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Nexus PPC5000 Manual

Fuel / air ratio controller
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PPC5000 Fuel / Air Ratio Controller
The equipment described in this bulletin contains hazardous voltages capable of inflicting
severe or lethal electric shock. It is the responsibility of the owner or user to ensure that the
equipment described herein is installed, operated and commissioned in compliance with the
requirements of local Health & Safety and applicable legislation, regulations and Codes of
Practice.
When this equipment is fitted to an appliance due regard must also be given to the requirements of that
appliance.
Before attempting to install, commission or operate this equipment all relevant sections of this
document must be read and fully understood. If in doubt about any requirements consult the
supplier.
Installation, commissioning or adjustment of this product MUST be carried out by suitably trained
engineers or personnel qualified by training and experience.
In all cases it is the responsibility of the owner or user of this equipment to ensure that it is
installed, operated and commissioned in accordance with the applicable legislation for the country
in which it is being operated.
The manufacturer of this equipment accepts no liability for any consequences resulting from inappropriate,
negligent or incorrect installation, commissioning or adjustment of operating parameters of the equipment.
This equipment must only be fitted to burners as detailed in the contract specification. The supplier must
approve any change in the specification in writing.
Control panels must not be left uncovered while power is on. If it is essential to do so while rectifying
faults only personnel qualified by training and experience should be involved.
The time any covers are off must be kept to a minimum and warning notices must be posted.
Before attempting any work on this equipment, the electrical supplies must be isolated.
Safety interlocks must not be removed or over-ridden. Any faults once detected must be corrected before
the unit is operated.
CAUTION – THIS EQUIPMENT MAY CONTAIN A LITHIUM BATTERY
The manufacturer of this equipment has a policy of continual product improvement and reserves the right
to change the specification of the equipment and the contents of this bulletin without notice.
Safety information
NOTE

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Summary of Contents for Nexus PPC5000

  • Page 1 PPC5000 Fuel / Air Ratio Controller Safety information The equipment described in this bulletin contains hazardous voltages capable of inflicting severe or lethal electric shock. It is the responsibility of the owner or user to ensure that the equipment described herein is installed, operated and commissioned in compliance with the requirements of local Health &...

  • Page 2: Table Of Contents

    Table of contents This bulletin (PPC-5001) describes the installation and commissioning of the PPC5000 fuel / air ratio controller. It may be used in conjunction with the following bulletins : • Nexus NEX-1001 bulletin • Nexus PPC5000 NEX – 1501 ComFire combustion analysis tool user bulletin •...
  • Page 3 Calibrating and servicing the oxygen probe SOx, NOx, smoke, CO, AUX1, AUX2, O/P1, O/P2 Oxygen trim operation Commissioning Oxygen trim Troubleshooting 7. Inverter (variable speed) drives System configuration Description of control method Setting up the inverter for use with the 5000 Setting up the 5000 for use with a inverter drive Troubleshooting inverter problems 8.

  • Page 5: Installation

    1. Installation Installation This section contains basic installation information concerning the PPC5000 system (controller and panel- mounted display), the servo-motors and the wiring. Mounting the control unit 1/8” (M4) CLEAR The control unit is designed to be fitted inside the burner control cabinet.

  • Page 6: Mounting The Display

    Mounting the display The display should be mounted on the front of the burner cabinet, or similar accessible location. It extends for [40mm]/[1.6in] behind the panel, and [4mm]/0.2in] in front of the panel. The maximum allowable panel thickness is [7mm]/[0.3in].

  • Page 7: Circuit Board Removal

    Circuit board removal Please refer to the exploded unit drawing over the page. 1. Disconnect the unit’s power supply. 2. Undo the four screws and remove the grey plastic lid to expose the connectors. 3. Remove all the connectors. 4. Undo the four hexagonal pillars, and lift away the retainer frame. Carefully remove the distribution board.

  • Page 8: Option Link Selection

    1. Remove all of the daughter boards as described in the preceding section. COMMS IC 2. The software EPROM is the device mounted in the socket immediately adjacent to the CPU (see diagram). To remove it, gently lever each end SOFTWARE alternately until the device comes free.

  • Page 9: Servo-Motor Selection

    If the potentiometer moves over its entire 270º range for 90º of servo-motor travel, select a +5v supply. If the potentiometer is a 340º type but only moves over 90º of its range for 90º of servo-motor travel, select a +15v supply. For the basic drive board, a single jumper link (LK1) is fitted which determines the supply voltage for all four feedback potentiometers connected to the board.

