Page 1 CONTROLLER DESCRIPTION The Fireye PPC6000 is a state of the art stand-alone parallel positioning system for all types of liquid or gaseous fuel fired combustion systems. When combined with a Fireye flame safeguard system such as the Fireye BurnerLogix control, the PPC6000 offers the most compact and advanced parallel positioning system available.
Page 2 Other options include, two Variable speed drive (VSD) outputs via daughter board, Oxygen Trim using Fireye’s proven heated zirconia oxide probe and optional interface, a wide variety of communications platforms such as Modbus is also available. An optional internal freely programmable logic section of the PPC6000 means that external PLC’s and expensive stand-alone sequencing controls may no longer be needed.
Page 3 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 4: Table Of Contents
Table of contents This manual describes the installation, commissioning, operation and maintenance of the PPC6000 series fuel air ratio controls. It may be used in conjunction with the following other manuals:  NEX-1502 - ComFire combustion analysis tool user manual Please read the safety information at the front of this manual before proceeding.
Page 5 2.6.2 Grounding cable screens 2.6.3 GROUND (EARTH) connection 2.6.4 Ground (earth) Connection (display unit) 2.6.5 Terminal Designation LINE and NEUTRAL supply (PPC6000) PE1 & PE2 2.6.6 2.6.7 Safety Shutdown output (PPC6000) ...
Page 6 5.4.5 Touchscreen Lockout Reset (Alarm Mute) Function. 5.4.6 Touchscreen LED Indication. 5.4.7 Touchscreen Fuel/Profile Select. 5.4.8 Touchscreen ‘Control’ screen. 5.4.9 Touchscreen ‘Menu’ button. 5.4.10 Touchscreen ‘Burner Settings’ button. 5.4.11 Touchscreen ‘Fault/Event Log’...
Page 7 Option 19.1 to 19.4 – Fail-safe Alarm / Lockout Display Messages LV3 Option 20.0 – Set-point Select input (0 - 35) LV3 Option 20.1 – Boiler Shutdown input (0 - 35). LV3 Option 20.2 – Low Fire Hold input (0 - 35). LV3 ...
Page 8 Option 28.6 – Analog Input 3 decimals (0-2) LV3 Option 28.7 – Analog Input 3 zero (0-999) LV3 Option 28.8 – Analog Input 3 span (0-999) LV3 Option 29.0 – 4-20mA Output 1 function if not VSD LV3 ...
Page 9 Description of control method Setting up the inverter for use with the PPC6000 series Setting up the PPC6000 series for use with a inverter drive The oxygen trim option Oxygen Pro probe description 8.1.1...
Page 10 9.7.12 Non-volatile lockout Fireye Nexus Combustion Curve Function Block Programming Details Introduction to Fireye’s Abacus Programming Software 1.1. Introduction 1.4. The schematic toolbar 1.5. Place Function blocks ...
Page 11: Technical Specification
1 Technical specification 1.1 General Supply voltage 120/230Vac +10% - 15% Power consumption Approx. 60VA 50/60 Hz 5% Supply frequency Ambient temperature range 0 to 60C (32 to 140F) Control unit protection category IP20. The control must be situated in a clean environment according to EN6730-1.
Page 12: Digital Outputs (Ppc6000)
Interface to PPC6000 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, NXC20A 20Nm/ 14.7 ft/lb 18Nm NXC40 40Nm/ 29 ft/lb 20Nm Voltage: 24-30Vac supplied from control only VA rating / Temperature NXC04 –...
Page 13: Digital Inputs (Ppc6000)
1.7 Communications interface (PPC6000) 2-wire RS485 plus ground, with termination resistor selected using a link. See Section 2.5.5. An isolated 2-wire RS485 interface is available as an option. See Section 2.5.6. See MOD-6101 (FIREYE serial communications protocol manual) for details.
Page 14: Optional Oxygen Probe Interface Unit (Nxo2Int) - Optional
NEMA4 (IP65). Unit dimensions 160 x 98 x 63mm (6.30 x 3.86 x 2.48“) deep Weight 1.34Kg (2.95 lbs) Interface to PPC6000 series. FIREYE specific CANbus. Interface to oxygen probe. FIREYE specific or 4-20mA 1.9 Optional Ambient Air Temperature Unit...
Page 15: Fireye Nxc04, Nxc12, Nxc20, Nxc20A, Nxc40 Servo Motors
1.11 Fireye NXC04, NXC12, NXC20, NXC20A, NXC40 Servo Motors Interface to PPC6000 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...
Page 16: Fireye Nxiats Ambient Air Temperature Sensor (Optional)
1.13 Fireye NXIATS Ambient Air Temperature Sensor (optional) Type CANbus Ambient temperature range -29C to 60C (-20F to 140F) NOTE: Accuracy below 0C (32F) may vary slightly. Agency testing conducted to 0C only. NEMA3 (IP54) Protection category Unit dimensions Weight FIREYE specific CANbus.
Page 17 NXDBVSD counter inputs, two programmable relays, isolated RS485, Modbus RTU communications NXO2INT CANbus O2 interface module with Fireye and generic (4-20mA) probe inputs. O2 PROBES FOR PPC6000 O2 probe assembly (for flues 300mm to 1000mm). Includes NXIATS CANbus NXO2PK4 ambient temperature sensor, flange kit.
Page 18: Installation
 Wiring must comply with all applicable codes, ordinances and regulations.  Loads connected to the PPC6000 series must not exceed those listed in the specifications as given in this manual.  All external components connected to the control must be approved for the...
Page 19: Mounting Details For The Ppc6000 Control
2.1 Mounting details for the PPC6000 control 6.26” (159mm) 0.75” (19mm) 4.65” 3.15” (118mm) (80mm) 6.93” (176mm) A Template for mounting is provided at the end of this manual for convenience. See Section 8. 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 20: Mounting Details For The Display Module
2.2 Mounting details for the display module A Template for mounting is provided at the end of this manual for convenience. See Section 8. NOTE: The four (4) M4 clearance holes are the mounting holes for the display. After removing the back cover, carefully remove the four brass hex standoff’s to secure the display to the panel.
Page 21: Mounting Details For Optional Oxygen Probe Interface Unit, Nx02Int
2.3 Mounting details for optional Oxygen Probe Interface unit, NX02INT A Template for mounting is provided at the end of this manual for convenience. See Section 8. The optional oxygen probe interface unit is designed to be fitted either within a control cabinet or without a control cabinet;...
Page 22: The Oxygen Trim Option
2.4 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 23: Mounting The Oxygen Probe
2.4.3 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 24: Mounting Arrangements For Temperature And Steam Pressure Sensors
DIRECTION OF LA220427 Assembly FLUE GAS FLOW 3 (1/8") FILLET WELD ALL ROUND FLUE WALL 30¦ FLUE APERTURE COVER M6 PROBE MOUNT HOLES GASKET VIEW OF MOUNTING PLATE WITH COVER (0.78") WELD FLANGE PROBE MOUNT ALL DIMENSIONS IN MILLIMETRES INCH EQUIVALENTS ARE IN ( ) PROBE MOUNT SYSTEM - CYLINDRICAL MATERIAL: MILD STEEL OR FLAT WALL FLUE.
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 P/N35-371.
Page 26: Option Link Selection (Ppc6000)
