 Oxygen probe cell temperature. The temperature of the zirconia cell inside the Fireye oxygen probe, if fitted. This value should be very close to 650ºC for accurate operation. EK73 Ambient air temperature.
Page 177 Name Description EK76 Second probe status The same as EK45, but for the second oxygen Longest task number. probe. This is provided for manufacturers diagnostics only and may be removed in future versions. EK77 Last program byte address This is the length of the currently running user Program size.
Page 178 Name Description EK94 IR DC Level If the IR input is set to function 2 (option parameter 12.0) then the flame signal is determined by the amount of flicker in the signal. EK 94 will show the average DC voltage level on the input, which corresponds to the resistance of the cell due to background IR radiation.
Page 179 No. * Name Description If the value is 1, the control limits are active EK103 Control Limits Active and will turn the burner on and off as the load dictates. The low and high limits are shown on EK153 and 154. If the control limits are holding the burner off, EK18 will be zero.
Page 180 No. * Name Description Lead is modulating to the load in the EK126 Lead in Prop band proportional band 1 = Burner available for sequencing EK127 Burner available 1 = 2 slaves available EK128 2 Slaves 1 = 3 slaves available EK129 3 Slaves 1 = Slave 1 will not be used...
Page 181: Troubleshooting
No. * Name Description EK155 Spare The current boiler measured value (actual EK156 Measured Value value) shown with increased precision. The modulation rate that the boiler will fire to if EK157 AUTO modulation rate in AUTO mode (providing option parameter 15.0 is not zero or 1).
Page 182 Problem Possible cause Suggested action Display will not light at 24VAC supply to display Check for 24VAC on PT1 and PT2. all. missing. Check fuse FS1. If blown, investigate all Main controller not running. high and low voltage external wiring and replace fuse, if necessary, with a new one of the correct type and rating.
Page 183: Startup
6.7.2 Startup Problem Possible cause Suggested action Burner will not start. Controller in non-volatile lockout. Hold FAULT MUTE key when faults clear. High control limit exceeded. Control in commission ratio Check EK18 and wait for press/temp to drop. mode. Press NEXT to advance to next setpoint. Burner off via serial comms.
Page 184: Gas Valve Proving
6.7.4 Gas valve proving Problem Possible cause Suggested action Proving sequence takes a Nominal gas pressure, test Check option parameters 10.1 to 10.7. long time. volume or leakage rate wrong. Expected time shown on EK52. Main valve 2 does not Vent valve has been selected.
Page 185: Inverters
6.7.6 Inverters Problem Possible Cause Solution Inverter does not start because it Ensure that the inverter receives a • • does not receive a RUN signal. RUN signal from the burner fan motor output daughter board fitted on the NX6100 control. TIME Inverter has a slow start.
Page 186: Oxygen Measurement And Trim
6.7.7 Oxygen measurement and trim Problem Possible cause Suggested action Oxygen display not No oxygen probe interface unit Enter serial number into option parameter serial number entered. 30.0 available. Enter serial number into option parameter No inlet temperature No inlet temperature unit serial 35.0 display number entered.
Page 187: Inverter (Variable Speed) Drives
7. Inverter (variable speed) drives This manual may cover more than one model in the NX6100 series. Check for additional information at the end of this chapter. System configuration The NX6100 control can control one or two inverter drive(s) to control a fuel and/or air drive(s) using a daughter board (fitted within the NX6100 enclosure).
Page 188: Description Of Control Method
Description of control method During start-up of the burner, and before any drives move to purge, the NX6100 control, moves all drives to their minimum positions by driving servo-motors down and setting an output current of 4mA to each inverter drive. The control waits for the inverter stop time Option 9.3 and then monitors the feedback signals of all drives and compares them to the values which were stored in memory at commission time.
Page 189: Setting Up The Nx6100 Series For Use With A Inverter Drive
• RUN/STOP active high (i.e. energize to start) Control characteristics: The control characteristics of the inverter should be configured in the following way: • Acceleration and deceleration time approximately 25 - 40 seconds, must be the same. • Straight line (linear) acceleration between reference points •...
Page 190: The Oxygen Trim Option
