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Fireye PPC5000 Manual

Fuel / air ratio controller
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®
PPC-5000
APRIL 18, 2013
PPC5000
Fuel / Air Ratio
Controller

DESCRIPTION

The PPC 5000 is an electronic fuel/air ratio controller employing techniques of parallel positioning
for industrial burners firing gaseous and/or liquid fuels.
The basic unit controls four servo motors, positioning them to within 0.1 of an angular degree. Seven
programmable profiles are available where each profile determines the positional relationship
between all servo motors across the firing range of the burner. The unit has the capability to increase
the number of motor drives from four to eight. These servo motors can operate fuel butterfly or
metering valves and air dampers.
Variable speed interfaces are available to control, the burner fan motor speed and water feed pumps.
Controlling the fuel/air ratio by adjustment of fan speed saves electrical energy and reduces noise.
When the motor speed is halved an 80% electrical energy saving can be realized. Up to four variable
speed interfaces can be added to a single PPC 5000.
Oxygen trim control is another valuable option to achieve maximum efficiency and fuel savings. Fir-
eye's zirconia oxygen probe has earned an international reputation for reliability and longevity. Oxy-
gen trim automatically and continuously compensates for all the variables that affect efficient
combustion. This option will give typical fuel savings of 2% and will ensure safe and efficient com-
bustion when firing fuels with varying calorific value.
Optional simultaneous firing software has been developed by Fireye which employs novel, dynamic
setpoint technology. It ensures that the correct fuel/air ratio is maintained across the firing range
when two fuels are being fired simultaneously and the ratio of one fuel to the other is maintained
correctly. A single 4 to 20mA signal varies the mix of the two fuels being fired. Oxygen trim is
needed for all simultaneous firing applications. Fuels or fuel combinations with differing and/or
varying calorific values can be accommodated. Switching between various fuel combinations
becomes a routine task.
"ComFire" communications software is an option available for the PPC 5000 electronic fuel/air ratio
controller. This powerful package gives connection to a local or remote personal computer via an
RS485 connection. Information such as setpoints, profiles and engineer's data is displayed in tabular
and graphic form. A dynamic plant mimic shows the status of all burners on the site provided that
they have PPC 5000 controls. Burner utilization curves can be displayed as chart recorder images
and alarms with time and date stamp are also shown. "ComFire" provides non-safety critical ana-
logue and digital control of the burner from the PC. It is possible to select "burner on", "trim on",
"release to ignite", "release to modulate", "enable boiler sequencing", lead boiler for sequencing
control and boiler setpoint. Modulation rate, boiler control setpoints and limits can also be varied
from the PC.
Sequencing software for up 10 boilers is also available allowing the operator to select any boiler as
the lead boiler. As the demand increases the burners progressively move to "high fire" leaving the
last two boilers brought "online" to "modulate".
As the demand decreases boilers progressively move from "high fire to "modulating" and then from
"modulating to "off-line". Three pass code levels ensure that unauthorized personnel cannot service
the burners nor change commissioning data. The unit has extensive self diagnostics with primary and
secondary level fault analysis.
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Summary of Contents for Fireye PPC5000

  • Page 1: Description

    This option will give typical fuel savings of 2% and will ensure safe and efficient com- bustion when firing fuels with varying calorific value. Optional simultaneous firing software has been developed by Fireye which employs novel, dynamic setpoint technology. It ensures that the correct fuel/air ratio is maintained across the firing range when two fuels are being fired simultaneously and the ratio of one fuel to the other is maintained correctly.

  • Page 2: Table Of Contents

     Table of Contents This bulletin describes the installation and commissioning of the PPC5000 fuel / air ratio controller. It may be used in conjunction with the following other bulletins: — Nexus NEX-1001 bulletin — ComFire combustion analysis tool user bulletin —...
  • Page 3 ® Troubleshooting .......................... 45 Inverter (variable speed) drives ....................47 System configuration ........................47 Description of control method ....................48 Setting up the inverter for use with the 5000................48 Setting up the 5000 for use with a inverter drive................ 49 Troubleshooting inverter problems.....................