2.5 Option link selection (PPC6000) 2.5.1 General (Access to jumper’s and fuse’s is gained by removing the back cover of the PPC6000) Wickmann-Littlefuse PN 3701100043 1 AMP (Fast Acting) ( to protect 5V DC circuit) Alternate Source: Mouser Electronics PN 576-371100000 Bussmann - S504 series P/N GMD-630 (Time Delay) for 115V P/N GMD-315 (Time Delay) for 230V...
Page 27: Sens In And Sens Supp (Boiler Temp/Pressure Sensor) (Ppc6000)
2.5.3 SENS IN and SENS SUPP (boiler temp/pressure sensor) (PPC6000) If a boiler pressure/temperature sensor or modulation potentiometer is used, links JP3 and JP1 must be set to suit the type of sensor and voltage requirement. For example:  For a 4-20mA loop-power sensor, choose a +30V supply. +30v ...
Page 28 Note: All wiring to terminals PA & PB are low voltage and must be braided shielded wire per table 2.6.1A. Wiring to terminals “PE” are line voltage. The maximum wire size is 16AWG (19.3mm) for all terminals. Note: PE7 & PE8 provide purge and low fire position signals to the flame safeguard control.
Page 29: Wiring
 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 30 Table 2.6.1-A provides the only approved wire for this application. No “or equal” is provided. Use of wire not approved by Fireye may VOID warranty. All wiring to terminal block “PA” & “PB” as well as to any optional daughter board (e.g. VSD) and the Power/CANbus wiring to the display, must be fully shielded braided wire per Table 2.6.1-A.
Page 31 Alpha Carol Belden (conductors) (conductors) (conductors) 300V 25164 25162 9940 600V 25524 25522 C2688 7895A* If Belden 7895A wire is used it will be necessary to use 2 conduit * NOTE: adapters per device if wired as a “daisy chain.” See Table 2.6.1-D Table 2.6.1-A IMPORTANT: Line Voltage (horizontal terminal bottom (PE) must NOT be shielded wire.
Page 32 CONDUIT CONNECTOR ADAPTERS Metric to ½ inch NPSL Female Device Fireye Part Number NXC04 Servomotor 35-321 NXC12 Servomotor 35-321 NXC20, NXC20A Servomotor 35-322 NXC40 Servomotor 35-372 NXIATS Inlet Air Sensor 35-336 NXO2INT Oxygen Interface 35-372 All O2 Probe Assembly 35-372 Table 2.6.1-D...
Page 33 2.6.4 Ground (earth) Connection (display unit) The display 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 34 Terminal Number Location Function Voltage Range PPC6000 S/S Relay 0 – 230Vac PPC6000 Ign Prove (Low Fire output) 0 – 230Vac PPC6000 Purge Prove (High Purge output) 0 – 230Vac PPC6000 Profile 1 Select 0 – 230Vac PE10 PPC6000 Profile 2 Select 0 –...
Page 35 Terminal Number Location Function Voltage Range Display Unit Relay output 3 common 0 – 250V Display Unit Relay output 3 normally closed 0 – 250V Display Unit Relay output 3 normally open 0 – 250V PR10 Display Unit Relay output 9 common (TSD104 0 –...
Page 36 If a limit device is fitted into the controlled shutdown circuit it must be capable of supplying the total current required by devices connected to this circuit.  Any limit device connected to the PPC6000 series control must be approved for the specific purpose for which it is being used. ...
Page 37 2.6.10 Auxiliary Relay Outputs (display) Fuses not exceeding 4A must protect all relay outputs. If a control panel fuse greater than 4A is fitted, the relay common MUST be RELAY 1 NORMALLY OPEN PR 1 separately fused at 4A maximum. Where the total relay current exceeds 4A, fit a separate fuse on each relay output to achieve this.
Page 38 2.6.12 Low Voltage Digital Inputs (PPC6000) – relevant Engineer’s Keys EK1-EK4 (Sec. 6.6.2) (See option parameter 16.1 and 18.1-18.4 for further details. These inputs must be connected DIGITAL INPUT 1 PA 5 using multi-strand overall DIGITAL INPUT 2 PA 6 screened two conductor PVC DIGITAL INPUT 3 PA 7 insulated 24 AWG (7/0.2mm) wire.
Page 39 Connect the YB110 using the three terminal connector labeled A+, B-, 0 volt. The A+ & B– connections are connected to the Fireye ED610 terminal block (purchased separately) on terminals 10 & 9 (A & B), the 0 volt connection is not used. The ED610 is connected to the YB110 via an ED512-4 cable (purchased separately).
Page 40 Change. Next, press the RS485 Comms button and select the baud rate that matches the BurnerLogix YB110. The default is 9600,N,1. The currently displayed message from the YB110 display should now appear in the lower right section of the TSD. Any status or lockout messages for the YB110 will be displayed here also. The fault numbers assigned to YB110 lockouts is the Modbus message number (found in BL-1001) plus 200.
Page 41 CABLE CLAMP 2.6.18 RS485 interface (PPC6000) 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 42 “A” and “B” wires. RS485 A (+) PB 5 For details on connecting PPC6000 series controls to a PC on the RS485 B (-) PB 6 communications bus, refer to the manual NX-1502 (Comfire2 combustion RS 485 GND PB 7 analysis tool).
Page 43 2.6.20 PPC6000 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. The cabling for all of these terminals must be 2-conductor (core) overall 4-20mA Output Channel 1 –...
Page 44 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 45 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 46 2.6.2. DO NOT connect the screens at the probe. Incorrect connection may damage or destroy the units being connected. 2.6.23 Inlet temperature sensor (optional) The system allows direct connection of an FIREYE inlet temperature sensor. The unit is connected via 24Vac PA/PB 1...
Page 47 NOTE: Insulate Shield Cover shield to (Terminal 5) to prevent Shield prevent short accidental shorting to CANbus - pins on circuit board (J1) CANbus + 24 VAC 24 VAC NXIATS Inlet Air Temperature Sensor 2.7 Final checks WARNING Incorrect setting of the Supply Voltage Links WILL damage or destroy the unit. Before applying power, make the following checks: ...
Page 48 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 49 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. Set screws alone are not recommended as they can come loose resulting in a potentially unsafe condition.
Page 50  Servomotor shafts are hardened; set screws alone are NOT sufficient to guard against slippage. A variety of “D” hole couplings are available. Contact your Fireye Distributor, or Fireye, Inc., for assistance. 3.4 Feedback potentiometer WARNING ...
Page 51 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 52 3.6 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. Eg. 5.3 is drive 3).
Page 53 4 Description of operation 4.1 The Display / Keypad The display is a 2 line, 20 character per line, dot matrix vacuum fluorescent type allowing the use of plain text messages for most display parameters. The keypad is a membrane construction with tactile keys to give a positive feedback of the actuation.