  • Page 10: Wiring

    • All servo-motors must have suitable protection for the burner environment (for example, IP65 for applications exposed to the weather). If in any doubt about a particular servo-motor’s suitability, seek confirmation from your equipment supplier, who have a list of suitable motors. Potentiometer requirements All servo-motor potentiometers should be good quality plastic film types, with high resolution.
  • Page 11 Pull the sleeving apart to expose 1/3 Inch (8mm) of the shield (2). Place the exposed length of shield under the clamp bar and tighten the screws (3). LIVE and NEUTRAL supply MAX 3A The LIVE and NEUTRAL supplies must be connected using single conductor TEW, AWM or MTW within the cabinet.
  • Page 12 The three fuel selection inputs are used to determine which profile the unit selects. Each profile can fire any combination of the three different fuels. FUEL 1 FUEL 2 FUEL 3 INPUT INPUT INPUT PROFILE SELECTED (PC13) (PC14) (PC17) NONE, BURNER OFF The two auxiliary inputs can be configured via option parameters to provide / override various status inputs such as fault mute, burner on etc.
  • Page 13 RS232 to local PC modem CLAMP CLAMP CLAMP For details on connecting NEXUS integrated burner controllers, PPC5000 fuel/air ratio controllers and a PC onto the communications bus, refer to bulletin NEX-1501 (ComFire combustion analysis tool) or NEX- SO (boiler sequencing).
  • Page 14 Controlled shutdown triac and safety shutdown relay The controlled shutdown triac should be wired into the ‘stat’ circuit to switch the burner on/off as the temperature/pressure reaches the limit condition. The safety shutdown relay must be wired to ensure that the burner is immediately switched off if the relay opens, to prevent any hazardous condition occurring.

  • Page 15: Final Checks

    Final checks Before applying power, make the following checks : • The unit is set for the correct line supply voltage. All other link positions are correct. • • All fuses within the unit are intact and of the correct value. •...

  • Page 17: Operation In Run Mode

    2. Operation in run mode Operation in run mode Start-up Sequence When a profile selection is made, and the ‘burner select’ signal is given, the burner will start up. The control unit will run through the sequence described below. Name Description 0, 1 INITIALISE...
  • Page 18 PROVE CLOSE The safety shutdown output (PC1-2), the controlled shutdown output (P0) POSITIONS (PC3-4) and the ignition prove output are all closed. All selected motors are driven fully down, and 4mA is output to the inverters. The unit will proceed to status 6 if : All drives have stopped moving and match their close (P0) •...
  • Page 19 PRE-PURGE The safety shutdown output (PC1-2), the controlled shutdown output (PC3-4) and the purge prove output (PC5-7) are all closed. All selected air and option drives are driven to their purge (P1) positions. All selected fuel drives are driven to their close (P0) positions. The unit will proceed to status 9 when the high/low initiate input (PC11) is turned off.
  • Page 20 MOVING TO THE The safety shutdown output (PC1-2) and the controlled shutdown LOW FIRE output (PC3-4) are both closed. POSITION All selected drives (motors and inverters) are driven to their low fire (P3) positions. The unit will proceed to status 12 if : •...

  • Page 21: Modulation

    Startup sequence Safety shutdown O/P (PC1-2) Controlled shutdown O/P (PC 3-4) Ignition prove output (PC 5-6) Purge prove output (PC 5-7) HI / LO initiate input (PC 11) Burner on input (PC 12) Fuel select i n puts (PC13, 14, 17) Fuel drive(s) Air and option drive(s) - Energised\active...

  • Page 23: The Display

    The display The display Description The display is a 2 line 20 character per line dot matrix vacuum fluorescent unit allowing the use of plain text messages for most display parameters. The display must be fitted to allow commissioning of the system but once commissioning has been completed, the display may be removed, providing either the control unit lamps and external switches and/or lamps are fitted for fault indication and reset.