  • Page 4: Safety Information

     SAFETY INFORMATION WARNING: The equipment in this manual is capable of causing property damage, severe injury or death. It is the responsibility of the owner or user to ensure that the equipment described herein is installed, operated and commissioned in compliance with the requirements of all national and local legislation which may prevail.

  • Page 5: Installation

    80% relative humidity continuous, non-condensing environment. Do not install the PPC5000 system where it can be subjected to vibration in excess of 0.5G continuous maximum vibration. The PPC5000 system is not a weather tight enclosure.

  • Page 6: Mounting The Display

    PANEL FRONT 4 HOLES (M4 CLEAR) PANEL CUT-OUT 3 7/16” (87mm) 1 5/8” (40mm) 4 1/4” (108mm) WIRING CONNECTIONS DISPLAY CONTROLLER PPC5000 1 = 5v 2 = KEY RETURN 3 = DATA PA10 4 = CLOCK PA11 5 = STROBE...

  • Page 7: Circuit Board Removal

    ® Circuit Board Removal Please refer to the exploded unit drawing below. Disconnect the unit’s power supply. Undo the four screws and remove the grey plastic lid to expose the connectors. Remove all the connectors. Undo the four hexagonal pillars, and lift away the retainer frame. Carefully remove the distribution board.

  • Page 8: Option Link Selection

     Option Link Selection The unit has a number of option selection links, located on various boards. The function and settings are marked along side each link. These links must be set to the correct position before power is applied. Power Supply Voltage The 5000 control system must be set for the correct supply voltage.

  • Page 9: Servo-Motor Selection

    Motor Requirements Since the servo-motors are not always supplied as part of the 5000 system, a few guidelines are useful when selecting suitable motors other than those supplied by Fireye. • All servo-motors must be of the same operating voltage, not exceeding 250V rms / 50V rms depending on board type.

  • Page 10: Wiring

     Wiring WARNING: Wiring Installation must be carried out by a competent electrician and is subject to I.E.E. wiring regulations (BS 7671:1992) and/or local standards. Hazardous voltages must be isolated before service work is carried out. The clamping bar on the control unit performs only an earth function and does not provide strain relief.
  • Page 11 ® LIVE and NEUTRAL Supply The LIVE and NEUTRAL supplies must be con- MAX 3A nected using multi-strand single core PVC insu- LIVE LIVE PA 1 lated 16/0.2mm wire. The live connection should NEUTRAL PA3 NEUTRAL be fused with a maximum rating of 3A. NEUTRAL PA4 The NEUTRAL connection for PC19 must be NEUTRAL...
  • Page 12  PROFILE 1 PROFILE 2 PROFILE 4 PROFILE INPUT INPUT INPUT SELECTED NONE (PC13) (PC14) (PC17) 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. If the hand/auto (H/A) input is off, the UP and DN inputs will have no effect, and the unit will mod- ulate automatically.
  • Page 13 ® Pressure/Temperature Sensor Input The pressure/temperature cabling Fireye PXMS-XXX must be overall shielded 3-conduc- SENSOR tor Belden 8735 or similar. Since this cable may be run in conduit with high voltage wiring, its voltage 5/20V rating must exceed the maximum SENSOR SUPPLY PA16 OR EXT.
  • Page 14 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). Controlled Shutdown Triac and Safety Shutdown Relay The controlled shutdown triac should be wired into the ”stat"...
  • Page 15 ® Digital Outputs The digital outputs are set-up via option parameters 16.1, 16.2, & 16.3. +12V PB7 The outputs are intended to drive exter- DIGITAL OUTPUT 1 PB8 EXTERNAL CIRCUITS nal relays, as shown here for output 2. DIGITAL OUTPUT 2 PB9 DIGITAL OUTPUT 3 PB10 USE ONLY MANUFACTURER APPROVED RELAYS...