Page 54 4.2 Start-up sequence This fuel / air ratio control performs burner start-up and shut-down in conjunction with an external ‘burner controller’. The external ‘burner controller’ provides burner management functions such as flame / air pressure monitoring and it also controls the fuel shut-off valves and combustion air fan. The start-up and shutdown sequence is handled by a progression of stages, each requiring a certain set of conditions to move on to the next one.
Page 55 Signal Name: Alternate Names / Pin: Description: HFS (HIGH FIRE Purge proved, PE8. When the purge (P1) position is reached (pre-purge or SWITCH) post-purge), LINE VOLTAGE will be present on this Line Voltage terminal. Line voltage will also be present here when the control is modulating and high fire is reached, but only if the AUTO input is ON.
Page 56 Stage Stage name Description Wait for purge The ‘controlled shutdown’ output on PE3 will be switched on, to tell the burner controller there is a call for heat. (EK5) This control waits for a fuel/profile select signal on one of the (line (EK11-14) voltage) terminals PE9, PE10, PE11 or PE12 and a purge request (EK31)
Page 57 Stage Stage name Description Pre-purge The controller confirms all required drives are at their purge positions, and gives a ‘purge proved’ signal by providing (line voltage) to terminal PE8 (high-fire-switch). The control will remain in this status until the burner controller signals the end of pre-purge by breaking PA11 –...
Page 58 Stage Stage name Description Moving to low fire Once the AUTO signal is received the fuel and air motors are moved from their ignition positions to their low fire positions. These positions may or may not be the same as the ignition positions. The ‘ignition prove’...
Page 59 During stage 16 (modulation), the control will position the fuel and air motors within the programmed profile appropriate to the requirement for heat. 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”...
Page 60 5 Commissioning the control WARNING  This manual may cover more than one model from the PPC6000 series. Check for additional information at the end of this chapter.  While the control is operating in commissioning mode 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 61 5.2.1 Option parameters The PPC6000 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.
Page 62 There are two (2) types of Displays available for the PPC6000. 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 63 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 64 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 65 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. Indicates AUTO Displays when the control is operating in AUTO AUTO modulation mode.
Page 66 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 67 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 PPC6000 allows for a maximum of four profiles. Any profiles, which are not programmed and therefore not available, will be ‘grayed-out’.
Page 68 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 69 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 70 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 PPC6000 manual – Fireye bulletin NEX-6101.
Page 71 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 72 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 73 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 74 NOTE: When adjusting servo motor positions, it may require the use of the “Fine Adjust” button to get the motor to the exact spot you desire. Once the required values have been entered or changed the mode can be exited by pressing RUN followed by ENTER, the ‘X’...
Page 75 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 76 Option 00.8 – Modbus communications speed (0 – 3) LV3 Default value 0 NOTE: Only available with NXDBMB (Modbus) or 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 77 Number entered in Mute/Reset Function Digital inputs used parameter 01.2 Comview & Keyboard only NONE Input 1 Input 1, PA5 to PA11 Low Voltage Input 2 Input 2, PA6 to PA11 Low Voltage Input 3 Input 3, PA7 to PA11 Low Voltage Input 4 Input 4, PA8 to PA11 Low Voltage Option 02.x –...
Page 78 The number entered also tells the control information about the drive. If the number entered here is less than 10, the drive is considered a fuel. If the number is greater than or equal to 10, it is considered an air drive. This only makes a difference when oxygen trim is enabled for a particular drive, since it determines the trim direction.
Page 79 The number to be entered is a binary code: +1 if the drive is used for profile 1, +2 if the drive is used for profile 2, +4 if the drive is used for profile 3, +8 if the drive is used for profile 4. This means that the number entered is from 0 to 15: (see chart below): Number entered in parameter 4.X Drive X used for...
Page 80 Options 06.1-06.4 – Profile Naming LV3 This selects the fuel associated with each profile (1 thru 4) to be displayed after the burner-on hours, e.g. 861 hours Profile 1 Gas, visible on the main display during operation. Normally available options: Number entered in parameter 6.X Fuel solenoid valves opened NONE...
Page 81 V S D Option 09.2 - Inverter closed loop gain (15 – 125%) LV3 DEFAULT: 100 This option parameter affects all inverters connected to the control. 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.
Page 82 Option 09.6 – VSD2 Speed Encoder Scaler (255 - 999) LV3 V S D When using encoder feedback for VSD2, this option should be programmed to ensure that the feedback signal gives between 950 and 995 when the motor is at maximum speed (drive signal at 20mA). The value for the parameter may be calculated using the following formula: (Motor Max RPM x No of teeth on encoder) = Scaler The value may need adjustment once the unit has been tested.
Page 83 Option 14.1 – Limit Relay (0 - 8) LV3 DEFAULT: Relay 4 (PD5) This option parameter assigns the limits to a specific relay. Relays 2 & 3 share a common connection on the NX610 display. NXTSD104 relays are independent. Option parameter 14.1 Meaning Connection Details NX610 value...
Page 84 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 85 Option 15.2 – Modulation input zero value (-999 to +999 / -99.9 to +99.9 / -9.99 to +9.99) This value will normally be left at zero. It is the measured value to be displayed when the sensor connected is at its minimum value. If a 4-20mA sensor is used, this parameter should be set to the 4mA value (usually zero).
Page 86 Option 15.7 – Bumpless Transfer (0 or 1) LV3 This parameter affects the burner operation while in MANUAL mode only. Option parameter Meaning 15.7 value When the burner comes back on after going off, it will remain at low fire. When the burner comes back on after going off, it will go to the last modulation rate that it was set to in manual mode and stay there.