  • Page 24: Display Parameters

    Description of display parameters The Fireye display will indicate all display information as plain text messages, with the exception of the engineer’s key values. Engineer’s key information is found by pressing the Fireye Logo. Press once to see status and subset information and again to see EK values. Press again to return to normal display FUEL 1 - 3 Indicates the position of each drive (up/down motor or inverter) connected AIR 1 - 4...
  • Page 25 CO2 LEVEL Indicates the calculated CO2 level in flue. This display parameter may not be available, depending on option parameter set-up, hardware set-up and oxygen display. This display shows ‘---‘ when the burner is not firing, or the oxygen value is showing ‘---‘. SMOKE LEVEL Indicates the measured flue gas level.

  • Page 26: Motor Adjustment

    Motor adjustment Motor adjustment Feedback potentiometer The servo-motor internal feedback potentiometer must be secured within the servo-motor to ensure that there is no possibility that the potentiometer can become disconnected from the motor output shaft. For each motor, it is necessary to adjust the potentiometer's position relative to its shaft in order to obtain the correct open and closed positions on the display.

  • Page 27: Locking The Servo-Motor To The Valve Shaft

    5. Move the motor up and down a few times to check that the motor stops each time at approximately 2°, and re-adjust the micro switch if necessary. This position will allow for some tolerance in micro switch operation. 6. Hold the UP key and tighten up the high limit micro switch until the motor will no longer move up. 7.

  • Page 29: Operation In Commissioning Mode

    • While the unit is operating in commissioning mode or adjust ratio mode certain safety checks cannot be performed by the Fireye Nexus PPC5000 Fuel Air Ratio Controller and therefore the safety of the system operation is the sole responsibility of the commissioning engineer.

  • Page 30: Commissioning Data

    Commissioning data Option parameters Option parameters contain information about the configuration of the burner and the boiler. Option parameters may be adjusted in option set mode, but it may not be possible to adjust all of them if the burner is on. Set points Set points contain information about required motor positions.

  • Page 31: Commission Ratio Mode

    Using option set mode • Use the LEFT/RIGHT scroll keys to point the select arrow at the option number on the top line of the display and use the UP/DOWN scroll keys to display the option parameter to be changed. •...
  • Page 32 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. Incorrect positioning of either fuel or air could cause a hazardous situation to •...
  • Page 33 6. Wait for the display to show P3 (low fire) after the relevant safety times have elapsed. If ignition is unsuccessful and a safety shutdown occurs, investigate the problem and repeat steps 2-5 to attempt ignition again. 7. If the low fire setpoint has been entered before and no change is required, press AUTO MAN (NEXT). Otherwise, move each motor to the required low fire position and press COM (ENTER).

  • Page 34: Adjust Ratio Mode

    Entering adjust ratio mode Supplier pass code Run mode, burner on To enter adjust ratio mode, turn the burner on. Once the burner begun its start up sequence, press the key labelled COM (ENTER) and obtain the supplier pass code value using the UP/DOWN keys. Once the correct pass code value has been obtained, press the key labelled COM (ENTER).

  • Page 35: Finding The Software Issue & Unit Configuration

    5. Press the COM (ENTER) key to store the new motor positions for the current setpoint. 6. Repeat steps 2-5 as required. Each time step 5 is completed, the new positions will be stored permanently. 7. Leave adjust ratio mode. If the ‘A n’...

  • Page 37: The Oxygen Trim Option

    6. The oxygen trim option The oxygen trim option CAUTION Use extreme care when handling the oxygen probe and wear heatproof gloves. • • Ensure the burner is off before removing the oxygen probe from the flue. • If the boiler is to be operated with the probe removed, fit the blanking cover supplied since dangerous levels of carbon monoxide may be present in the flue.

  • Page 38: Installation Of Oxygen Probe

    Installation of oxygen probe Mounting the oxygen probe The probe must be mounted in a manner which 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 39 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 (3.15") PCD TO FLUE APERTURE FLUE APERTURE...
  • Page 40 Wiring where required, must comply with NEC Class 1 (Line Voltage) wiring. Both the Nexus and PPC5000 systems are designed to interface to the Fireye oxygen probe, which allows the unit to monitor to flue oxygen and temperature and if required to provide full closed loop oxygen trim control.
  • Page 41 INLET TEMP - PN1 sensor. The Nexus PPC5000 system allows direct connection of an Fireye 3035 inlet temperature sensor. This is provided with the zirconium probe kit itself. The cabling between the units is via an overall shielded 2 conductor 22AWG-7/30, 300V 80 DegC (7/0.2mm) PVC insulated cable. Wiring must comply with all applicable codes, ordinances and regulations and where required, must comply with NEC Class 1 (Line Voltage) wiring.
  • Page 42 Interface to auxiliary equipment The interface cabling, to either flue gas analysers or systems connected to the 4-20mA outputs, must be SOx + INPUT PM18 overall braid shielded 2-conductor PVC insulated monitor SOx – INPUT PM17 – 7/32 (300V 80°C), for all signals. Wiring NOx + INPUT PM16 must comply with all applicable codes, ordinances and NO x –...