  • Page 16: Operation In Run Mode

     Operation in Run Mode Start-up Sequence When a fuel 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 INITIALIZE The unit has just been powered up.
  • Page 17 ® If any of the measured drive positions do not match P0, the unit will change to status 2 with a drive positioning fault. PROVE PURGE The safety shutdown output (PC1-2) and the controlled (P1) POSITIONS shutdown output (PC3-4) are both closed. All selected motors are driven fully up, and 20mA is output to the inverters.
  • Page 18  POSITION All selected drives (motors and inverters) are driven to their ignition (P2) positions. The unit will proceed to status 10 if: — The drives have stopped moving. — If selected, a ‘release to ignite’ signal is received via serial comms or an auxiliary input (see option parameters 15.1 and 15.2) If the burner select input (PC12) is turned off, the profile...

  • Page 19: Startup Sequence

    ® value exceeds the high control limit, the unit returns to status 3 (or status 13 if a post purge has been selected using option parameter 09.1). The high/low initiate input (PC11) is ignored. If any selected drive deviates from its profile setpoint, the unit will change to status 2 with a drive positioning fault.

  • Page 20: Modulation

     Modulation During stage 12 (modulation), the unit will position the fuel and air motors as programmed for the profile selected. In auto modulation mode, the system will modulate as necessary to either track the input or maintain the pressure/temperature of the boiler at the entered setpoint (See Option parameters section). If boiler sequencing is enabled and active, the unit will start, stop and modulate according to instruc- tions issued from the unit controlling the lead boiler.

  • Page 21: The Display

    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...
  • Page 22  SETPOINT Indicates the required pressure or temperature of the boiler, according to the zero and span values entered as option parameters. If a tracking modulation input is selected, this display parameter shows percentage rate. EFFICIENCY Indicates the calculated percentage net or gross efficiency of the boiler, according to option parameter 36.0.
  • Page 23 ® STATUS This display parameter is used to indicate the burner status. In the event of a safety shutdown the display will flash the burner status at which the safety shutdown occurred TRIM Indicates the amount of trim currently being applied, in terms of percentage flow deviation, from -25 to 25.

  • Page 24: Motor Adjustment

     MOTOR ADJUSTMENT Control Direction It is necessary to ensure that each motor travels in the correct direction when moved using the UP/DOWN keys on the keyboard. To do this, follow the procedure below. Enter commission ratio mode. With the display showing P0, use the UP/DOWN keys to move each motor. If the displayed position decreases as UP is pressed, or decreases as DOWN is pressed, reverse the motor output UP/DOWN connections.

  • Page 25: Locking The Servo-Motor To The Valve Shaft

    ® Locking the Servo-Motor to the Valve Shaft Once the control and feedback connections to the servo-motors are correct, each motor must be locked to its valve shaft. In order to prevent the joint between motor and shaft moving, it is recommended that the device used to link the two items is pinned together.

  • Page 26: Operation In Commissioning Mode

    WARNING: While the unit is operating in commissioning mode or adjust ratio mode cer- tain safety checks cannot be performed by the Fireye Nexus PPC5000 Fuel Air Ratio Con- troller and therefore the safety of the system operation is the sole responsibility of the commissioning engineer.

  • Page 27: Option Set Mode

    ® PX (X<24) FUEL/AIR IGNITION LOW FIRE HIGH FIRE RATIO 3 CLOSE SETPOINT PURGE SETPOINT SETPOINT SETPOINT SETPOINT 1.5° 87.4° 20.6° 14.3° 74.6° FUEL 1 1.8° 64.5° 10.5° 10.4° 50.3° FUEL 2 2.1° 88.0° 3.5° 5.8° 80.9° DAMPER 1 1.1° 87.6°...

  • Page 28: Commission Ratio Mode

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

  • Page 29: Adjust Ratio Mode

    ® Select the burner and the required profile. The motors will automatically move to their highest positions and stop. If the purge setpoint has been entered before and no change is required, press AUTO MAN (NEXT). Otherwise, press COM (ENTER). P2 (ignition) is displayed. Wait for the pre-purge time to elapse.
  • Page 30  • It is not possible to modify the close, purge or ignition positions (P0, P1 or P2 respectively). For this, commission ratio mode must be used. Entering Adjust Ratio Mode RUN MODE, BURNER ON SUPPLIER PASSCODE To enter adjust ratio mode, turn the burner on. Once the burner begun its start up sequence, press the key labeled COM (ENTER) and obtain the supplier pass code value using the UP/DOWN keys.