Page 87 Number entered in parameter 16.1 Digital input used: None. Input 1, PA5 to PA11 Low Voltage supplied from PA11 ONLY Input 2, PA6 to PA11 Low Voltage supplied from PA11 ONLY Input 3, PA7 to PA11 Low Voltage supplied from PA11 ONLY Input 4, PA8 to PA11 Low Voltage supplied from PA11 ONLY Do not use.
Page 88 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 89 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 90 Option Relay GENERAL PURPOSE Connection Detail for NX610 Only Parameter Output 17.1 Display, Low or Line voltage Normally Open Normally Closed Common 17.2 Display, Low or Line voltage Normally Open Normally Closed PR7* Common 17.3 Display, Low or Line voltage. PR7* Common Normally Closed Normally Open...
Page 91 Option Relay ALARM Function Connection Detail for NXTSD104 Only 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 17.3 Display, Low or Line voltage Common Normally Open Normally Closed 17.4...
Page 92 NOTE: In order to enable any Digital Input, a value greater than 0 MUST be entered in one of the three columns. HUNDREDS TENS UNITS (fault type) (fuel type) (burner status type) 0 – This alarm will lockout the 0 or 1 – Fault will be active for 0 or 1 –...
Page 93 HUNDREDS TENS UNITS (fault type) (fuel type) (burner status type) 8 - fault activates at pre-purge only (status 8) All other values will work like selection 1 (including zero). 7 to 9 are spare so new functions can be added later. NOTE: In order to enable any Digital Input, a value greater than 0 MUST be entered in one of the three columns.
Page 94 Option parameter Meaning 19.X (or 16.5 / 16.6) value Low Draft BurnerDoorSwitch Emergency Stop ExitDamperClosed 28 to 31 (spare) CAUTION  The product allows for customization of various non-safety critical functions including the modulation control. The option parameters shown below relate to the default modulation control function programmed in the control at the factory.
Page 95 Option Table 20.0 A Digital Input Numbers Digital input used: Digital Input Numbers Input CLOSED Input OPEN Powered ON Powered OFF None. Input disabled. Input 1, PA5 to PA11 LOW VOLTAGE supplied from PA11 ONLY Input 2, PA6 to PA11 LOW VOLTAGE supplied from PA11 ONLY Input 3, PA7 to PA11 LOW VOLTAGE supplied from PA11 ONLY...
Page 96 Option 20.4 – Ignition Wait input (0 - 35). LV3 (1 – 4) A high level on the input specified here will prevent the burner from igniting. The drives stay at their ignition positions, but the light up sequence will not start until this input is removed. (16 or 20) Should NOT be used.
Page 97 Option 20.8 – Digital Input - Lead Boiler Select (0 – 35) LV3 (1 – 4) A high level on the input specified here will select the lead boiler when closed. (16 or 20) Should NOT be used. (21– 24) A low level on the input specified here will select the lead boiler when open.
Page 98 Option 21.4 – Set-point 1 derivative time (0 – 999 seconds) LV1 This is the derivative time used in the PID control loop for setpoint 1. It may be set to any value from 0 to 999. A value of zero will disable the derivative function. A non-zero value will have the effect of ‘advancing’ the modulation rate change caused by a constantly changing measured value by the number of seconds given.
Page 99 Option 22.1 – Set-point 2 control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 This is the control value used in the PID control loop for setpoint 2. When the control is in auto mode, the PID control loop will modulate the boiler to maintain the measured value at the same level as set by this parameter.
Page 100 Option 22.6 - Setpoint 2 low limit control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 If the boiler is off due to a controlled shutdown, this parameter defines the measured value at which the boiler will be turned on again.
Page 101 Options 24.x – Sequencing Sequencing (lead/lag) is managed by using the “setpoint select” function internally to choose between Setpoint 1 and Setpoint 2 via the communications bus between PPC6000’s. The “lead” or “master” boiler controls the “lag” or “slave” boiler(s) by switching them from setpoint 2 (“lag stand by” or “banking”) to the setpoint 1 values, and turns on based on Option 24.6 (lag (slave) On Rate) value.
Page 102 The temperature sensor must be a 4-20mA device. If this device is to be loop-powered by the PPC6000, it should be connected to the 30V output, “sensor supply” on PA16. See option 25.0 – 25.5. Example: Fireye Temp. Sensor – TS350 PPC6000 Sensor Terminal (1) 4-20mA...
Page 103 Option parameter Comms. Address Boiler 24.x value 24.1 24.2 24.3 The sequencing order would be boiler 2, 3 and 4. If boiler 2 were set to lead via Option 24.5, the order would be boiler 3, 4 and 1. Setting boiler 3 to master (lead), the order would be boiler 4, 1 and 2. Other sequencing orders can be achieved by changing the communications address entered in Options 24.1-24.3.
Page 104 Option 24.6 – lag (slave) On Rate (0-100%) LV1 This value determines the firing rate of the lead (master) boiler at which the first and all subsequent slave(s) (lag) boilers come on. The slave(s) (lag) boiler(s) will be delayed in coming on by the time set in Option parameter 24.7.
Page 105 The following option parameters are only visible if option 25.0 is non-zero: Option 25.1 – Water temperature zero value LV3 Sets the zero value for the 4-20mA input (usually 0 for a 0-xxx degree temperature sensor). Option 25.2 – Water temperature span value LV3 Sets the span value for the 4-20mA input (i.e.
Page 106 Option 28.7 – Analog Input 3 zero (0-999) LV3 Set the number to be displayed when the input 3 current is 4mA. Option 28.8 – Analog Input 3 span (0-999) LV3 Set the number to be displayed when the input 3 current is 20mA. Setting this parameter to a non-zero value also enables this item.
Page 107 Option 29.3 – 4-20mA Output 2 function if not VSD LV3 Set this option to a value from the table in 29.0 to enable an analog output to re-transmit system variables as a 4-20mA signal. If this output has been assigned for VSD control in option 3.x, then this setting will be ignored. Option 29.4 –...
Page 108 2. Flow values and O2 setpoints. The flow and O2 values may be entered manually by the engineer (option 34.5), or the system can automatically calculate the values and enter them itself by using automatic trim commissioning (option 30.9). If the automatic trim commissioning is performed, the engineer MUST CHECK THAT THE VALUES ENTERED ARE VALID AND SAFE AFTER COMPLETION.
Page 109 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 110 This option parameter is only available if option 30.0 is non-zero. This option parameter must be set to the calibration gain value that is specified with the Fireye probe supplied. When using another manufacturer’s O2 probe with a 4-20mA signal for the O2 value, enter the O2 value for 20.0mA in this option parameter.