  • Page 43: Calibrating And Servicing The Oxygen Probe

    Calibrating and servicing the oxygen probe 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 44 Oxygen Probe Filter Testing. The filter can be tested without removing the probe from the flue. Before proceeding, ensure the oxygen trim function is disabled using option parameter 30.5. The check is carried out by passing air at 350cc/min (22cu. ins/min) into the calibration gas connection on the rear of the probe adjacent to the flexible conduit fitting, and checking the pressure drop.
  • Page 45 • Remove the six retaining screws. The probe can be extracted from the flue taking care not to damage the sealing gasket. • The only customer replaceable items are the flue thermocouple and oxygen filter. • If it is necessary to operate the boiler while the probe is removed, the blanking plate supplied with the equipment must be fitted to the probe flange.

  • Page 46: Sox, Nox, Smoke, Co, Aux1, Aux2, O/P1, O/P2

    Probe mounted flue thermocouple replacement. • Remove the oxygen probe from the flue as detailed in section 0. Disconnect the internal connections to the thermocouple. • • Unscrew the 2 thermocouple-mounting blocks from the probe snoot to allow the thermocouple to be straightened.

  • Page 47: Commissioning Oxygen Trim

    The adaptive algorithm used will then remember how much trim was applied at this point and next time this firing point is reached, the same trim will be applied immediately without having to wait for the oxygen value to change. Trim is not applied if the unit is in commission mode.
  • Page 48 Using adjust ratio mode to enter oxygen set points and flow values manually 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.
  • Page 49 3. Record the excess air value at location x in the table. For single fuel profiles, this value may be found using the Engineers Key parameter EK88 (provided the hydrocarbon ratio has been entered into the appropriate option parameter (36.4 - 36.6) for this fuel). For multiple fuel profiles, the tables in section 0 will aid an estimate to be made, using the current oxygen reading.
  • Page 50 Flow calculation table Profile Excess Air Ex. Air + 100 Ratio Airflow Fuel flow position y = x + 100 c = a + 100 d = b + 100 High fire 1 = A (99.9) (y/c 2 = A (y/c 3 = A (y/c...
  • Page 51 Profile Excess Air Ex. Air + 100 Ratio Airflow Fuel flow position y = x + 100 c = a + 100 d = b + 100 13 = A (y/c 14 = A (y/c 15 = A (y/c 16 = A (y/c 17 = A (y/c...

  • Page 52: Troubleshooting

    3. 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’. 4. When the new oxygen reading settles, the unit calculates and stores the new flow value. If the oxygen reading exceeds 15.0% during this stage, the unit shuts the burner down with F77.
  • Page 53 Problem Possible cause Suggested action Oxygen trim will not work Trim is not operative. Use EK25 to decide if trim is operative. If trim is not operative, use EK53 to find out why. Check that option 30.0 =1 or 2. Boiler just fired up.
  • Page 54 Relationship between flue gases - Heavy Fuel Oil Notes: 1. ETC syste ms display Oxygen 'wet' , Carbon dioxide 'dry'. 2. Heavy fuel oil ( 8 5cSt/3500Sec), R=0.128 16.00 14.00 Carbon dioxide (dry) 12.00 10.00 Oxygen (dry) 8.00 6.00 4.00 Oxygen (wet) 2.00 0.00...

  • Page 55: Inverter (Variable Speed) Drives

    Wiring, where required, must comply with NEC Class 1 (Line Voltage) wiring. System configuration The Nexus PPC5000 fuel air ratio control system uses a 4-20mA output on the IDB (isolated drive board), AH221244 as a speed reference signal to the inverter. A matching 4-20mA input is used to monitor a feedback signal from the inverter, representing the speed of the motor.

  • Page 56: Description Of Control Method

    Description of control method During start up of the burner and before the drives move to purge, the Nexus PPC5000 fuel air ratio control system moves all motors to their minimum positions and outputs a current of 4mA to each inverter drive.
  • Page 57 • Maximum feedback frequency same as reference for 20mA signal • No filtering (time constant = 0.0) and no rate limiting...