  • Page 31: Finding The Software Issue & Unit Configuration

    ® • The burner is not firing. Switch the burner on and wait for the unit to begin modulating. • The current setpoint is A0, A1 or A2. Use commission ratio mode to adjust these set points. • The motors are moving to the required positions. Wait for the motors to stop moving. Leaving Adjust Ratio Mode ADJUST RATIO MODE RUN MODE...

  • Page 32: The Oxygen Trim Option

     OXYGEN TRIM OPTION WARNING: 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 33: 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 34  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 35: Wiring

    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 36 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°C (7/0.2mm) PVC insulated cable. Wiring must com- ply with all applicable codes, ordinances and regulations and where required, must comply with NEC Class 1 (Line Voltage) wiring.

  • Page 37: Interface To Auxiliary Equipment

    ® Interface to Auxiliary Equipment The interface cabling, to either flue gas analyzers or systems connected to the 4-20mA outputs, must be overall braid SOx + INPUT PM18 screened 2-core PVC insulated 24 – 7/32 (300V monitor SOx – INPUT PM17 80°C), for all signals.

  • Page 38: Calibrating And Servicing The Oxygen Probe

     CALIBRATING AND SERVICING THE OXYGEN 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 39: Removing The Oxygen Probe

    Do not operate the boiler without the probe or blanking plate fitted since dangerous levels of carbon monoxide may be present in the flue. The Fireye Oxygen Probe Type NX2012 is retained in the flue by six 6mm stainless steel socket head cap screws.

  • Page 40: Sox, Nox, Smoke, Co, Aux1, Aux2, O/P1, O/P2

     • The new filter assembly (part number LA220623) can then be inserted into the snout, beveled side inwards. • The snout can be refitted, ensuring that the filter locates into the probe body. The retaining wash- ers and nuts should be tightened sequentially to seal the filter assembly to the flange. Probe Mounted Flue Thermocouple Replacement •...
  • Page 41 ® If the automatic trim commissioning is performed, the engineer MUST CHECK THAT THE VAL- UES ENTERED ARE VALID AND SAFE AFTER COMPLETION. Additionally, the oxygen probe calibration should be checked before and after the procedure since the results are highly dependent on measurements taken using the probe.
  • Page 42  Calculating and Entering the Flow Values Manually If the flow values are to be calculated manually, the procedure listed below must be followed. Enter Adjust Ratio Mode with oxygen trim disabled as outlined above. Select the high fire position. This will cause the display to show A(n), where n is the number of the high fire profile point.

  • Page 43: Flow Calculation Table

    ® Table 1: Flow calculation table Ex. Air + 100 y = x + 100 Profile Excess Air Ratio Airflow Fuelflow c = a + 100 Position d =b + 100 High fire 1 = A (99.9) g (y/c 2 = A (y/c 3 = A (y/c...
  • Page 44  Automatic trim commissioning The unit is able to automate the above procedures, automatically calculating and entering flow val- ues, oxygen trim setpoints, and boiler transport delay. The automatic commissioning procedure will only work if the following conditions are met: •...

  • Page 45: Troubleshooting

    ® Troubleshooting PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Oxygen display not No FMI board installed in option slot 2. Check for board installed. available. Probe calibration values not entered | Re-enter values (options 30.1, 30.2, correctly. 30.6). Probe installed incorrectly. Check wiring. No inlet temperature No FMI board installed in option slot 2.
  • Page 46  Excess air graphs Relationship between flue gases - North sea gas. Notes: 1. ETC systems display Oxygen (Wet), Carbon dioxide (Dry). 2. North sea gas R=0.32 14.00 12.00 Oxygen (Dry) 10.00 8.00 Oxygen (Wet) 6.00 4.00 Carbon dioxide (Dry) 2.00 0.00 % Excess air.

  • Page 47: 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 48: 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 49: Setting Up The 5000 For Use With A Inverter Drive

    • Motor slip ratio Setting up the Nexus PPC5000 fuel air ratio control system for use with a inverter drive In order to use an inverter drive with a 4-20mA interface, an isolated drive board must be installed in one of the option slots. The following steps must then be taken: •...