Page 111 This option parameter is only available if option 30.0 is non-zero. This option parameter must be used when calibrating the oxygen probe. There are three possible values: Option parameter 30.6 Meaning value No calibrate. This is the normal operating condition, where the probe is used to measure the oxygen concentration in the flue.
Page 112 The unit is able to automate the manual calculation procedures (option parameter 34.5), automatically calculating and entering flow values, oxygen trim setpoints, and boiler transport delay. The automatic commissioning procedure will only work if the following conditions are met:  Option parameter 30.9 (automatic trim commissioning) is set to 1 ...
Page 113 Confirm setup using “adjust ratio” mode. NOTE: If the boiler shuts off for any reason during automatic commissioning, the sequence will continue when the boiler re-starts. Option parameter Meaning 30.9 value Not selected. Perform automatic trim characterization. The control will attempt to characterize the burner profile by calculating flow values and selecting oxygen setpoints to match the currently commissioned points.
Page 114 These option parameters determine which drive will be trimmed (Air or Fuel) in profiles 1 to 4. These parameters are used together with the parameters entered in option parameters 2.0 to 2.9 to determine which drives are trimmed, and in which direction. Parameter Meaning 31.1...
Page 115 In order for the oxygen trim control loop to be stable, the integral gain must be set correctly. Options 33.1 to 33.4 allow the integral gain to be set individually for each profile combination to any value between 0.0 and 99.9%.
Page 116 8. Repeat the above for all other profile positions including low fire (profile position A3), recording each time the values at locations a and b in the table. When extra air is added at P3, the time taken before the flue oxygen reading starts to increase should be measured and entered into option parameter 30.7.
Page 117 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 118 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 PPC6000 and displayed as a ‘list’...
Page 119 Option Table 35.x A 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.
Page 120 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 121 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 122 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 123 Option 42.5 – Max flue temp variation (0 to 999 ºC) LV3 If non-zero, the burner will lockout if the two oxygen probes vary by more that this many degrees (Celsius). This can be used in applications where flue temperature is especially critical. Option 42.7 –...
Page 124 Option 44.4 – Set Day of Week (1 - 7) LV1 For reference 1=Sunday, 2=Monday through 7=Saturday See “SET CLOCK” Example after Option 44.7 Option 44.5 – Set Hours (0 - 23) LV1 Hours use 24 hour format. AM= 0-11, PM=12-23; For reference 0=midnight, 12=noon, 18= 6 pm (12+6) See “SET CLOCK”...
Page 125 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 PPC6000. A...
Page 126 When erase / restore enable (option 45.0) is set to '1', this option parameter allows the back-up data held in the display to be loaded into the PPC6000, this may take up to 5 minutes to complete during which time the control will not allow the burner to operate.
Page 127 Each setpoint in the profile is referred to with a letter and number (refer to the table below). Name Comments Close This defines the positions the motors will move to when the burner is off, and must be set to the lowest position each motor can reach. Purge This defines the positions the motor will move to when the burner is purging, and can be set as required for each servo-motor.
Page 128 5.6.3 Leaving commission ratio mode ENTER Commission ratio mode Run mode To leave commission ratio mode and return to run mode, press the key labeled RUN followed by the key labeled ENTER.  If P3 (or higher) has been commissioned, the existing profile will be overwritten. If you do not wish the existing profile to be overwritten, disconnect the power to the control without pressing RUN and ENTER.
Page 129 5.7.3 Using adjust ratio mode CAUTION  Use extreme care while commissioning the system. While operating in adjust ratio mode the safety of the system is the sole responsibility of the commissioning engineer.  Incorrect positioning of any drive could cause a hazardous situation to occur. ...
Page 130 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 131 6.1 The fault display The PPC6000 series carry 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 132 The function of the MUTE/RESET key may also be achieved via ComFire or using the MUTE/RESET input. See option parameter 1.2. 6.3 Non-volatile lockout If power is removed from the control while a fault is still present, the fault will be stored in non-volatile memory. When power is restored to the control, the fault number will still be present and it will be necessary to remove the fault before restarting the burner.
Page 133 Fault Cause Description Number 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, when a drive stops at a position fault that is outside the close set position by more than five degrees.
Page 134 Fault Cause Description Number Burner input fault One or more of the high voltage (profile select) inputs is registering a fault. Subset: Failure mode. Primary relay fault One or more of the internal relays is not responding correctly. Subset : 1 - 10 = Failed relay number ADC fault One of the internal checks on the analog to digital converter has failed.
Page 135 Fault Cause Description Number Program memory The program memory in the control has been corrupted. CRC fault  Interrupt power to the control.  This could be due to high levels of electrical interference getting into the product. Check all cables are correctly screened, and screens are terminated correctly.
Page 136 Fault Cause Description Number EEPROM memory The EEPROM memory in the control has been corrupted. This CRC fault memory is used to store the option parameters,  Interrupt power to the control.  Erase the system using option parameter 45.1 = 5 and re commission (or restore with option parameter 45.2).
Page 137 Fault Cause Description Number The trim drive has reached the allowed maximum deviation limit. Trim limit alarm  Change trim limit.  Re-commission fuel / air ratio. Subset: Not applicable. The measured oxygen level exceeded 15.0% during auto trim Auto trim commissioning.
Page 138 Fault Cause Description Number Profile Invalid This fault means that the control 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 139 Fault Cause Description Number Secondary A fault has occurred with the program memory in the control. A program memory Self check is performed once an hour and two consecutive failures checksum fault will cause the fault to appear and the burner to lock-out immediately.