  • Page 58: Setting Up The 5000 For Use With A Inverter Drive

    • If problems are encountered monitor the reference signal from the Nexus PPC5000 fuel air ratio control system. With the inverter drive selected, the UP key should increase the current gradually up to 20mA and the DOWN key should decrease the current gradually down to 4mA.

  • Page 59: Troubleshooting Inverter Problems

    • Ensure that the inverter does not receive a RUN signal. receives a RUN signal from the burner controller at the same time as the Nexus PPC5000 fuel air ratio control system. TIME • Inverter has a slow start. •...

  • Page 61: Option Parameters

    8. Option parameters Option parameters CAUTION • Use extreme care when entering option parameters. Incorrect data entry could cause a hazardous situation to occur. Option parameter list Note : If an option parameter is marked with ‘*’, it is not possible to adjust its value using the site pass code.
  • Page 62 To protect against the wrong variant of board being fitted, the unit must be configured for the correct motor supply voltage. The unit checks the value of this option parameter against the board variants fitted. If the wrong type of board is fitted, a potentiometer supply fault will be given, and the unit will undergo a safety shutdown.
  • Page 63 Option 02.6 - Position display type (0 – 3)* It is possible to allow the servo-motor position to be displayed in angular degrees or percentage opening, relative to their respective close and purge positions. Further to this it is also possible to select the display resolution, selecting to 1 decimal place or no decimal place.
  • Page 64 This option parameter allows the normal modulation range of the burner to be limited so that the burner may only modulate between points P4 (one setpoint above low fire) and Px-1 (one setpoint below high fire). Since oxygen trim is not affected by this limitation, each drive may be trimmed between the points P3 and Px.
  • Page 65 Options 05.1 to 05.4 - Set air drive output mapping (0 – 12)* Option number Drive Output 05.1 Air damper 1 0-12 * 05.2 Air damper 2 0-12 * 05.3 Air damper 3 0-12 * 05.4 Air damper 4 0-12 * NB : The air damper drive output selection must be unique.
  • Page 66 Fuel 3 Option 1 Option 2 Option 3 Air damper 1 Air damper 2 Air damper 3 Air damper 4 Option 4 Option 5 * If all drives have not been selected, then not all drive numbers will be available. Option 08.1 - Ignition time (0 –...
  • Page 67 2 – Measured value input display range up to 999 with PID control 3 – Measured value input display range up to 99.9 with PID control 4 – Measured value input display range up to 9.99 with PID control Option 13.0 - Setpoint 2 input type (0 – 5)* The setpoint 2 input type must be selected as one of six options.
  • Page 68 Option 11.5 - Setpoint 1 integral term (0 – 100) Option 13.5 - Setpoint 2 integral term (0 – 100) This is the integral term which is used in the PID control loop for the appropriate setpoint. It may be set to any value from 0 to 100, where 0 means no integral term.
  • Page 69 When an absolute limit is selected, the values entered in option parameters 12.1 to 12.4 OR 14.1 to 14.4 are the actual limit values. When a deviation limit is selected, the values entered in option parameters 12.1 to 12.4 OR 14.1 to 14.4 form a deviation from the appropriate setpoint control value.
  • Page 70 Option 12.5 – Setpoint 1 warming limit (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) Option 14.5 – Setpoint 2 warming limit (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) If the boiler’s measured temperature/pressure is below this limit, the burner will be held at low fire. This low fire hold may be overridden using manual modulation mode.
  • Page 71 No function. The output will always be off. Manual selected from keyboard. The output will be turned on when manual modulation mode has been selected from the keyboard. alarm. The output will be turned on when the measured oxygen level falls outside the high or low alarm levels.