8. The oxygen trim option CAUTION Use extreme care when handling the oxygen probe and wear heatproof gloves. • Ensure the burner is off before removing the oxygen probe from the flue. • If the boiler is to be operated with the probe removed, fit the blanking cover •...
Page 191: Mounting The Oxygen Probe
8.1.2 Mounting the oxygen probe The probe must be mounted in a manner that ensures that the flue gases pass into the gas tube at its open end and out of the tube at the flange end. Furthermore, if possible, the flange should be vertical with the gas tube angled downwards to ensure that particulates do not build up within the sample tube.
Page 192 DIRECTION OF DIRECTION OF PART A PART B FLUE GAS FLOW FLUE GAS FLOW 3 (1/8") FILLET WELD MOUNTING ALL ROUND PLATE FLUE WALL FLUE WALL Ø M6x25 ST.STL. BE220069 SCREW - TAP FLUE WALL IN 6 POS'NS ON 80 30¦...
Page 193: Appendix
9. Appendix Calibrating and servicing the oxygen probe 9.1.1 Probe calibration WARNING Before proceeding with probe calibration, ensure you have a suitable air and reference gas supply, since both are required to complete the calibration procedure. The calibration gas concentration must be entered as option parameter 30.3 and the oxygen trim function must be disabled using option parameter 30.5.
Page 194: Oxygen Probe Filter Testing
150mm (6ins) If the pressure is 150mm (6ins) water gauge or more the filter must be replaced. NOTE: Fireye offers a calibration pump kit, part number CAP-1. See your local Fireye Distributor for details. 9.1.3 Removing the oxygen probe from the flue CAUTION Before attempting to remove the probe, switch off the system and the boiler.
Page 195: Filter Replacement
The Fireye Oxygen Probe Type NX2012 is retained in the flue by six 6mm stainless steel socket head cap screws. Loosen the 3 screws securing the probe end cap and slide the cap down the flexible conduit. Use • caution the end cap unit may be hot.
Page 196 • through the probe body. Refitting is the reverse of the removal procedure. The electrical connection and polarity of the • thermocouple are detailed on the following page. Fireye O2 Probe Connector *02- PROBE T/C- PROBE T/C+ EXTERNAL FLUE T/C-...
Page 197: Troubleshooting Inverter Problems
Troubleshooting inverter problems Problem Possible Cause Solution • Inverter does not start because it • Ensure that the inverter receives does not receive a RUN signal. a RUN signal from the burner controller at the same time as the NX6100. TIME Inverter has a slow start.
Page 198: Pid Tutorial
PID Tutorial PID Adjustment The NX6100 utilizes and advanced algorithm in order to maintain setpoint over a variety of load conditions. This three term PID can be infinitely adjusted to suit almost any application. The operator should have a basic understanding of the relationship between the three terms - proportional, integral and derivative.
Page 199: Combustion Profile Setup Guideline
This is normal and due to the difference between wet and dry samples. Bear in mind the NX6100 will trim to the value of the Fireye probe, not to the value of a portable analyzer.
Page 200: Fireye Nx6100 Efficiency Calculations
Fireye NX6100 controls can display calculated combustion efficiency. For the displayed efficiency to be meaningful the correct values for Calorific Value and Hydro-Carbon Ratio for the fuel in use must be entered in the related Fireye NX6100 option parameters. Efficiency may be displayed as Net or Gross.
Page 201 The NX6100 ensures consistent fuel: air ratios. The Fireye O2 Trim option continuously compensates for changes that affect efficient combustion due to such variables as: viscosity of liquid fuels, density of gaseous fuels, changes in temperature of fuels, changes in gas and oil pressures, worn and damaged burners, dirty burners, scaling if boiler tubes, ambient temperature, barometric pressure and tramp air.
Page 202: Typical Wiring Diagrams
Typical Wiring Diagrams System connection drawing L1 - 115/230Vac L1-L3 Supply Combustion Air Fan Aux / Oil Pump Ignition Tx Gas Block Vent Valve Dig Input 12 Lockout alarm Dig Input 13 Burner Select Input flame Main Gas1 scanner Main Gas2 Pilot valve Main Oil1 PE10...
Page 203: Fireye Ep And Yp Series Programmer Equivalents
Fireye EP and YP Series Programmer Equivalents Safety Time Configurations Table Safety time configurations similar to Flame Monitor (EP) and BurnerLogix (YP) timings are indicated by programmer model number. Fireye EP and YP Pre- Pre- Pilot Pilot Main Ignition Flame...
Page 204: 10. Function Block Programming Details