Page 140 Fault history The PPC6000 series stores information on faults. The memory in the unit will store the last 128 faults and associated status data and as an option a date and time stamp. The 100 most recent faults are available via the display unit and all 128 are available through ComFire.
Page 141 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 control is in auto or sequencing mode.
Page 142 Name Description EK27 Commission setpoint The current setpoint being commissioned. 0 - Closed setpoint. 1 - Purge setpoint. 2 - Ignition setpoint. 3 - Low fire setpoint. 4 - 24 - profile setpoints The number of setpoints that have been EK28 Commission Setpoints entered successfully entered during this commission...
Page 143 Name Description EK39 Fuel Swap Status If non zero, the control is in the process of performing a fuel profile swap (without turning the burner off). The nearest setpoint (EK36) when the burner EK40 Shutdown setpoint last locked out. The number of times adjust ratio mode has been EK42 Adjust ratio counter used.
Page 144 Name Description EK50 Trim deviation (% flow) Deviation in air flow imposed by trim (-25 to +25%) EK55 Main PCB issue The issue number of the main circuit board that the firmware is expecting. This may be different to the actual PCB issue if they are compatible. EK56 Software issue.
Page 145 Name Description EK62 Analogue/Digital Input 2. The raw ADC counts from analogue/digital input PPC6000 Terminal PA6. 0 to 1023 for 0 to 5.00 volts. 4mA = 180 counts 20mA = 900 counts EK63 Analogue/Digital Input 3. The raw ADC counts from analogue/digital input PPC6000 Terminal PA7.
Page 146 Name Description EK71 Daughter board Frequency input 3 Gives the measured frequency in Hz on this input. If the input is not changing, this value will (PZ11). 0 to 12 volts. be 0 for OFF (open circuit) and 1 for ON. EK72 Oxygen probe cell temperature.
Page 147 Name Description EK93 Flow value The instantaneous calculated air or fuel flow value, as used by the oxygen trim function. If flow values have been entered during commissioning for the current profile, this value will show the flow rate that corresponds to the current modulation rate.
Page 148 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 149 Name Description This value = 1 if the control is currently EK136 Lag on temperature active banking based on a temperature setpoint for This value = 1 if the another boiler has been EK137 Remote lead selected selected to be lead boiler instead of this one. If this value = 1, the first PID modulation EK138 SP1 selected remotely...
Page 150 6.7 Troubleshooting 6.7.1 Display / General Problem Possible cause Suggested action Display shows it’s serial Display CAN bus wired Check wiring of CAN bus (PT3 and PT4). number but not data incorrectly. from control unit PPC6000 not running. Check PPC6000 low voltage electronics fuse FS2.
Page 151 A display can only log the faults of up to eight PPC’s, therefore the fault log range is selected by holding down the right arrow key and the Engineers Key (Fireye logo) simultaneously. The ranges are as follows; Fault Mode on CANbus...
Page 152 6.7.4 Modulation Problem Possible cause Suggested action Sensor or modulation rate V/I input setting incorrect. Check option parameter. inaccurate. 5/24V supply setting incorrect. Check SENSOR IN and SUPPLY links. Intermittent positioning Profile too close to micro-switch. Move end points further away from high/low. faults.
Page 153 PPC6000 series control. TIME   Control is unstable Adjust option parameters 9.0, 9.2 and 9.3 on the PPC6000 series control to reduce accuracy & slow down control response.  Check Option parameter 9.4 matches the acceleration / deceleration time TIME programmed into the VSD.
Page 154 In extreme cases, it may be necessary to increase the inverter error tolerance to prevent non-volatile lockouts caused by positioning faults (set option 9.1 = 1). This must only be changed if an inverter error of 55 will not cause unsafe combustion. Variable Speed Drive Selection: Important Note: When selecting a VSD or variable frequency drive (VFD) consideration must be given to the size and weight of the blower wheel.
Page 155 6.8 YB110/TSD104 Fault Messages Due to the increased use of the Nexus Touchscreen in combination with the Burnerlogix, the numbering format for fault messages is formatted as below. The fault numbers are taken from table 7 in the BurnerLogix manual BL-1001-pdf, but with 200 added to the message number.
Page 156 Fault Description Number LOW OIL PRESSURE HIGH OIL TEMPERATURE LOW OIL TEMPERATURE LOW ATOMIZING MEDIA HIGH PRESSURE HIGH TEMPERATURE AUX #4 OPEN AUX #5 OPEN AUX #6 OPEN AUX #7 OPEN Interlock annunciation messages THESE CAN BE MODIFIED BY THE USER Fault Description Number...
Page 157 7 Inverter (variable speed) drives This manual may cover more than one model in the PPC6000 series. Check for additional information at the end of this chapter. 7.1 System configuration The PPC6000 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 PPC6000 enclosure).
Page 158 If the feedback signal from the drive is lost during a run condition (e.g. the loop current drops below 3.5mA or encoder feedback fails) the control will perform a non-volatile lockout. 7.3 Setting up the inverter for use with the PPC6000 series The PPC6000 will work with most inverters that meet the following criteria: ...
Page 159  U/F ratio. Use the ‘SQUARED’ option for fans and pumps.  Motor slip ratio. Use drive default, if unknown 7.4 Setting up the PPC6000 series for use with a inverter drive In order to use a inverter drive with a 4-20mA interface, the optional inverter interface daughter board must be fitted.
Page 160 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 supplied since dangerous levels of carbon monoxide may be present in the flue.
Page 161 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 162 DIRECTION OF DIRECTION OF PART A PART B FLUE GAS FLOW FLUE GAS FLOW 3 (1/8") FILLET WELD MOUNTING ALL ROUND FLUE WALL FLUE WALL Ø M6x25 ST.STL. BE220069 SCREW - TAP FLUE WALL IN 6 POS'NS ON 80 30¦ (3.15") PCD TO FLUE APERTURE FLUE APERTURE...
Page 163 9 Appendix 9.1 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 164 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 is retained in the flue by six 6mm stainless steel socket head cap screws. ...
Page 165  Access is now available to the electrical terminations. Remove the plug from the printed circuit board allowing the flexible conduit fitting to slide out of the probe body complete with the plug. Since the body of the probe will be hot, it will be necessary to use heat resistant gloves to hold the probe.