  • Page 72 Option Profile Number 0 - default to corresponding 20.0 fuel 1 - select per 'profile' 20.1 Profile 1 1 - 7, where : 20.2 Profile 2 1 = Fuel 1 only 20.3 Profile 3 2 = Fuel 2 only 20.4 Profile 4 3 = Fuel 1 + 2 20.5...
  • Page 73 CAUTION • Only use the large tolerance setting if an inverter error of up to ±55 will not cause unsafe combustion. This option parameter affects all inverters connected to the unit. Small tolerance (normal setting). The unit will perform a safety shutdown if the inverter positioning error exceeds ±30 for 15 seconds or ±55 for 1 second (units conform to those seen on the display).
  • Page 74 Option 25.2 - Low fire burner power output (0.0 - 99.9MW)* Option 25.3 - High fire burner power output (0.0 - 99.9MW)* These option parameters must be set to the power output from the burner when operating at low fire and at high fire.
  • Page 75 Option 30.3 - Oxygen probe calibration gas concentration (0.00 – 9.99%) This option parameter is only available if option 30.0 is set to 1 and an FMI board is installed in option slot This option parameter must be set to the percentage oxygen concentration of the calibration gas used if the probe is to be calibrated using a reference gas (see option parameter 30.6).
  • Page 76 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 77 Option 33.0 - Trim limit default (0/1)* Options 33.1 to 33.7 - Trim limits (0.0 – 25.0)* Option 33.0 is only available if option 30.5 (oxygen input function) has been set for closed loop oxygen trim. It is possible for the system to trim the air or fuel drives up to a maximum deviation of ±25.0% of the total air or fuel flow for the chosen trim drives.
  • Page 78 Options 36.1 to 36.3 - Calorific values of fuels 1 to 3 respectively (0.0 – 99.9) These option parameters are only available if option 36.0 (inlet temperature sensor) is not set to zero. If a display of calculated burner efficiency is required, the calorific value of the required fuels must be entered.
  • Page 79 Options 38.1 to 38.7 - Flue temperature high alarm values (0 – 999)* Using option parameters 38.1 to 38.7, it is possible to set a different flue temperature high alarm value for each profile selection. Each option parameter may be set to any value between 0 and 999 inclusive. The temperature units should be set with respect to option parameter 03.1.
  • Page 80 An oxygen high alarm will be caused by one or more of the following events : • The level rises above the high alarm limit for 2 minutes • The level rises above twice the high alarm limit for 30 seconds See section 9 for details of fault numbers.
  • Page 81 If the burner is firing, it is only possible to make an adjustment to the option parameter which relates to the selected profile combination. If the burner is not firing, the high alarm value for any profile combination may be adjusted. If the CO level exceeds the high alarm value for the selected profile combination, a fault number will appear.
  • Page 82 Note that the values entered for these option parameters are in units of x10 p.p.m, and therefore an entered value of 999 means 9990 p.p.m. Option 50.0 - NO level high alarm select (0/1)* Options 50.1 to 50.7 - NO level high alarm values (0 - 999)* Option parameter 50.0 is only available if option 49.0 (NO input select) is not set to zero.
  • Page 83 If the burner is firing, it is only possible to make an adjustment to the option parameter which relates to the selected profile combination. If the burner is not firing, the high alarm value for any profile combination may be adjusted. When the SO level rises above the high alarm value for the selected profile combination, a fault number will appear.
  • Page 84 Depending on the values of option parameters 58.0, 59.0, 60.0 and 61.0 (see table above), it is possible to transmit one of the variables from the list below as a 4-20mA signal : No function. The output will transmit 0mA. Modulation rate (4mA when not modulating).
  • Page 85 Option 70.1 - Erase command (0 – 8)* When erase enable (option 70.0) is set to '1', this option parameter determines which information will be erased when the unit leaves set-up mode. No erase. Erase profile 1 set points. Erase profile 2 set points. Erase profile 3 set points.