  • Page 50: Troubleshooting Inverter Problems

     Troubleshooting inverter problems PROBLEM POSSIBLE CAUSE SOLUTION Inverter does not start because it does Ensure that the inverter receives a not receive a RUN signal. RUN signal from the burner controller at the same time as the Nexus PPC 5000 fuel air ratio control system.

  • Page 51: Option Parameters

    Note that serial data communications is always available in commission ratio mode regardless of the passcode value, as long as a RAM chip is fitted (this chip must be obtained from Fireye Inc.). Option 01.1 - Power supply frequency (50/60)* The unit must be configured for the correct power supply frequency, which is required for use by the on-board software plausibility checking.
  • Page 52  If the burner is fired up in MANUAL mode, the drives remain at low fire until modulated manually. If the modulation mode is changed from AUTO to MANUAL while the burner is firing, the drives remain at their current positions. 1 - The unit powers up in the last selected modulation mode.
  • Page 53 ® Option 03.6 - Limit Modulation Range (0/1)* By default, the unit modulates the burner between the set points P3 (low fire) and Px (high fire), where Px is the last setpoint entered in commission ratio mode. If oxygen trim is fitted, it is not pos- sible for any drive position to be trimmed lower than point P3 (low fire) or higher than point Px (high fire).
  • Page 54  Options 04.1 to 04.3 - Set fuel drive output mapping (0 – 12)* OPTION NO. DRIVE OUTPUT Fuel 1 0-12 * 04.1 04.2 Fuel 2 0-12 * 04.3 Fuel 3 0-12 * • Setting an option to 0 means that the corresponding drive is not available. Available outputs will depend on the option boards fitted.
  • Page 55 ® 0 - DEFAULT TO AIR DAMPER 1 OPTION 07.0 PROFILE NUMBER 1 - SELECT PER ‘FUEL’ 07.1 Profile 1 1 - 12 * see table on the following page 07.2 Profile 2 07.3 Profile 3 07.4 Profile 4 07.5 Profile 5 07.6 Profile 6...
  • Page 56  3 - Flue gas limit and secondary (24 hour) faults 4 - Primary (e.g. drive positioning) faults only 5 - Primary and flue gas limit faults 6 - Primary and secondary (24 hour) faults 7 - ALL FAULTS - Primary, secondary and flue gas limits Option 11.0 - Setpoint 1 input type (0 –...
  • Page 57 ® This is the proportional band 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 proportional band. The parameter may be adjusted if the following conditions exist: •...
  • Page 58  Option 12.1 - Setpoint 1 low limit control value (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) Option 14.1 - Setpoint 2 low limit control value (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) If the controlled shutdown triac is off, this parameter defines the highest measured value at which the triac will be switched on.
  • Page 59 ® If both inputs are selected to have the same function, input 2 is ignored and input 1 is used. The auxiliary input functions are detailed below. 0 - No function. The input is ignored. 1 - Setpoint select. The level of the input determines whether setpoint 1 or setpoint 2 is used.
  • Page 60  Option 20.0 - Profile mapping default (0 – 1)* Option 20.1 - 20.7 Profile mapping (1 – 7)* If option parameter 20.0 is set to 0, the profile mappings will assume default values. In this case, the profile 1 input selects fuel 1, profile 2 input selects fuel 2 and profile 4 input selects fuel 3. If option parameter 20.0 is set to 1, it is possible to determine which fuels are to be fired when a given profile is selected.
  • Page 61 ® WARNING: Only use the large tolerance setting if an inverter error of up to±55 will not cause unsafe combustion. Option 22.2 - Inverter error tolerance (0 / 1)* This option parameter affects all inverters connected to the unit. 0 - 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 62 1 - FIREYE oxygen probe for monitoring or trim with no pre-purge test. 2 - FIREYE oxygen probe for monitoring or trim with a pre-purge test. If the measured oxygen level is less than 18.0% at the end of the pre-purge period, F76 is given and oxygen trim will be disabled.
  • Page 63 This option parameter is only available if option 30.0 is set to 1 and an FMI board is installed in option slot 2. This option parameter must be used when calibrating the FIREYE oxygen probe. There are three possible values: 0 - No calibrate.
  • Page 64  If option 32.0 is set to 1, the system will default to trimming the selected fuel drives for all profile selections. Option parameters 32.1 to 32.7 will not be available. If option 32.0 is set to 2, it is possible to select the trim drive individually for each profile combina- tion using option parameters 32.1 to 32.7.
  • Page 65 ® 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 66  When the flue temperature rises above the high alarm value for the selected profile combination, a fault number will appear. See section xxx for details of fault numbers. Option 39.0 - Oxygen alarm select (0 – 2)* Option parameter 39.0 is only available when option 30.0 (oxygen input select) is not set to zero. Since the oxygen alarm values relate to the oxygen setpoint values, oxygen setpoint values must first be entered in adjust ratio mode.
  • Page 67 ® The instantaneous fuel flow for the currently selected profile may be seen on EK76. Totalized fuel flows are only available via the serial communications link using the ComFire software package. Fuel flows are not calculated when the unit is firing a multiple fuel profile. For the system to calculate fuel flow, the high fire fuel flow must be entered.
  • Page 68  Options 48.1 to 48.7 - Smoke level high alarm values (0.0 – 99.9%)* Option parameter 48.0 is only available if option 47.0 (smoke input select) is not set to zero. If option 48.0 is set to 0, the smoke level high alarm is disabled. If option 48.0 is set to 1, the smoke level high alarm is enabled and option parameters 48.1 to 48.7 become available.
  • Page 69 ® If option 51.0 is set to 1, options 51.1 & 51.2 give the zero and span values for the input. There are the measured values that are displayed when 4mA and 20mA appear at the 4-20mA SOx input (PM17-18) on the FMI board. Note: 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.
  • Page 70  Options 58.0 to 61.2 - 4-20mA output functions * These option parameters determine the function of each 4-20mA output on the boards installed in option slots 1 and 2. The table below details each option parameter. OPTION OUTPUT DESCRIPTION PARAMETER 58.0 Opt.
  • Page 71 ® Option 70.0 - Erase enable (0/1)* WARNING: If this value is displayed as a ‘2’, the option parameter data has been ‘up- loaded’ into the unit, ensure all option parameters are set to match the requirements of the burner to which it is connected. Failure to do so could cause a hazardous condition to occur. After all option parameters have been checked to match the requirements of the burner to which it is connected, reset this option parameter to zero to allow the system to operate.