Page 166 Fireye O2 Probe Connector *02- PROBE T/C- PROBE T/C+ EXTERNAL FLUE T/C- CONNECTIONS INTERNAL FLUE T/C+ CONNECTIONS HEATER HEATER COMPONENT SIDE VIEW OF INTERNAL ELECTRICAL INTERCONNECTION PCB...
Page 167 9.2 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 PPC6000. TIME ...
Page 168 9.3 PID Tutorial PID Adjustment The PPC6000 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 169 This is normal and due to the difference between wet and dry samples. Bear in mind the PPC6000 will trim to the value of the Fireye probe, not to the value of a portable analyzer. Also, when using adjust ratio mode to re-tune an existing profile, do not simply charge the O2 target value.
Page 170 6) Fireye O2 probes measure oxygen in the flue without extracting and drying flue gases. If attempting to compare the oxygen values being measured by the PPC6000 and a hand held equipment ensure the value being given by the hand held is corrected from a dry to a ‘wet’...
Page 171 The PPC6000 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 172 9.6 Typical Wiring Diagrams provides the only approved wire for this application. No “or equal” is provided. Use of wire not approved by Fireye may VOID warranty. Typical Wiring Diagram / YB110 All wiring to terminal block “PA” & “PB” as well as to any optional daughter board (e.g.
Page 173 Table 2.6.1-A provides the only approved wire for this application. No “or equal” is provided. Use of wire not approved by Fireye may VOID warranty. All wiring to terminal block “PA” & “PB” as well as to any optional daughter board (e.g.
Page 174 NOTE: These templates should be measured for accuracy as distortion from printing may occur. See section 2.0 for details. PPC 6000 3.15” (80 mm) 6.26” (159mm)
Page 176 NX600, NX610 ” (87 mm) 7/16 ” (105 mm) 8 mm 8 mm TEMPLATE: Remove to use NOTE: These templates should be measured for accuracy as distortion from printing may occur. See section 2.0 for details.
Page 178 NX02INT TEMPLATE: Remove to use NOTE: These templates should be measured for accuracy as distortion from printing may occur. See section 2.0 for details.
Page 179 9.7.1 Introduction This guide can be downloaded from the Fireye web site at www.Fireye.com. Search bulletins for NXOG-6001 under the Nexus products family. As an operator there are generally only a few items of interest as far as operating the Nexus PPC6000. They are: ...
Page 180 5. Use the left or right arrow key to move the cursor to the lower portion of the display, then using the up/down arrow key change the setting. 6. Press the ENTER key to accept the new setpoint. 7. To exit and return to the normal run mode, press the RUN key followed by the ENTER key. Note: The next time you enter the site password you will return to the last option selected.
Page 181 Boiler OFF (Cut Out) at ......75 psi Boiler ON (Cut In) at ........55 psi Boiler maintains (Setpoint) ......60 psi via PID NOTE: NEW I (integral time) and D (derivative time) values - Option Parameters 21.3(22.3) and 21.4(22.4), may be required to achieve desired results.
Page 182 Where applicable, the subsets are given in the fault listing in section 0 of Fireye Bulletin PPC6001. For details of how to view a subset, refer to Section 6.0 of...
Page 183 9.7.9 Fault listing For specific Fault listing see Section 6.5 of Fireye Bulletin PPC-6001. 9.7.10 PID Tutorial PID Adjustment The PPC6000 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;...
Page 184 maintain the desired setpoint. It is normal for a slight over and undershoots of setpoint during serious load changes. The values for the PID’s are found at option parameters 21.2, 21.3 and 21.4 for setpoint 1 (PID1), and 22.2, 22.3 and 22.4 for setpoint 2 (PID2). These values are adjustable using the Site Passcode 154. 9.7.11 The startup / shutdown stages are as follows: Stage Stage name...
Page 185 Stage Stage name Description 3. & 4. Not Applicable to PPC6000 Note: Statuses 3 and 4 are reserved for a gas valve proving system and are not implemented on this control. This control will advance directly to status 5 once the conditions above have been met. Prove closed The fuel and air motors are moved down until they are stopped by the positions...
Page 186 Stage Stage name Description Ignition The controller confirms all required drives are at their ignition positions, and gives an ‘ignition proved’ signal by supplying line voltage to terminal PE7 (low-fire-switch). The controller will hold the drives at their respective ignition positions until the signal to modulate is received from the burner controller.
Page 187  In stages 5, 7 and 8, stages 10-16 (inclusive) and stage 18 if a motor is not in the correct position  In any stage, if an internal or external fault not previously mentioned occurs which may affect the safe operation of the burner (see section 0 of Fireye Bulletin PPC6001)
Page 188 9.8 Fireye Nexus Combustion Curve Site: Date: Profile: Fuel: Drive Drive Drive Drive Drive Drive Drive Drive Drive Drive P 10 P 11 P 12 P 13 P 14 P 15 P 16 P 17 P 18 P 19 P 20...
Page 189 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 190 First draw the blocks, then connect them. Using the toolbar, click the top button twice to bring up two digital input blocks. You will notice that the blocks always appear in the middle of the visible window. In this case, one is on top of the other.
Page 191 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 192 1.3.7. Linking and uploading your program In order to upload the program to the Fireye PPC6000 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 193 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 194 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 195 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 196 11 Circuit board connections 11.1 Inlet Air Temperature Sensor (Optional) NOTE: Insulate Shield Cover shield to (Terminal 5) to prevent Shield prevent short accidental shorting to CANbus - pins on circuit board (J1) CANbus + 24 VAC 24 VAC NXIATS Inlet Air Temperature Sensor...
Page 197 11.2 PPC6000 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 –...
Page 198 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 NX02INT...
Page 199 11.4 PPC6000 Note: All wiring to terminals PA & PB are low voltage and must be braided shielded wire per table 2.6.1A. Wiring to terminals “PE” is line voltage. The maximum wire size is 16AWG (19/.3mm). Note: PE7 & PE8 provide purge and low fire position signals to the flame safeguard control.
Page 200 Fireye shall be limited exclusively to the right to replacement or repair as above provided. In no event shall Fireye be liable for consequential or special damages of any nature that may arise in connection with such product or part.