  • Page 86: Option Parameter Selection Of Profiles And Drives

    Option parameter selection of profiles and drives Profile 1 (PC13) Shown by Profile 2 (PC14) EK39 Profile 3 (PC17) Input selection of profile. Option params 20.X Option params 21.X PROFILE MAPPING AIR DRIVE SELECT Permissible trim drives. FUEL 1 04.1 FUEL 2 04.2 FUEL 3...

  • Page 87: Derivation Of Modulation Rate

    Derivation of modulation rate 11.1, 11.2 11.4, 11.5, 11.6, 12.X SWITCH by 11.0 15.1, 15.2, COMMS PA17 ZERO 11.0 = 0 SETPOINT LOWEST & & 11.0 = 1,2,3,4 SELECT PRIORITY Modulation SPAN Measured LIMITS value LOWEST 11.3 PRIORITY 11.7, 11.8 IF 3.3 = 1 &...

  • Page 89: Faults And Fault Finding

    9. Faults and fault finding Faults and fault finding The fault display The unit carries out a number of internal and external checks during operation. If a fault is found, a fault number is used to identify the type of problem. A list of fault numbers may be found later in this chapter. Depending on the type of fault, the unit may perform a safety shutdown of the burner and/or activate the alarm relay (activation of the alarm relay is determined by option parameter 10.1).

  • Page 90: What To Do If A Fault Occurs

    What to do if a fault occurs To cancel the alarm relay, briefly press the FAULT MUTE key, if no display is connected a separate FAULT MUTE 'switch’ will be available. Use the scroll keys to view the FAULT NUMBER parameter and look up the fault number(s) shown to discover why the fault occurred If all faults that caused a safety shutdown have cleared, hold down the FAULT MUTE key for approximately three seconds to remove the faults and re-start the burner.

  • Page 91: Fault Listing

    Fault Listing Name Description Fuel 1 incorrect A drive positioning fault has occurred, which will cause a safety position shutdown of the burner. This fault has occurred for one of the following reasons : Fuel 2 incorrect position • During close position prove, when a drive stops at a position which is outside the close set position by more than five degrees.
  • Page 92 Name Description Fuel 1 feedback A drive feedback fault has occurred, which will cause a safety failed shutdown of the burner. This fault has occurred for one of the following reasons : Fuel 2 feedback failed • A potentiometric feedback signal from a servomotor is outside the range of 0-5v.
  • Page 93 Name Description Fuel 1 illegal speed The specified drive is outside the allowable speed range of 10s/90º to 60s/90º. Fuel 2 illegal speed If the drive is an inverter, adjust the acceleration and deceleration times accordingly. Fuel 3 illegal speed Before the pre-purge starts, all required drives are moved from their lowest positions (closed set points) to their highest positions (purge set points).
  • Page 94 Name Description Burner interface The unit has detected a fault with the mains inputs on the burner board input fault interface board. Is the burner interface board installed correctly? • • Are inputs in the range 0 – 30v (OFF) and 93 – 264v (ON) RMS? •...
  • Page 95 Name Description Option slot 2 voltage The board installed in option slot 2 has an incorrect on-board reference fault reference level. • Is the option board installed correctly? Subset : +1 – channel 0, +2 – channel 1 Commissioning data The commissioning data memory on the CPU board has been checksum fault corrupted.
  • Page 96 Name Description Burner on fault PC12 did not go low when the controlled shutdown triac (PC3-4) switched off. • Is the burner I/O board installed correctly? • Is the wiring between the burner I/O board and burner controller correct? Subset : burner status Purge prove fault The purge prove terminals have not got a feed during purge, or the terminals have been shorted out.
  • Page 97 Name Description Lead drive not A lead drive value has been entered (option 07.X) which does not present exist. • Are the lead drive option parameters set correctly? Are the correct boards installed? • Subset : lead drive Drive not mapped A fuel/air ratio has been selected which has one or more un-mapped drives.
  • Page 98 Name Description Trim drive not One of the trim drives has been specified as the same as the lead allowed drive. Are option parameters 7.X set for the same drive as option • parameters 32.X? Trim limit alarm The trim drive has reached the allowed maximum deviation limit. •...

  • Page 99: The Engineer's Key

    Name Description Option board 2 The calibration data on the board installed in option slot 2 has calibration fault become corrupted. If the fault persists for 23 hours, the burner will shutdown. Is the board in option slot 2 installed correctly? •...
  • Page 100 When using the engineer’s key it is not possible to change any parameters. Therefore it is not possible to affect the operation of the burner. Engineer’s key parameter list Name Description PC8 (DOWN) input PC9 (UP) input Shows the state of each input. PC10 (HAND/AUTO) input Where : PC11 (HI/LO INIT) input...
  • Page 101 Name Description EK20 Setpoint high alarm 0 - Setpoint high alarm off 1 - Setpoint high alarm on. The temperature/pressure measured value has risen above the setpoint high alarm value EK21 Warming limit 0 – Measured value above warming limit 1 –...
  • Page 102 Name Description EK38 Burner status Shows what state the burner is in. Where : 0 - Initialisation 1 - Initialisation 2 - Safety shutdown 3 - Controlled shutdown triac OFF 4 - Waiting for fuel, burner on and high/low initiate signals 5 - Prove closed positions 6 - Prove purge positions 7 - Close fuel drives...
  • Page 103 Name Description EK44 Commission ratio setpoint The current commission ratio setpoint, where : 0 - Closed setpoint 1 - Purge setpoint 2 - Ignition setpoint 3 - Profile 1 setpoint 4 - Profile 2 setpoint 5.24 - Profile 3.20 set points 255 - Setpoint not adjustable EK45 Modulation mode...
  • Page 104 Name Description EK53 trim status 0 - O trim working, or +1 - FMI not fitted +2 - Option 30.0 not 1, or option 30.5 not 1, or option 30.8 not 0 or trim not selected via aux input or trim not selected via serial comms +4 - O set points or flow values incorrect +8 - Option 30.6 not 0...
  • Page 105 Name Description Used to identify the type of basic drive board EK80 Basic drive board feedback value fitted and the supply voltage to the feedback potentiometers EK81 PSU reference error (V) The difference between the calibrated and the measured voltage reference values on the PSU board F39 will be generated if this value <-0.25 or >0.25...