  • Page 72: 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 Option params 20.X 21.X Permissible trim drives. 04.1 FUEL 1 FUEL 2 04.2 04.3 FUEL 3 AIR 1 05.1...

  • Page 73: Derivation Of Modulation Rate

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

  • Page 74: Faults And Fault Finding

    As an aid to fault finding, most faults have a fault subset that gives additional information about the type of fault or what the burner was doing when the fault occurred. Where applicable, the subsets are given in the fault listing section. Subsets are viewed using the engineer’s key within the Fireye logo.

  • Page 75: Fault Listing

    ® Fault Listing NAME DESCRIPTION NUMBER Fuel 1 incorrect position A drive positioning fault has occurred, which will cause a safety shutdown of the burner. This fault has occurred for one of the following reasons: 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 76  NAME DESCRIPTION NUMBER Basic drive board potentiometer supply fault The unit has detected that the supply to the potentiometers on the basic drive board is too high or too low. • Is the basic drive board installed correctly? • Is the potentiometer supply voltage selection link on the basic drive board installed? •...
  • Page 77 ® NAME DESCRIPTION NUMBER 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...
  • Page 78  NAME DESCRIPTION NUMBER Oxygen probe purge check The measured value from the oxygen probe was less than 18.0% at the end of pre-purge. Trim is disabled. Subset: Oxygen level x 10 Auto trim commissioning fault The measured oxygen level exceeded 15.0% during auto trim commissioning. The burner is shutdown.