After the program is completed it is then uploaded to the control via optional Fireye Comfire software. The user can run the optional program by selection in option parameter 00.4. The factory default program is always available as a back up by deselecting the user program.
Page 205 After loading and executing the Abacus software and following the required steps, a blank schematic page will appear. The toolbar on the right hand side of the main abacus window is used to place blocks on the screen. First draw the blocks, then connect them. Using the toolbar, click the top button twice to bring up two digital input blocks.
Page 206 1.3.5. Entering Parameters Some function blocks require parameters to be entered to work. The sloped top-left corner can easily identify these blocks. The digital input and output blocks on the previous page are examples of this.  Double click one of the digital input blocks on the left hand side of the schematic. The parameters window should now open and show the two parameters to be entered.
Page 207 1.3.7. Linking and uploading your program In order to upload the program to the Fireye PPC600 or NX6100 control, Fireye’s Comfire 2 version 2.0 or above must be running on your PC. For a complete description of Comfire 2 capabilities refer to Fireye bulletin NEX-1502.
Page 208: The Schematic Toolbar
 If Fireye Comfire 2 is not already running on your system, start it up. You can do this from the menu. You'll find it under programs - Comfire 2. After Comfire 2 starts, it should see the units connected to it - if it has been connected. Click the 'Scan Units' button.
Page 209: Place Function Blocks
1.5. Place Function blocks When the button is clicked on the schematic toolbar, this window will open. By clicking in the list you can preview all available function blocks. Click 'Add' to add the currently shown block to your schematic. To get help on the currently selected block, press F1. 1.6.
Page 210 In this case, block x2 has been moved to the right, and now the link goes backwards through the block itself. There is nothing wrong, the program is the same, however, the appearance is unclear. If you grab and drag the line handles in this case, you will not be able to improve the appearance. It is here that you need to use the line style buttons on the schematic toolbar.
Page 211: Canbus Servomotors - Drawings & Templates
11. CANbus Servomotors - Drawings & Templates 11.1 NXC04 4Nm (3 ft/lb) Servo 11.2 NXC12 10Nm (9 ft/lb) Servo...
Page 212: 11.3 Nxc20 20Nm (15 Ft/Lb) Servo
11.3 NXC20 20Nm (15 ft/lb) Servo...
Page 213: 11.4 Nxc40 40Nm (30 Ft/Lb) Servos
11.4 NXC40 40Nm (30 ft/lb) Servos...
Page 214: 11.5 Nx6110 12 Key Display
11.5 NX6110 12 Key Display NOTE: Drawing is NOT to scale.
Page 215: Nxtsd104 10.4" Touchscreen Display
11.6 NXTSD104 10.4” Touchscreen Display NOTE: Drawing is NOT to scale.
Page 216: Nxo2Int Oxygen Interface
11.7 NXO2INT Oxygen Interface TEMPLATE: Remove to use NOTE: Templates should be measured for accuracy as distortion from printing may occur. See section 2.0 for details.
Page 217: 12. Circuit Board Connections
12. Circuit board connections 12.1 Variable Speed Drive (VSD) Daughter Board P/N NXDBVSD See Section 5.4.1 Option 03.x for setup details CAUTION Due to the possibility of High Frequency electrical noise, BOTH ends of the shielded signal wire to the VSD must be grounded. The cabling for all of these terminals must be 2-conductor (core) 4-20mA Output Channel 1 –...
Page 218: Oxygen Probe Connection (Optional Oxygen Probe Interface Unit)
4 + 20mA (+) see note PL 5 N/A future use PL 4 CANbus – PL 3 CANbus + PL 2 Neutral PL 1 Live Ground (Earth) (screw) NOTE: 4-20mA O input from non-Fireye O probe. See sections 30.1 and 30.2...
Page 219: 12.3 Inlet Air Temperature Sensor
12.3 Inlet Air Temperature Sensor Shield CANbus - CANbus + 24 VAC 24 VAC NXIATS Inlet Air Temperature Sensor NOTE: When wiring the shield wire to terminal 5 be sure to insulate to prevent grounding against pins located on the circuit board.
Page 220 Intentional blank page...
Page 221: Nx6100 Terminal Details
12.4 NX6100 Terminal Details PA1 24Vac 24Vac PB1 PA2 24Vac 24Vac PB2 PA3 CAN+ CAN+ PB3 PA4 CAN- CAN- PB4 PA5 Infra-red 5V Dig low test2 PB5 PA6 Infra-red i/p Pro1/2 Dig i/p 8 PB6 PA7 Analogue i/p 1+ Pro3/4 Dig i/p 9 PB7 PA8 Analogue i/p 2+ Dig High test PB8 PA9 Analogue i/p 3+...
Page 222 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 NEXUS NX6100 series Manual

1 Technical Specification

2 Installation

3 Servo-Motor Selection and Calibration

4 Description of Operation

5 Commissioning the Control

Quick Links

Troubleshooting

Related Manuals for Fireye NEXUS NX6100 series

Summary of Contents for Fireye NEXUS NX6100 series