  • Page 106: Troubleshooting

    Troubleshooting CAUTION Use extreme car while testing the system. Line voltage is present on most • terminal connections when power is on. • Disconnect the power supply before beginning to fault find to prevent electrical shock, equipment and control damage. More than one power supply disconnect may be involved.
  • Page 107 Start up Problem Possible cause Suggested action Burner will not start. Unit in safety shutdown. Hold FAULT MUTE key when faults clear. No fuel selected. Check EK6 (profile 1 input), EK7 (profile 2) & EK10 (profile 4). Burner not selected. Check EK5 (burner select input).
  • Page 108 Commissioning Problem Possible cause Suggested action Cannot get past P0. Unit in safety shutdown. Hold FAULT MUTE key when faults clear. Check EK6 (profile 1 input), EK7 (profile 2) & No fuel selected. EK10 (profile 4). Burner not selected. Check EK5 (burner select input). High control limit exceeded.
  • Page 109 Problem Possible cause Suggested action Unit stuck at low fire. Meas. value exceeds setpoint. No fault. Low fire hold time not expired. Wait for low fire hold time to expire. Wait for boiler to warm up. Warming limit active (EK21=1). Unit in manual.

  • Page 111: Technical Specification

    10. Technical specification Technical specification General Supply voltage 110 – 120Vac Power consumption Approx. 20VA Supply frequency 50/60 Hz Temperature range 0 to 60°C Control unit protection category and IP20 – The unit must be situated in a clean mounting position environment.

  • Page 112: Power Supply And Boiler I/O Board (Standard)

    Controlled shutdown, ignition & purge triacs Max. 0.5A @ 250Vac RMS Digital inputs (10) Max. 1.5mA @ 250Vac, Min. 110Vac Digital outputs (3) Max. 15mA @ 12Vdc. RS485 2 - wire with ground, termination resistor selected using a link. Fireye specific protocol. See NEX-1501 (Fireye serial communications protocol manual) for details.
  • Page 113 220 ohms Isolation voltage 50v (not isolated from each other) Oxygen probe kit The oxygen probe kit (series PPC5000) AH221245 consists of : 1 x NX280PK Oxygen probe 1 x Mounting flange kit 1 x Ambient air temperature sensor (3035)

  • Page 115: Commissioning Sheet

    11. PPC5000 Commissioning Sheet...

  • Page 116: General & Drive Positions

    Nexus PPC5000 fuel air ratio control system Commissioning sheet General & drive positions Site : Engineer : Comments : Serial No : Boiler No : Fuel : Date : Profile : Drive position (°) Drive : Drive : Drive :...

  • Page 117: Option Parameters

    Option parameters Note : Not all option parameters are always available. XX.0 XX.1 XX.2 XX.3 XX.4 XX.5 XX.6 XX.7 XX.8 XX.9 00.X 01.X 02.X 03.X 04.X 05.X 06.X 07.X 08.X 09.X 10.X 11.X 12.X 13.X 14.X 15.X 16.X 20.X 21.X 22.X 25.X 30.X...

  • Page 119: Distribution Board Connections

    12. Distribution board connections Distribution board connections AH221250 (for use with 2 x IDB)

  • Page 120: Ah221312 (For Use With 1 X Idb & 1 X Fmi)

    AH221312 (for use with 1 x IDB & 1 x FMI)

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