  • Page 79: The Engineer's Key

    The Engineer's Key The engineer's key is a hidden key that is located under the Fireye logo in the top left hand corner of the display. With the use of the engineer's key it is possible to read the values of internal system vari- ables and external input and output states.
  • Page 80  Engineer’s Key Parameter List NAME DESCRIPTION NUMBER PC8 (DOWN) input Shows the state of each input. Where: PC9 (UP) input 0 = OFF PC10 (HAND/AUTO) input 1 = ON PC11 (HI/LO INIT) input PC12 (BURNER ON) input C13 (PROFILE 1) input C14 (PROFILE 2) input C15 (AUX 1) input PC16 (AUX 2) input...
  • Page 81 ® NAME DESCRIPTION NUMBER EK34 Option 1 board type Where: 0 - No board fitted EK35 Option 2 board type 1 - Isolated drive board (IDB) 2 - Flue gas monitoring board (FMI) 6 - Board not recognized EK38 Burner status Shows what state the burner is in.
  • Page 82  NAME DESCRIPTION NUMBER EK48 Potentiometer supply option board 2 +16 - Motor 2 5V supply * IDB MUST BE INSTALLED +32 - Motor 2 15V supply EK50 Enclosure temperature (ºC) Unit's internal temperature * FMI MUST BE INSTALLED EK51 O2 probe heater power output Power output to the probe heater (0-100%) * FMI MUST BE INSTALLED...
  • Page 83 ® NAME DESCRIPTION NUMBER EK85 Oxygen probe cell temperature (ºC) Temperature of oxygen cell, nominal 650ºC. F70 will be generated if outside the window 600ºC (after 15 minutes of power on) to 700ºC EK86 Oxygen error (%) Error between O2 measured value and O2 setpoint EK87 Trim deviation (% flow) Deviation in air flow imposed by trim (-25 to +25%)

  • Page 84: Troubleshooting

     Troubleshooting Display WARNING: Use extreme care while testing the system. Line voltage is present on most ter- minal 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. PROBLEM POSSIBLE CAUSE SUGGESTED ACTION...
  • Page 85 ® Commissioning PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Cannot get past P0. 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 86  PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Unit stuck at modulation Serial communications. Disable release to modulate button, or change modulation rate slider in ComFire. Unit in commission mode. rate. Press RUN then ENTER to enter run mode. Drives are "stuck" in purge Has post purge been selected? Check option parameter 9.1 position when burner is...

  • Page 87: Technical Specification

    ® Technical Specifications Supply voltage 110/120/220/240 Vac Power consumption Approx. 20VA Supply frequency 50/60 Hz Temperature range 0 to 60°C Control unit protection category IP20 – The unit must be situated in a clean environment and mounting position Indoor: must be mounted in an IP40 enclosure. Outdoor: must be mounted in an IP54 enclosure.
  • Page 88  RS232 & RS485: FIREYE specific protocol. See NEX-1501 (FIREYE serial communications protocol manual) for details. Power supply and boiler I/O board (standard) RTD input: 3 wire, 0 to 350ºC Pressure/temp input (0 – 5V): less than 2mA, ±15V max.

  • Page 89: Oxygen Probe Kit

    ® 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 1 x Probe heater transformer Nexus PPC5000 Fuel Air Ratio Control System Commissioning sheet...

  • Page 90: Option Parameters

     Option Parameters Note: Not all 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 32.X...

  • Page 91: Distribution Board Connections

    ® Distribution Board Connections AH221250 (For use with 2 x IDB)

  • Page 92: Ah221312 (For Use With 1 X Idb & 1 X Fmi)

     AH221312 (FOR USE WITH 1 X IDB & 1 X FMI...
  • Page 93 ® COMMUNICATION PPC5000 PPC5000 PPC5000 PB1+ PB1+ PB1+ PB2- PB2- PB2- PB5 Gnd PB5 Gnd PB5 Gnd Belden 9939 only one ground IC485 RS-485/ RS-232 IBM Compatible W/ COMFIRE Software 12 vdc RS485 OR MODBUS INTERFACE E110/EP160 E110/EP160 E300 E300...
  • Page 94 Fireye warranty, as stated in its General Terms and Conditions of Sale, pertains only to the Fireye products and not to any other equipment or to the combined system or its overall performance.

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