Fireye PPC6000 Series Manual

1 Technical Specification

2 Installation

Quick Links

Summary of Contents for Fireye PPC6000 Series

Page 4: Table Of Contents

Page 11: Technical Specification

Page 12: Digital Outputs (Ppc6000)

Page 13: Digital Inputs (Ppc6000)

Page 14: Optional Oxygen Probe Interface Unit (Nxo2Int) - Optional

Page 15: Fireye Nxc04, Nxc12, Nxc20, Nxc20A, Nxc40 Servo Motors

Page 16: Fireye Nxiats Ambient Air Temperature Sensor (Optional)

Page 18: Installation

Page 19: Mounting Details For The Ppc6000 Control

Page 20: Mounting Details For The Display Module

Page 21: Mounting Details For Optional Oxygen Probe Interface Unit, Nx02Int

Page 22: The Oxygen Trim Option

Page 23: Mounting The Oxygen Probe

Page 24: Mounting Arrangements For Temperature And Steam Pressure Sensors

Page 25: Steam Pressure Sensors

Page 26: Option Link Selection (Ppc6000)

Page 27: Sens In And Sens Supp (Boiler Temp/Pressure Sensor) (Ppc6000)

Page 29: Wiring

Fireye PPC6000 Series Manual

1 Technical Specification

2 Installation

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Related Manuals for Fireye PPC6000 Series

Summary of Contents for Fireye PPC6000 Series

Table of Contents